Expertise in computational modeling, electro-thermal analysis of Li-ion batteries, conjugate heat transfer, multiphase flows, external airflow flows, turbulence models.
Skills in STAR-CCM+, Fluent, OpenFOAM, ANSA, ProE, ParaView, Teamcenter, Unix/Linux Bash Scripting, Java, Python, and MATLAB.
Ph.D. in Mechanical Engineering with +11 years of hands-on technical and leadership skills in industrial sectors.
A highly self-motivated, independent, creative problem-solver with excellent communication, presentation, and team-working skills.
Overview
16
16
years of professional experience
Work History
HV Battery Thermal CAE Engineer
For Motor Company
08.2023 - Current
Led development of the Ford-first 1D/3D CAE Thermal co-simulation model for HV battery by integrating 3D HV Battery Thermal CAE STR-CCM+ models with 1D MoSuite models developed by EVEMS using industry standard FMU (Functional Mock-up Units).
Mentored junior engineers on best practices in computational analysis and simulation techniques and proactively provided technical guidance, minimizing errors in model setup and assumptions, and identified and resolved issues within. This ensured the timely delivery of high-quality CAE results, accelerating progress toward program milestones.
Developed and executed a physical test study to verify the maximum design temperature (MDT) of cell tabs in pouch cells used in battery packs. The innovative nature of this test method gained internal recognition, prompting Ford Ion Park to request our support to improve FIP cell designs and performance.
Identified and rectified an incorrect coolant flow direction for the V801 packs. This critical early detection prevented costly delays and the erroneous testing and sign-off of the pack with an incorrect coolant flow configuration.
Demonstrated critical thinking by questioning the assumption of uniform coolant flow targets across arrays with varying cell counts. Proposed an optimized approach to set array target flow rates as a function of their respective sizes, which was subsequently accepted.
Uncovered a critical inconsistency of V710 coolant flow direction revealing vehicles had been erroneously assembled for +6 years with reversed coolant flow. This critical finding drew management attention, prompting urgent requests to evaluate potential issues in the affected packs and the potential risk of costly product recalls.
Advanced the automation of 3D battery pack thermal performance analysis by improving a Star-CCM+ template. This template supports detailed modeling enhancing efficiency and consistency in our analytical processes.
CFD Technical Specialist
Roush
04.2022 - 08.2023
Lead CFD team to coordinate workloads, exceed customer expectations, and timely meet deadlines
Perform electrothermal analysis of lithium-ion pouch/cylindrical/prismatic battery cell, modules, and pack level at normal and thermal runaway conditions
Modify air and liquid battery cooling systems of electrical vehicles
Improve aero-thermal performance of drones by improving their fan, fin, vent, and spinner designs
Multiphase simulations of oil tank at stationary and sloshing conditions
Cabin airflow and thermal comfort analysis in hot and cold ambient including conjugate heat transfer and radiation
Conduct external aero analysis to determine efficient vehicle aeroshape with improved drag, lift, and stability
Collaborate with project teams to understand requirements and develop appropriate solutions while ensuring technical feasibility
Discuss CAE findings with customers and propose design changes to meet their targets
Water Management CAE Engineer at Ford Motor Compan
Roush
05.2021 - 04.2022
Led air intake system snow ingress program including CAE simulations and correlation testing in global wind tunnels
Assisted attribute engineers with experimental measurement techniques
Performed and validated structural STAR-CCM+ CAE program by developing JavaScript code
Performed wind tunnel physical tests and documented lessons learned and supported program review meetings
Correlated CAE predictions with physical measurements
Deployed water management CAE programs: water wading, water management into engine bay, roof runoff, rear door closure
Post-Doctoral Associate
Clarkson University
06.2020 - 04.2021
Conducted direct numerical simulations (DNS) of respiratory airflow and droplet propagation during speech
Coordinated group meetings, developed documentation, published manuscripts, and presented at conferences
Respiratory aerosol and droplet transmission due to speech (Funded by NSF)
Research Assistant
Clarkson University
08.2014 - 05.2020
Quantified effective program size with maximum fracture coverage (OpenFOAM coupled with LIGGGHTS)
Paralleled 4-way coupling CFD-DEM simulations of particle transportation using MPI
Modeled program transportation in synthetic rock geometries (DEM model in STAR-CCM+)
Evaluated Local Cubic Law (LCL) approach in predicting sheared rock fracture pressure drops with OpenFOAM results
Improving turbulence stochastic models
Improved predictions of particle distributions and depositions in inhomogeneous turbulent flows
Investigated particle distributions and depositions in inhomogeneous turbulent flows
Developed a parallel MATLAB particle tracking code to set up a 2D channel flow benchmark for stochastic models
Enhanced ANSYS-Fluent particle tracking performance by employing novel stochastic models (added C++ User-Defined-Functions)
Water Management CAE Engineer at Ford Motor Compan
Roush
05.2021 - 04.2022
Post-Doctoral Associate
Clarkson University
06.2020 - 04.2021
Research Assistant
Clarkson University
08.2014 - 05.2020
Research Assistant
Sharif University of Technology
08.2009 - 05.2012
Doctor of Philosophy - Mechanical Engineering
Clarkson University
Master of Science - Mechanical Engineering
Sharif University of Technology
Bachelor of Science - Mechanical Engineering
K. N. Toosi University of Technology
Publications
Mofakham, A. A. et al. Influence of two-dimensional expiratory airflow variations on respiratory particle propagation during pronunciation of the fricative [f]. Journal of Aerosol Science (2023).
Mofakham, A. A. et al. On the variation of fricative airflow dynamics with vocal tract geometry and Speech Loudness. Aerosol Science & Technology (2022).
Mehrabi, A., Mofakham, A. A. & Shafii, M. B. Numerical optimization of three-cavity magneto mercury reciprocating (MMR) micropump. Engineering Applications of Computational Fluid Mechanics (2021).
Mofakham, A. A. et al. Investigation of program distributions in rock fractures with applications to hydraulic fracturing. ASME-FEDSM (2021).
Mofakham, A. A. & Ahmadi, G. Particles dispersion and deposition in inhomogeneous turbulent flows using continuous random walk models. Physics of Fluids (2019).
Mofakham, A. A. et al. Significance of vocal tract geometrical variations and loudness on airflow and droplet dispersion in a two-dimensional representation of [f]. ASME-FEDSM (2021).
Mofakham, A. A. & Ahmadi, G. On random walk models for simulation of particle-laden turbulent flows. International Journal of Multiphase Flow (2020).
Ahmed, T. et al. Variability in expiratory trajectory angles during consonant production by one human subject and from a physical mouth model: Application to respiratory droplet emission. Indoor Air (2021).
Mofakham, A. A. & Ahmadi, G. Improved discrete random walk stochastic model for simulating particle dispersion and deposition in inhomogeneous turbulent flows. Journal of Fluids Engineering (2020).
Mofakham, A. A. et al. Computational modeling of hydraulic properties of a sheared single rock fracture. Transport in Porous Media (2018).
Mofakham, A. A. et al. Influence of Expiratory Airflow Variations on Respiratory Droplet Propagation during Fricative Utterance Productions. Under Review by Journal of Aerosol Science (2022).
Awards
2020 Graduate Returning Scholarship (ASME FED), 2019 Technical Committee Best Paper Award (ASME FED Multiphase Flow), Graduate Student Scholarship (ASME FED), 2017 Best Oral Presentation (RAPS Conference at Clarkson University)
Senior Software Engineer, •Senior Java Developer at Ford Motor Company, Ford Motor CoSenior Software Engineer, •Senior Java Developer at Ford Motor Company, Ford Motor Co