Abhisar Kaushal

About Abhisar Kaushal

Automotive CAE Engineer with 3+ years of specialized experience in Crash & Safety simulation at Maruti Suzuki India Limited — one of India’s largest OEMs. Expert in Full Vehicle Crash CAE across all regulatory load cases (Frontal, Offset, Side, Rear) and Occupant Injury Prediction using LS-DYNA, with a strong focus on HIC, chest deflection, femur loads, and Nij evaluation to meet NCAP and AIS compliance targets. Proficient across the complete CAE workflow — pre-processing in HyperMesh, ANSA, and PRIMER (mesh discretization, BIW & subsystem assembly, contacts, constraints) through LS-DYNA explicit dynamics solving, to post-processing and failure mode interpretation in LS-PrePost, HyperView, and HyperGraph. Experienced in conducting parameter studies, FEM model debugging, and preparing technical reports with countermeasure proposals for design and testing stakeholders. Strong fundamentals in Strength of Materials, Theory of Elasticity & Plasticity, and Automotive Body, Sheet Metal & Plastic part design.

Experience

1. Deputy Manager

   Maruti Suzuki India Limited

   Apr 2025 — Present · Gurgaon, IN

   Prepare full vehicle CAE models using HyperMesh, ANSA, and PRIMER — covering mesh discretization, BIW & subsystem assembly, contacts, constraints, material definitions, and load setting for regulatory crash load cases (Frontal, Offset, Side, Rear)Execute full vehicle and system-level crash simulations in LS-DYNA (explicit dynamics), ensuring model stability, convergence, and alignment with NCAP protocols and AIS Safety RegulationsLead occupant injury prediction using Hybrid and THOR dummy models — evaluating HIC, chest deflection, femur loads, and Nij to validate occupant protection performance targetsConduct parameter studies on FEM models to optimize restraint system performance (seatbelt & airbag interaction with occupant) and reduce predicted injury severityInterpret simulation results in LS-PrePost, HyperView, and HyperGraph — comprehending failure modes and providing direction for countermeasures and design modificationsPrepare comprehensive technical analysis reports and communicate countermeasure proposals to design and testing stakeholders for implementation of safety improvementsCollaborate with testing teams to analyze failures, correlate CAE results with physical crash test data, and improve CAE methodology accuracy through systematic FEM debugging in LS-DYNAPerform model optimization and robustness studies to improve simulation efficiency, reduce model errors, and support design exploration across multiple crash scenarios

Education

• National Institute of Technology Calicut

  Master of Technology - MTech, Energy Engineering and Management

• Gyan Ganga Institute of Technology Sciences

  Bachelor's degree, Mechanical Engineering