Under hood and under body

Simgrosys provides services in thermal management of automotive under hood and under body. Having equipped with higher end hardware, Simgrosys can deliver the results design changes made in under hood or body in very less time. Thermal design engineers here will solve the design issues related with radiators, intercoolers, condensers, fans within a shorter lead time as they are facing number of similar challenges each and every day. They use various CAD, FEA, CFD and Multi body dynamics packages to solve the problem very quickly.


Image Simgrosys provides services in aerodynamics of automotive vehicles such as cars and trucks. It has already executed number of projects in the design and development of add-on aerodynamic structure for tractor-trailers. The structure developed by Simgrosys was able to reduce the drag by 25% and increase the fuel efficiency by 4%.
The aerodynamics deals with the flow of gases (especially air) over bodies such as aircraft, rockets, and automobiles at high or low speeds. Understanding motion of air around an object enables the calculation of forces and moments acting on the object. Typical properties calculated for a flow field include velocity, pressure, density and temperature as a function of spatial position and time. Aerodynamics allows the definition and solution of equations for the conservation of mass, momentum, and energy in air. Simgrosys supports aerodynamics design of automotive body shapes through mathematical analysis, empirical approximations, wind tunnel experimentation, and computer simulations.

Image Simgrosys consists of experts who can perform external aerodynamics study of flow around solid objects of various shapes. Evaluating the lift and drag on an airplane or the shock waves that form in front of the nose of a rocket are examples of external aerodynamics. Simgrosys also performs internal aerodynamics study of flow through passages in solid objects. For instance, internal aerodynamics encompasses the study of the airflow through a jet engine or through an air conditioning pipe. We solve the problems at subsonic, transonic, hypersonic at different speed conditions.

Under hood and under body

Simgrosys provides services in thermal management of automotive under hood and under body. Having equipped with higher end hardware, Simgrosys can deliver the results design changes made in under hood or body in very less time. Thermal design engineers here will solve the design issues related with radiators, intercoolers, condensers, fans within a shorter lead time as they are facing number of similar challenges each and every day. They use various CAD, FEA, CFD and Multi body dynamics packages to solve the problem very quickly.

Engine Lubrication

Generally, oil pumps are used for pumping lubricating oil into engine parts which will become hot while running at high speeds. Lubricating oil pumping mechanism is one of the critical members in a engine system which consists of components such as oil pump, inlet pick-up tube, strainer, pressure relief valve, and inlet and outlet ports.

The performance of a lubrication system is mainly controlled by the overall efficiency of oil pump along with its inlet and outlet components. Very recently, gerotor (generated rotor) pump - an internal rotary positive displacement pump started to replace other members of the group of positive displacement pumps due to its higher volumetric efficiency, smooth pumping action and ability to handle a wide range of fluid viscosities.

ImageSimgrosys supports the manufacturers of following pumps in CAD modeling, FEA, CFD and technical documentation:

  • Gerotor pumps
  • gear pumps
  • Sliding vane pumps

Simgrosys has proven capabilities in,

  • Rotor profile design
  • Pump body and cover design
  • Pressure relief valve design
  • Formulation of bolt layouts
  • Leakage losses prediction and reduction
  • FEA analysis for positive sealing
  • FEA analysis for bolt strength of cover plate
  • Vibration analysis for gear wheel rotation
  • CFD analysis for flow rate prediction
  • CFD analysis for cavitations
  • Noise prediction and reduction
  • Prototyping and testing

Oil pans

  • Oil pan structure design and optimization
  • Pick- up tube and baffle design
  • Stability analysis
  • Multiphase CFD analysis of oil pan sloshing
  • Multiphase CFD analysis of pick up tube exposure to air
  • Leakage losses prediction and reduction
  • FEA analysis for impact loads
  • Vibration analysis for different loading
Engine cooling

Simgrosys supports engine cooling activities by performing CAD modeling, finite element analysis (FEM) and Computational Fluid Dynamics (CFD). Our team has good exposure in design and development of engine cooling pumps to the automotive OEMs and tier-1 suppliers. As our prime design centre is located in Coimbatore - the hub of pump manufacturers, design and manufacturing coordination will be highly effective to make the product in time to push into market. Simgrosys can support the engine cooling module manufactures in the following domain:

  • Product design to formulate the conceptual design to final design
  • CAD modeling- 3D models, Legacy conversions
  • 2D drawings and detailing
  • Finite Element analysis for deformation of pump shafts, stress development, vibration analysis, structural borne noise
  • CFD analysis for predicting the flow performance, pressure drop , erosion rate inside the cooling pump
  • Technical documentation for preparing user manuals, operating manuals, animations related to product description

Key differentiators of Simgrosys engine cooling services:

  • Already supported more than 50 cooling pump development process
  • Good exposure to automotive regulations of India, Europe and USA
  • All designs are enhanced with FEA and CFD based simulations for optimizing performance
  • Approach towards cost and weight reduction of the components
  • Established practices to design and develop the pump in shorter span of time to make the customers push the product well ahead of time to market.
Passenger Comfort Systems

Automotive Cabin HVAC Duct Design

Image HVAC duct designers in Simgrosys are having more experience and expertise in conceptual design through preliminary to final design of automotive cabin ducts to achieve target air flow. All these design phase are driven and enhanced by FEA and CFD simulation processes.
They design

  • IP chest
  • Face ducts
  • Tunnel ducts
  • Roof ventilation
  • Blower of HVAC unit of an automotive
Perhaps, Simgrosys evaluates third party design using Computational Fluid Dynamics simulations and suggest the design improvements to reach the target performance.

Defrosting and Deicing

Image HVAC engineers in Simgrosys have more knowledge and exposure in the European and USA Federal automotive regulations and they design the HVAC systems of automotive vehicles cabin accordingly. They also perform FEA/CFD simulations for evaluating their design is compliance with prescribed regulations. In Simgrosys, lot of such simulations was carried out to validate the HVAC design. For example, a detailed defrosting and deicing study was carried out to validate the design, as per EEC 317 regulations. These simulations results are compared with test results and the correlation was found to be good.

Heater Cores / Heat Exchangers / Fans

Simgrosys will help for designing all kind of heat exchangers such as radiators, condensers, intercoolers. We make hand design calculations, 2D and 3D drawings, FEA validation for thermal deformation, and CFD for pressure drop prediction and heat transfer happened in heat exchangers. Our engineers also deal with the design of heater cores. They will decide the number of tubes, ways to improve the heat transfer area using various techniques such as iterative, simulation, thermal calculations.

Simgrosys designs fans. Based on the customer requirements, the blade profiles are designed and optimized to reach the target mass flow rate. The aerodynamics of fan shroud are also formulated and validated by our engineers. CFD simulations are conducted to enhance the design process and physical testing also carried out to confirm. Our well talented acoustic team works for noise monitoring and control techniques.

Passenger Safety systems

Simgrosys has vast experience and expertise in design and simulation of the physics of automotive safety systems such as airbags and seat belt. Safety and pyrotechnic experts in Simgrosys, formulate the automotive safety systems as per respective norms. They make the concepts for the design of seat belts and perform various validation studies for that design. In case of airbags, Simgrosys performs variety of analyses to evaluate the design. They are Burst cup, Inflator opening mechanism and bulging and jumping pattern , Airbag surface temperature determination, Inflator hydro burst analysis, Flow and thermal simulation, Wafer fracture mechanism, Inflator response time refinement, Airbag deployment time estimation ,Simulation of sublimation process. All these simulations can be performed for both pyrotechnic and stored gas technology airbags that are used for front and knee sides.



Image Development of base model to investigate performance parameters and prediction of following parameters of interest:

  • Tank pressure and temperature, filling phenomena of gases
  • Chamber pressure and temperature
  • Body temperatures adjacent to orifice, Exit gas temperature
  • Mass flow and velocity distribution in the filter surface
  • Baseline model without coolant : Determination of mass flow rate of hot gas coming out from the orifices by using pressure profiles
  • Determination of vaporizing rate of the liquid coolant condition


  • Determination of pressure loading on wafers for subsequent non-linear FEA analysis
  • Prediction of Inflator body and booster cup pressure , Flow distribution over propellant tablets for following cases:
    • Without propellant tablets and solid filter
    • Without propellant tablets and regular filter
    • With propellant and regular filter


  1. CFD simulation for Hybrid Inflator to predict the following parameters:
    • Mixing phenomena of combustion gases and Ar/He mixture in the bottle
    • Mixing fraction of gases inside the bottle
    • Mixing fraction of gases at orifice
    • Bottle pressure and temperature
    • Mass flow rate and total mass exited at orifice
    • Exit gas temperature
    • Shock wave (pressure) development phenomena
  2. CFD simulation for the gas flow characterization airbag inflator with respect to retainer interface and predict the following parameters:
    • Shock wave (pressure) development phenomena.
    • Mixing phenomena gases (mass fraction).
    • Bottle pressure and temperature.
    • Individual gas and total mass flow rate and accumulated mass exited through orifice
    • Exit gas temperature at the bottle orifice exit plane.
    • Exit gas velocity vectors through orifice.
    • Tank pressure and temperature.
    • Gas temperature at the predetermined points.
    • Individual gas and total mass flow rate & accumulated mass exited at the predetermined points.

    1. A transient thermal analysis followed by a structural analysis to determine the changes in mechanical properties attributed to the density loss during the storage and/or aging.
    2. Thermal Analysis of inflator components in conduction mode
    3. Thermal Analysis of inflator components in conduction with convection and radiation modes
    4. Propellant tablet diametrical compression analysis
    5. Nonlinear structural dynamic analysis on inflator and determination of the pressure at which outer baffle starts bulging.
    6. Determine minimum static pressure at which bulging starts and perform analysis.
    7. Hot plate thermal analysis of inflator
    8. Fatigue analysis of inflator burst cup
      • Perform elasto-plastic structural analysis for burst cup to evaluate stress distribution.
      • Perform fatigue simulation and estimate fatigue life of burst cup for given load cycle.
    9. Drop test simulation of inflator, considering failure criteria for propellant wafer and evaluate the following
      • Fracture mode of the propellant
      • Stress on propellant tablets
      • Spring displacement and force applied on spring
      • velocity at plate strike
    10. Non-linear hydro-burst test simulations for determining the pressure, stress and strain magnitude inside inflators
Steering Wheels

Image Image


  1. Hub draw down simulation to find stress and displacement under different loading conditions
  2. Hub push out of the boss testing simulation for different load conditions
  3. Static stiffness test for determining tangential rim force deflection
  4. Static stiffness test for determining axial steering force deflection
  5. Torsion durability test to predict the life cycles for different torque values
  6. Bending durability test to predict the life cycles for different bending loads
  7. Modal and harmonic response analysis for different 'g' values
  8. Sand bag impact test simulation
  9. Body Block Impact Analysis
  10. Constant Amplitude Vibration - Fatigue Analysis
  11. Finite element analysis on Steering Wheel Assembly to evaluate the performance under different loading conditions.
  12. Modal Analysis to determine the Natural Frequency of steering wheel assembly