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Udaykumar Borale
R&D — Powertrain · BIW

Hi, I'm Udaykumar

R&D Engineer — Powertrain & BIW Design

R&D Engineer — Powertrain & BIW Design

Experienced Mechanical Design and Simulation Engineer specializing in advanced 3D modeling, simulation, and full-cycle product development. Skilled in CATIA, SolidWorks, Creo, Siemens NX, Autodesk Inventor, ANSYS, Abaqus, and MATLAB, with a strong focus on delivering innovative and reliable engineering solutions.

Currently working at Chropynska India Private Ltd as an R&D Engineer (Powertrain and BIW Design), leading end-to-end design and development of Powertrain and Body-in-White systems. Dedicated to driving engineering excellence through automation-driven design and continuous innovation.

+91-8660272709 udaykumarborale9@gmail.com
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1+
Years Experience
1+
Projects Delivered
Highlighted Project
Lightweight e-axle integration
Udaykumar Borale
Udaykumar Borale
R&D Engineer — Powertrain & BIW
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About Me

Experienced Mechanical Design and Simulation Engineer with hands-on product development and PLM/PDM experience.

Design Excellence

Advanced 3D modeling and detailed design using CATIA, SolidWorks, PTC Creo, Autodesk Inventor, Siemens NX, and Solid Edge. Strong application of DFM/DFA, GD&T, tolerance & stack-up analysis, weld and joint design, and design optimization for manufacturability, weight reduction, and cost efficiency.

Simulation & Analysis

Comprehensive mechanical simulation using ANSYS, Abaqus, HyperMesh, ANSA, and MATLAB including: Static Structural, Contact & Nonlinear, Buckling, Modal, Harmonic, Transient Dynamic, Thermal, Thermo-Structural, Fatigue, Optimization (Topology/Shape/Size), Weld & Joint, Tolerance Stack-up, Creep, Rotor Dynamics, and Impact / Explicit analyses.

Product Development

End-to-end product development from concept to validation, including BOM management, PLM/PDM workflows, cross-functional collaboration, and compliance with automotive and Industry 4.0 standards (IATF 16949, ISO 26262, ISA-95, RAMI 4.0).

Work Experience

Professional journey and key achievements

R&D Engineer – Powertrain & BIW Design

CHROPYNSKA Group
Oct 2025 – Present
  • Advanced R&D engineering in automotive and automation systems, focusing on powertrain components, concept development, detailed design, and validation.
  • Spearheaded design and development of powertrain components, improving structural integrity, performance, and manufacturability in compliance with IATF 16949.
  • Delivered 100+ CAD models and assemblies, reducing design iteration time by 25% and enabling first-time-right production using Siemens NX, CATIA V5, PTC Creo, and Autodesk Inventor.
  • Executed FEA-driven validation using ANSYS aligned with ISO 26262 (Functional Safety) and IEC 61508 standards.
  • Applied DFM/DFA principles to reduce weight, optimize cost, and enhance manufacturability.
  • Collaborated with cross-functional teams (R&D, Manufacturing, Quality) to ensure compliance with global automotive and Industry 4.0 standards.

Mechanical Analysis & Simulation

  • Performed Static Structural, Contact, and Nonlinear analyses to evaluate stress, deformation, safety factors, and interface behavior in powertrain and machine components.
  • Conducted Modal, Harmonic, and Transient Dynamic analyses to predict vibration behavior, avoid resonance, and assess impact and time-dependent loading conditions.
  • Executed Thermal, Fatigue, and Optimization (Topology/Shape/Size) analyses to prevent thermal failure, predict component life, and achieve lightweight, high-stiffness designs.

Quality and Product Design Engineer

JK Fenner India Ltd, Patancheru
2021-2022
  • Created detailed 3D models and simulations to support product design initiatives.
  • Assisted QA processes to meet industry standards and improve product reliability.
  • Collaborated cross-functionally to improve design methodologies.

Internship & Training

Bajaj Engineering & Skills Training (BEST), PES University

Mechatronics & Automation Trainee

Feb – Jul 2025

Six-month residential program focusing on motion control, robotics, sensor tech, PLCs and Industry 4.0.

MechatronicsPLCAutomation

CONCEPTIA KONNECT

Simulation & Structural Analysis

Feb – May 2025

Training in ANSYS, SolidWorks and PTC Creo for simulation-driven design improvements.

ANSYSSolidWorksPTC Creo

PRIME TOOLING

Design & Structural Analysis

Mar – Feb 2025

Intensive training in precision engineering, CAD/CAM and design validation.

PTC CreoCATIAAnsys

CNC Machines – Bharat Fritz Werner

Machining & Manufacturing

Oct – Nov 2023

Practical exposure to CNC machining processes and manufacturing techniques.

CNCCAM

BELATHUR INDUSTRIES

Machining Operations

May – Jun 2023

3D modelling and technical drawings using CATIA V5; assisted in process optimization.

CATIA V5CAD/CAM

Bosch – Diesel Services Division

Intern (CFD & Flow Simulation)

Feb – Mar 2023

Fluid flow simulation with ANSYS Fluent and SolidWorks Flow Simulation for diesel systems.

ANSYS FluentCFD

Featured Projects

Innovative engineering solutions and research work

Lightweight e-Axle Integration

Apr – Jul 2024

Engineered and validated a lightweight electric axle (e-axle) architecture for EV applications with focus on structural durability, torque density improvement, and packaging optimization. Multi-body kinematic studies, FEA, and topology optimization performed.

CATIA V5 SolidWorks ANSYS Workbench Topology Optimization
  • Complete e-axle housing geometry developed including motor interface, differential casing, lubrication channels, and mounting bosses.
  • Structural FEA for torque reaction loads, bending stiffness, bearing seat deformation, and load-path evaluation.
  • Topology optimization reduced ~18–25% non-load-bearing mass while maintaining strength and fatigue safety factors.
  • Thermal analysis verified operating temperature limits under continuous and peak loads.
  • NVH evaluation ensured resonance modes outside motor torque harmonics.
  • Optimized packaging for compact EV rear subframe integration ensuring manufacturability and assembly accessibility.

Modeling and Analysis of Vertical Axis Wind Turbine Blade

Apr – Jul 2024

Designed and analyzed a Savonius-type Vertical Axis Wind Turbine (VAWT) blade using CATIA V5, SolidWorks, QBlade, and ANSYS. Evaluated aerodynamic forces, structural deformation, and stress distribution under varying wind conditions. Simulations confirmed that aluminium alloy blades maintain low deformation and operate within safe stress limits.

CATIA V5 SolidWorks ANSYS QBlade
  • Developed complete 3D blade geometry focusing on aerodynamic efficiency.
  • Performed FEA to analyze stress, deformation, and structural safety factors.
  • Used QBlade for aerodynamic curve analysis and performance evaluation.
  • Explored composite and H-rotor (Darrieus-type) design alternatives.
  • Optimized blade design for improved performance and manufacturability.
View Project PDF

Studies on Free Convection in a Trapezoidal Cavity with Porous Media

Aug – Dec 2024

Conducted FEM-based numerical simulations to analyze natural convection in a porous trapezoidal cavity. Studied the influence of Rayleigh number, porosity, boundary conditions, and internal heat generation on heat transfer and flow behavior. MATLAB simulations were used to validate thermal and fluid flow trends for engineering thermal management applications.

MATLAB CFD Thermal Analysis
  • Performed FEM-based thermal and flow simulations in MATLAB.
  • Analyzed Rayleigh number, porosity, and geometry effects on heat transfer.
  • Investigated internal heat generation and flow circulation patterns.
  • Interpreted temperature contours, streamlines, and velocity fields.
  • Summarized findings for thermal management in engineering systems.
View Project PDF

Skills & Tools

Expertise in industry-leading engineering tools and technologies

3D Modeling Tools

3D Modeling CATIA Siemens NX SolidWorks Autodesk Inventor Auto Cad Solid Edge PTC Creo

Simulation Software

ANSYS Abaqus Hyper Mesh ANSA MATLAB ANSYS Fluent CFD

Product Development & Tools

Product Development Product Design BOM Management PLM/PDM Tools Design Optimization GD&T RT Toolbox3 Microsoft Office Technical Documentation

Certifications

CATIA V5 Certification SolidWorks CAD Design ANSYS Workbench Python Programming

Education

Academic background and qualifications

Master of Technology (M.Tech)

Engineering Design

Symbiosis Institute of Management Studies, Pune

2025 – 2027 Working Professional

Bachelor of Engineering (B.E)

Mechanical Engineering

Bangalore Institute of Technology, Bengaluru

2022 – 2025 CGPA: 8.5

Diploma

Mechanical Engineering

Jawaharlal Nehru Polytechnic (Aided), Thana Kushnoor, Bidar

2018 – 2021 72%

Let's Work Together

Ready to bring innovative engineering solutions to your next project. Let's discuss how we can collaborate.

Location
Banashankari 1st Stage, Bangalore - 560050

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