Battery Thermal Management: Simulation Based Design

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

Safe, efficient, and cost-effective designs of Electric Vehicles (EVs) batteries become more important. Lithium-ion batteries are the mainstream battery solution for today’s EVs but are sensitive to their operational thermal conditions. Therefore, thermal simulation of these battery packs is paramount in the designing phase, which includes consideration of heat production by battery electro-chemistry, internal resistivity and cooling, EV cooling system, etc.

We offer consulting to simulation plan that will achieve customer objectives. Our staff can rapidly mesh vehicle or battery geometry for optimal simulation time and carry out the model setup, analysis, and validation/verification. Using the advanced methods, we can simulate battery operating scenarios using 3D Advanced simulation tools.
  • Optimized simulation process for cell and pack level studies
  • Cooling, insulation, and heat protection studies
  • Vehicle drive cycle model: heat up and cool down
  • Electrical drive cycle power profile
  • Coupled thermal-electrical simulation
  • Analysis of battery cells
  • Design of battery pack systems
  • Packaging and vehicle integration
  • Battery life prediction and battery runaway
Battery Electric Vehicle EV Thermal Analysis simulations FEA CFD Cradle abaqus ansys fluent siemens star-ccm+
Battery Electric Vehicle EV Thermal Analysis simulations FEA CFD Cradle abaqus ansys fluent siemens star-ccm+

Why we use Coupled FEA-CFD?

Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).

Battery Simulation Battery Electric Vehicle EV Thermal Analysis simulations FEA CFD Cradle abaqus ansys fluent siemens star-ccm+
Battery Thermal Management: Simulation Based Design
Battery pack thermal simulation - Siemens Star-ccm+ CFD Simcenter
Battery Thermal Management: Simulation Based Design
With using CFD based design optimization solutions serve as an important link for our clients to realize their product promise right from concept to realization. Our team of CFD engineers in conjunction with experienced FEA Engineers for FSI and complicated industrial multiphysics problem is delivering solutions to major engineering verticals globally.
  • Conduction, convection and radiative heat transfer
  • Conjugate heat transfer
Equipped with multi-domain knowledge and deep technical expertise, Enteknograte engineering team offers global strategic engineering and environmental consultancy that specializes in performing 1D-Multi-Physics CAE simulations, 3D FEA and CFD thermal analyses and design optimization to a wide variety of clients and industries. Typical applications include:
  • PCB Thermal Design
  • VTOL, e-VTOL and UAM – Urban Air Mobility Systems Thermal Design
  • Electronic Enclosures & Cooling Systems
  • Heat Exchanger Design
  • Heat Shield & Insulation Design & Optimization
  • Underbody and engine compartment thermal protection.
  • Brake cooling
  • Key-off/soak
  • HVAC system performance
  • Cabin and passenger thermal comfort
  • Defrost and demist
  • Thermal comfort in buildings
  • Gas turbine cooling
  • Heat Transfer in Porous Media
  • Turbo machines thermal design
  • Combustion and multiphase flows.
  • IC Engine flows
  • Thermal analysis of radiator with heat pipe

Vehicle Thermal Management Simulation

We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort and covers a wide range of Industries.

Electronic Systems Cooling & Heating: Simulation-Based Thermal Management Design

In the design phase of electronic devices, components such as electronic chips, or power systems, the CFD and FEA based heat transfer softwares used to analyze cooling capacity and Simulate conduction and convection in these applications to ensure optimal performance and operation.

Battery Thermal Management: Simulation Based Design

Safe, efficient, and cost-effective designs of Electric Vehicles (EVs) batteries become more important. Lithium-ion batteries are the mainstream battery solution for today’s EVs but are sensitive to their operational thermal conditions. Therefore, thermal simulation of these battery packs is paramount in the designing phase, which includes consideration of heat production by battery electro-chemistry, internal resistivity and cooling, EV cooling system, etc.

Underbody & Underhood Simulation for Thermal Management

An underbody/underhood and exhaust system modeling effort is a complex thermal management challenge, but Enteknograte engineering team uses MSC Cradle, Ansys Fluent and Siemens Star CCM+ in coupled with Structural Solvers(Abaqus, LS-Dyna, Ansys, MSC MARC) to solve this issue daily. Our team establishes an efficient process for modeling the exhaust system in a realistic, time-dependent environment. CFD and FEA simulation of the systems, allows our team to make design changes to protect unwanted thermal load on critical components. This could reduce overall vehicle development costs, reduce your testing expenses.

Heat Exchangers: Simulation-Based Design for Thermal Performance Optimization

Heat exchanger analysis involves a combination of heat transfer in fluids and solids. The fluid carries energy over large distances, while the solids separate the fluids so that they can exchange energy without mixing. Heat exchangers are involved in a variety of application areas, such as water treatment, resource refinery, nuclear power, food and beverage production, refrigeration, and more.

Thermal Stress and Fatigue Simulation: Coupled CFD and Finite Element Approach

Enteknograte’s Engineering Team provides a comprehensive Steady-State and Transient CFD Thermal Analysis & Design services using MSC Cradle, Siemens Star-ccm+, OpenFoam and Ansys Fluent Flow Simulation. CFD Thermal Analysis extends the capability of FEA thermal analysis with MSC Nastran, Abaqus and LS-Dyna by replacing the simplistic convection boundary conditions with direct calculations of the heat transfer coefficients based on the fluid flow properties and is often referred to a conjugate heat transfer analysis.

Thermal Management in Buildings: HVAC/Climate Control Analysis

Thermal management is vital to the design of buildings, as building designers need to consider heat and moisture variations in building components.
We use the Heat Transfer to analyze thermal management in wooden frames, window frames, porous building materials, and other building components. Enteknograte’s engineering team analyze water condensation and evaporation on building surfaces, heat and moisture storage, latent heat effects, as well as diffusion and convective transport of moisture and eddy-based turbulent mixing for heat and moisture transport in air with using advanced CFD and FEA tools such as MSC Cradle, Siemens Star-ccm+, Ansys Fluent, Abaqus and Nastran.

Heat Transfer Simulations for Turbomachinery Including FSI Effect with Coupled FEA & CFD

For turbomachinery real-world simulation, many elements have to be taken into consideration, in particular, the diversity of flow configurations and applications; the complexity of geometries and physics, the requirements for multidisciplinary analysis and optimization including conjugate heat transfer (CHT) coupling flow and heat transfer: fluid-structure interactions (FSI); fluid-chemistry and multiphase interactions, as in combustion; aero-acoustics coupling flow and noise.

Cabin Aerodynamics: Passenger’s Thermal and Acoustic Comfort

CFD Simulation for Thermal Comfort & Aeroacoustic analysis of HVAC components, fans, blowers and air channels
The passenger’s thermal and acoustic comfort is an essential design-criterion for the air-conditioning and customization of a cabin. In industry, engineers conduct costly and time-consuming test series with specifically built cabin mock-ups to obtain some information about the expected passenger’s sensation of comfort already in the design process.

Stress Relief Heat Treatment: Finite Element Simulation

Stress relieving reduces residual stresses in the assembly after welding.The Stress Relief Heat Treatment performed including definition of time-temperature curves for heating, holding and cooling phases with individual convective heat transfer to environment definition. FEA Stress relief is modeled taking into account two mechanisms: Stress relaxation due to decreased yield stress of material during heating - Time-dependent creep properties of the material

Electromagnetic Multiphysics FEA & CFD Based Simulation

Including Thermal Stress, Vibration, Acoustics and Fatigue
Enteknograte Finite Element Electromagnetic Field simulation solution which uses the highly accurate finite element solvers and methods such as Ansys Maxwell, Simulia Opera, Simulia CST, JMAG, Cedrat FLUX, Siemens MAGNET and COMSOL to solve static, frequency-domain, and time-varying electromagnetic and electric fields includes a wide range of solution types for a complete design flow for your electromagnetic and electromechanical devices in different industries.

MultiObjective Design & Optimization of Turbomachinery: Coupled CFD & FEA

Optimizing the simulation driven design of turbomachinery such as compressors, turbines, pumps, blowers, turbochargers, turbopumps, centrifugal compressors, radial turbines, hydraulic turbines, low speed to transonic fans and torque converters offers enormous potential. . Our experience covers all branches of turbomachinery design and related fields of knowledge including: aerodynamics, hydraulics, thermodynamics, Acoustics, structural, Computational Fluid Dynamics and Finite Element Analysis.

Hydrodynamics CFD simulation

Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, Cavitation, Vibration and Fatigue
Hydrodynamics is a common application of CFD and a main core of Enteknograte expertise for ship, boat, yacht, marine and offshore structures simulation based design. Coupling Hydrodynamic CFD Simulation in Ansys Fluent, Siemens Star-ccm+ and MSC Cradle with structural finite element solver such as Abaqus and Ansys, enable us to Simulate most complicated industrial problem such as Cavitation, Vibration and Fatigue induced by hydrodynamics fluctuation, Transient Resistance, Propulsion, Sea-Keeping and Maneuvering Simulation, considering two way FSI (Fluid Structure Interaction) coupling technology.

Additive Manufacturing and 3D Printing

FEA Based Design and Optimization with Simufact, Abaqus, ANSYS and MSC Apex
Additive manufacturing, also known as 3D printing, is a method of manufacturing parts typically from powder or wire using a layer by layer approach. Interest in metal based additive manufacturing processes has taken off in the past few years. The three-major metal additive manufacturing processes in use today are powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes.

Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation

Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention.
With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.

eVTOL (Electric Vertical Take-Off and Landing) & UAM (Urban Air Mobility)

FEA & CFD Based Simulation for Airworthiness Certification, Aerodynamics, Aeroacoustics and Crashworthiness
The VTOL, eVTOL and UAM market is constantly changing and evolving, so maintaining a competitive edge both within the industry and supporting mission effectiveness requires significant research and development activities. Enteknograte offers the industry’s most complete simulation solution for Urban Air Mobility (UAM) and Vertical Take off and Landing (VTOL) aircrafts.

Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation

We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.

Seat Design: Finite Element and CFD Simulation for Static & Dynamic Comfort, Whiplash, Acoustic & Thermal Comfort, Crash Test

Simulation Based Design can help us to ensure the right occupant posture, which is essential for safety, Static and Dynamic Comfort, for example by predicting the H-Point and incorporating whiplash, thermal and Acoustic comfort simulation. The ability to predict the comfort of innovative seat designs using simulation tools, a library of human models with our team experience in CFD (Siemens Start-ccm+, Ansys Fluent and OpenFoam) and FEA (Ansys LS-DYNA, Simulia Abaqus, ESI Pam-Crash and Altair RADIOSS) simulation software with integrated Artificial Intelligence and Machine Learning for innovative design, can help manufacturers to create seats that provide a superior driving experience for their customers.


We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

Enteknograte’s Engineering team with efficient utilizing real-world transient thermal analysis with FEA – CFD coupling if needed, with FEA Solvers such as Abaqus, Ansys, LS-Dyna, Nastran and MSc Marc and computational fluid dynamics (CFD) solver like MSC Cradle, Siemens Star-ccm+ and Ansys Fluent for advanced Thermal simulation and have clear knowledge about the assumptions and simplifications that must be made to get results with required accuracy.



Finite Element Analysis of Durability and Fatigue Life

Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.

Electric Motors Cooling

Coupled Electromagnetic Solver with Finite Element & CFD Based Multiphysics simulation
Our FEA and CFD based multiphysics simulation design provides electronics cooling simulation products for chip, package and board thermal analysis as well as thermo-mechanical stress analysis. Multiphysics simulation tools help our customers to enhance reliability of the entire electronic system by managing excessive heat that can otherwise lead to increasing leakage and electromigration failure. Electric motors cooling becomes critical as we want to move to higher power, high-efficiency equipment.

Creep and Creep-Fatigue Interactions

considering Creep-Fatigue interaction in high temperature simulations identifies whether fatigue and/or creep are the dominant damaging mechanisms, thus allowing re-design to focus on the relevant damage mechanisms and significantly reduce pre-service component testing.

Vibration Fatigue Finite Element Simulation: Time & Frequency Domain

Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.

Acoustics and Vibration: FEA and CFD for AeroAcoustics, VibroAcoustics and NVH Analysis

Noise and vibration analysis is becoming increasingly important in virtually every industry. The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.

Aerodynamics Simulation: Coupling CFD with MBD, FEA and 1D-System Simulation

Aerodynamics studies can cover the full speed range of low speed, transonic, supersonic and hypersonic flows as well as turbulence and flow control. System properties such as mass flow rates and pressure drops and fluid dynamic forces such as lift, drag and pitching moment can be readily calculated in addition to the wake effects. This data can be used directly for design purposes or as in input to a detailed stress analysis. Aerodynamics CFD simulation with sophisticated tools such as MSC Cradle, Ansys Fluent and Siemens Star-ccm+ allows the steady-state and transient aerodynamics of heating ventilation & air conditioning (HVAC) systems, vehicles, aircraft, structures, wings and rotors to be computed with extremely high levels of accuracy.