Rahul Kumar

M.Tech graduate in Cryogenic Engineering from IIT Kharagpur specializing in thermal systems, CFD simulation, mechanical design, cryogenic technology, rocket propulsion, and AI/ML in robotics. Developed a validated transient CFD model of a micro-channel plate-fin heat exchanger using COMSOL Multiphysics and ANSYS, achieving under 2% deviation from experimental results, and designed a heat exchanger using NTU-Effectiveness and LMTD methods. Proficient in REFPROP, MATLAB, CATIA, AutoCAD, Autodesk Inventor, SolidWorks, Python, and C++.

Experienced in building ANN and CNN models for image-based classification and autonomous robotics systems using ROS2, Gazebo, and the Nav2 navigation stack.

Transient CFD Analysis of Micro-Channel Plate-Fin Heat Exchangers IIT Kharagpur, [Jan 2025 – Jun 2026]

•Developed a transient thermo-hydraulic CFD model of a micro-channel, cross-flow plate-fin heat exchanger using COMSOL Multiphysics and ANSYS.

• Determined cool-down time for cryogenic heat exchanger transient operation, supporting design optimization for thermal systems.

• Conducted a comprehensive literature review of 30+ numerical and analytical transient models for micro-channel heat exchangers.

• Designed a counter-current heat exchanger with Nitrogen gas (80K, 1.2 bar) and Hydrogen gas (300K, 25 atm) using NTU-Effectiveness and LMTD methods, validating thermal performance targets.

• Validated CFD simulation results against experimental data, achieving under 2% deviation.

Robotics and Applied AI – Autonomous Navigation System (ROS2) IIT Kharagpur, [Feb 2026 – May 2026]

• Implemented and benchmarked machine learning models (regression, classification, SVM, neural networks) for robotic sensor data analysis. • Developed and trained ANN and CNN models for image-based object classification using Python and TensorFlow/Keras. • Built generative AI models including GANs and transformer-based chatbots using Hugging Face libraries. • Simulated autonomous navigation, localization, and path planning using ROS2, Gazebo, RViz, AMCL, and the Nav2 navigation stack.

Research Intern – Heat Exchanger Thermal-Hydraulic Analysis at IIT Kharagpur [ May 2025 – July 2025]

• Reviewed and consolidated external pressure drop correlations across multiple heat exchanger geometries (spiral, finned tube), reducing design selection time via a single unified reference framework. • Derived best-fit Colburn j-factor and Fanning f-factor correlations for spiral and finned tube heat exchangers within acceptable engineering tolerance. • Validated derived correlations against published experimental datasets, quantifying deviation to confirm reliability for cryogenic and thermal system design workflows. • Evaluated Goodness Factor as a comparative performance metric for heat exchanger selection, supporting evidence-based design decisions in low-temperature systems.

Solenoid Vacuum Valve – Electromagnetic Design, CAD Modelling, and Field Simulation

Cryogenic Engineering, IIT Kharagpur [Oct 2024 – Dec 2024]

• Studied construction and working principle of a solenoid vacuum valve through lab teardown of coil, plunger, and spring. • Calculated spring stiffness (k = 34.81 N/m) and actuation pull force (Fpull = 1.08 N) from spring, friction, and pressure loads. • Designed the solenoid coil (22 AWG, 5V/960mA) to achieve a target magnetic flux density of 0.038 T at the plunger. • Developed a CAD model of the full valve assembly in ANSYS based on calculated design parameters. • Simulated the electromagnetic field in COMSOL, achieving 0.0403 T at 2300 coil turns, exceeding the 0.038 T target. • Estimated aluminium component outgassing rate (8.23×10⁻¹⁰ Torr·L/s), confirming compatibility to 10⁻⁵ mbar.

Mechanical Properties of Natural Fiber Composites – Experimental Study

B.Tech Project, [Jun 2023 – Oct 2023]

• Conducted tensile testing on 6+ natural fiber composite combinations; identified that aloe vera + pineapple fiber + wiremesh achieved the maximum tensile stress among all variants. • Evaluated flexural strength across treated and untreated fiber composites; determined that treated aloe vera + pineapple fiber + wiremesh delivered the highest ultimate force. • Characterized water absorption behaviour of 5+ fiber combinations; quantified untreated aloe vera fiber at 4.74% absorption, the highest recorded, establishing a moisture-resistance baseline for composite design.

Mechanical Installation and Project Engineering Intern at Satnam Global Infraprojects Limited [June 2022 – July 2022]

• Conducted site inspections and progress monitoring of mechanical installation across multiple plant areas. • Observed and documented piping fabrication, welding, and alignment procedures in compliance with refinery safety and quality standards. • Gained practical exposure to machinery installation protocols, commissioning sequences, and performance verification.

Mechanical Design and Assembly Modelling using CATIA at E and ICT Academy, IIT Kanpur [September 2020 – October 2020]

• Generated 2D manufacturing drawings with geometric dimensions, tolerances, and annotations. • Created 3D models of mechanical components using CATIA Part Design. • Developed assembly models and verified component fitment using the Assembly Design workbench.

Engineering Geometry and Component Design using AutoCAD at E and ICT Academy, IIT Kanpur [June 2020-August 2020]

• Designed and dimensioned mechanical part drawings adhering to IS/ISO drafting standards, ensuring manufacturability. • Practised standard dimensioning techniques, including linear, angular, radial, and baseline dimensions, to produce complete and unambiguous engineering drawings. • Constructed multi-view orthographic projections and sectional views of complex mechanical assemblies for engineering documentation. • Organised drawing files using structured layer management, title blocks, and annotation styles to maintain drafting standards.

M.Tech in Cryogenic Engineering – Indian Institute of Technology (IIT) Kharagpur (2024 – 2026)

B.Tech in Mechanical Engineering – Katihar Engineering College (2019 – 2023)

Class XII (CBSE) – Kendriya Vidyalaya Muzaffarpur (2018 – 2018)

Class X (CBSE) – Kendriya Vidyalaya Muzaffarpur (2016 – 2016)