Interactive Simulators & Numerical Tools
Bridging theoretical elastohydrodynamics, non-linear rheology, and real-time open-source computational apps for researchers and automotive engineers.
Live EHL-Simulator & Code Portfolio
Empowering researchers and drivetrain engineers worldwide through open-access cloud simulators and reproducible computational scripts.
EHL-Simulator (Open Source Web Application)
Interactive Cloud-Based Line and Elliptical Contact Lubrication Solver
An open-source, interactive web simulation tool developed by Deepak Kumar Prajapati deployed on Streamlit. Engineers and researchers worldwide can interactively adjust contact loads, entrainment velocities, lubricant rheology properties, and surface roughness to compute central and minimum film thickness, pressure distributions, and traction coefficients in real time.
Key Solver Capabilities:
- Interactive line and elliptical elastohydrodynamic contact geometries
- Real-time pressure distribution and film thickness profile generation
- Non-Newtonian shear-thinning and thermal traction coefficient estimations
- Instantaneous comparison with Dowson-Higginson and Hamrock-Dowson empirical formulas
- Open access for university students and powertrain design practitioners
3D Transient Mixed-EHL Finite Element Code
Coupled non-Newtonian Reynolds and 3D elasticity equation solver with non-Gaussian rough surface contact mechanics.
View on GitHub →Ti6Al4V Rough Nanoindentation FEA Pipeline
Automated Python scripts extracting optical profilometer point-clouds into 3D Abaqus meshes to predict localized plastic strain and hardness.
View on GitHub →Tribo-Informatics Friction Neural Surrogates
Deep learning models predicting real contact area, friction coefficient, and transition boundaries trained on MTM-EC and EHL numerical datasets.
View on GitHub →Working Approach & Research Philosophy
A rigorous four-phase methodology: uniting continuum multiphysics modeling, high-throughput computational code development, and precision laboratory tribo-testing.
Multiphysics Problem Formulation
Continuum Mechanics & Governing PDE SystemsFormulating fundamental coupled field equations: generalized Reynolds equation for fluid films, elasticity equations for contacting solids, 3D energy equations for thermal dissipation, and Maxwell-based electro-mechanical current transmission equations.
High-Resolution Numerical Discretization
FEA, Finite Difference & Custom Multi-Grid SolversImplementing custom algorithms in COMSOL Multiphysics, Abaqus, MATLAB, and C++ with multi-grid acceleration and Newton-Raphson non-linear iterations to guarantee quadratic convergence even under severe contact pressures (>2.5 GPa).
Precision Experimental Rig Validation
MTM-EC, Micropitting Rig (MPR) & 3D MetrologyBridging numerical simulations with physical reality through precision experimental rigs: PCS Instruments MTM-EC for traction and electrical contact resistance, MPR for rolling contact fatigue and micropitting, plus optical profilometry (ISO 25178).
AI/ML Integration & Open Science Delivery
Surrogate Digital Twins & Cloud DeploymentTraining artificial neural networks and machine learning regression models on high-fidelity simulation datasets, followed by packaging open-source tools (Streamlit apps, GitHub repositories) for immediate industrial and academic utilization.
Computational Solvers & Precision Experimental Apparatus
Full-spectrum capabilities spanning multi-scale continuum modeling to ISO 25178 metrology.
COMSOL Multiphysics
Flow-factor thermal-EHL line and point contact solvers, electro-thermal bearing simulations.
Abaqus / CAE
Non-linear elastoplastic rough surface nanoindentation on Ti6Al4V alloy, contact stress analysis.
MATLAB
Algorithm development for 3D mixed-EHL multi-grid solvers, fractal surface generation, and data processing.
Python (NumPy / SciPy / PyTorch)
Machine learning surrogates, surface metrology pipelines, Streamlit cloud web application architecture.
C++
High-performance computational kernels for intensive iterative contact mechanics solvers.
MTM-EC (Mini Traction Machine)
Traction coefficient and real-time electrical contact resistance measurements for EV motor bearings.
Micropitting Rig (MPR)
Rolling contact fatigue (RCF), running-in surface topography evolution, and micropitting failure testing.
Optical 3D Profilometer
Multi-scale areal surface roughness characterization complying with ISO 25178 spatial standards.
Scanning Electron Microscope (SEM)
Micro-scale wear debris morphology, white etching crack (WEC) inspection, and indenter contact examination.
SolidWorks & FreeCAD
Parametric mechanical CAD geometry creation, boundary surfaces, and experimental fixture design.
Need Customized FEM EHL Suite or Consulting?
Deepak Kumar Prajapati collaborates with industrial OEMs and academic labs on specialized numerical simulations.