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Gokulraj User

@gokulrajuser2

Mechanical engineering student developing Formula Student electric vehicles, with a SolidWorks accumulator design that reduced weight by 30%.

India

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What I'm looking for

I'm looking to apply my mechanical engineering skills to impactful projects in a growth-oriented organization.

On the Formula Student Electric Vehicle Development project for Formula Bharat, I led the SolidWorks design and structural optimization of the EV accumulator container, reducing its weight by 30% while meeting Formula Bharat safety rules. I also validated the enclosure assembly with structural FEA in ANSYS.

I'm currently developing CAD models and CFD simulations to study flow channels for PEM fuel cell bipolar plates. My other work includes Excel-based lap-time prediction, thermal analysis of flue gas duct insulation at BHEL, PSSR – Udangudi, and a YOLOv8-based defect-detection system that reached finalist status in the Caterpillar Tech Challenge.

Experience

Work history, roles, and key accomplishments

Current

PEMFC Flow Channel & Performance Optimization

Current

PSG Institute of Technology and Applied Research

Studying bio-inspired flow channel designs for PEM fuel cell bipolar plates to improve overall cell performance. Developing CAD models and CFD simulations to study gas flow, pressure drop, and reactant distribution across different channel configurations.

CAD CFDs PEMFCs Flow Channel Design Simulation

Battery Pack Designer

Formula Student Electric Vehicle Development – Formula Bhara

Jan 2025 - Jan 2026 (1 year)

Led the design and structural optimization of the EV accumulator container in SolidWorks, achieving a 30% weight reduction while ensuring full compliance with Formula Bharat safety rules. Executed structural FEA in ANSYS on the enclosure assembly to validate mechanical load requirements under dynamic operating conditions.

Solidworks Ansys FEA Structural Analysis EV Battery Pack Design Formula Bharat Safety Standards

Junior Technical Engineer

Drivetrain Sub-System

Mar 2024 - Jan 2025 (10 months)

Analyzed an existing transmission shaft to determine its minimum required diameter and validated its structural performance in ANSYS. Analyzed gear ratio selection by evaluating torque requirements of the vehicle.

Ansys Structural Analysis Transmission Shaft Design Gear Ratio Analysis Torque Analysis

3-in-1 Parabolic Trough Collector System

PSG Institute of Technology and Applied Research

May 2026 - Present (4 months)

Designed and fabricated a 3-in-1 Parabolic Trough Collector for water heating, hot air production, and crop drying under forced convection. Integrated an automated solar tracking system with LDR sensor and conducted parametric thermal performance evaluation across flow rates (60–140 LPH).

Solidworks Fabrication Solar Thermal Systems LDR Sensor Thermal Performance Assessment

Intern

Metro School of Composites, Laywell Composites Pvt. Ltd.

Fabricated composite plates using bamboo, grass, glass fiber, jute, and silk wool as reinforcement materials. Gained hands-on experience in hand lay-up, compression moulding, and vacuum bagging fabrication techniques.

Composites Fabrication Hand Layup Compression Molding Vacuum Bagging

Intern

BHEL, PSSR – Udangudi

Conducted steady-state thermal analysis in ANSYS and evaluated multi-material insulation options (Silica Aerogel, Ceramic Fiber, Glass Wool, LRB). Optimised insulation thickness through thermal calculations to minimise heat loss and reduce structural loads on duct supports.

Ansys Thermal Analysis Insulation Materials Heat Transfer Cost Optimization