ANSYS Workbench Foundation to Expert – Episode 3: Thermal Analysis – Steady-State & Transient Simulation (Updated June 2026)

The AURIC corridor near Sambhajinagar is bringing ₹71,343 crore in investment and 62,405 manufacturing jobs to Maharashtra — and thermal simulation is one of the fastest-growing skill gaps inside that industrial base. Every EV battery pack needs a cooling system designed and validated before hardware is built. Every engine cylinder head needs thermal stress analysis to prevent cracking. Every power electronics module needs a heat sink optimised before it goes into a PCB. Episode 3 of our ANSYS Workbench Foundation to Expert series covers both steady-state thermal analysis (where we find the equilibrium temperature distribution) and transient thermal analysis (where we simulate the heat-up and cool-down process over time). These are the two thermal tools that thermal engineers at Bosch, Bajaj, and KPIT use every day.

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Why Thermal Analysis Is Critical in Modern Product Engineering

Thermal analysis answers the question: will this component overheat in service? In an EV battery pack, the answer determines whether the cells stay in their safe operating temperature range (typically 20–40°C) or degrade and potentially fail. In an automotive exhaust manifold, the answer determines whether the cast iron cracks from thermal cycling. In a motor controller, the answer determines whether the IGBT junction temperature stays below the maximum rated value. Getting thermal analysis wrong — or skipping it — leads to field failures that are expensive and dangerous. ANSYS Workbench gives you two thermal solvers: steady-state, which finds the stable final temperature distribution under constant heat input, and transient, which tracks temperature as a function of time during a heat-up or cool-down event.

Steady-State Thermal Analysis in ANSYS: Setting Up the Simulation

In Episode 3 we run a steady-state thermal analysis on an aluminium heat sink used in a power electronics module. Workflow: drag a Steady-State Thermal analysis block onto the Workbench project schematic, link it to the existing Engineering Data and Geometry from our structural analysis. Assign aluminium 6061 as the material with a thermal conductivity of 167 W/mK. Apply a Heat Generation boundary condition of 50 W to the IGBT footprint region. Set a Convection boundary condition of 25 W/m²K ambient temperature 25°C on the fin faces to model forced air cooling. Solve. The result is a temperature contour showing peak junction temperature of 78°C — safely below the 125°C maximum for the IGBT. If it were above maximum, we would increase fin surface area, change the fin pitch, or switch to liquid cooling.

Transient Thermal Analysis: Simulating Heat-Up and Cool-Down Over Time

Transient thermal analysis is where you add the time dimension. Instead of asking for the final steady-state temperature, you ask: how does temperature evolve from cold start to operating temperature? How quickly does a turbine blade reach creep temperature after engine start? How fast does a brake disc cool down after a hard stop? In Episode 3 we run a transient thermal analysis on the same heat sink, starting from 25°C ambient with the power electronics switching on at t=0. We define an Initial Temperature condition, set the end time to 600 seconds, and configure the time step to 10 seconds. The output is a temperature vs. time plot at the IGBT footprint — we see it rise asymptotically toward the steady-state value we calculated previously, reaching 75°C at 300 seconds. This kind of result is what goes into a thermal validation report for a customer.

Material Properties, Heat Flux, and Convection Boundary Conditions

Material thermal properties drive everything in thermal simulation. Thermal conductivity determines how quickly heat flows through a solid. Specific heat and density determine how much thermal energy a given volume can store. In ANSYS Engineering Data you assign these properties per material — either from the built-in library or by entering custom values from a material datasheet. Boundary conditions include: Temperature (fixing a surface at a known value), Heat Flux (applying watts per square metre to a surface), Heat Generation (watts per cubic metre inside a volume), and Convection (combining a film coefficient in W/m²K with a bulk fluid temperature). Episode 3 explains when to use each type, how to get the film coefficient value from a heat transfer calculation or experimental data, and how to handle contact conductance between mating surfaces.

Thermal Engineer Salaries and Key Recruiters Across Maharashtra

Thermal and mechanical simulation roles are in high demand across Maharashtra. In Pune: Bosch Engineering Centre at Ranjangaon MIDC (Plots A1/A2) has a large CAE group covering thermal and structural analysis; KPIT Technologies Hinjewadi runs simulation for EV powertrain thermal management; Tata Technologies hires multi-physics simulation engineers; Whirlpool Pune uses thermal simulation for appliance development. In Sambhajinagar: Bajaj Auto Waluj (Plot G-137) employs thermal engineers on engine and EV thermal systems; Endurance Technologies (E-92 Waluj) uses thermal simulation in die-cast and heat treatment process validation. Fresher thermal/CAE engineers earn ₹4–₹7 LPA; mid-level engineers ₹10–₹18 LPA. Source: AmbitionBox, PayScale India 2025–2026.

Join ANSYS Workbench Training at ABC Trainings

ABC Trainings offers ANSYS Workbench Foundation to Expert training across five Maharashtra centres. CMYKPY (Chief Minister Yuva Karya Prashikshan Yojana) provides ₹6,000–₹10,000/month to eligible domicile students. We also support PMKVY 4.0 and self-funded enrolments. Centres: Wagholi (Laxmi Datta Arcade, Pune-Ahilyanagar Highway), Hadapsar (Shree Tower, opp. Vaibhav Theater), Cidco (Kalpana Plaza, N-1 Cidco, Sambhajinagar), Osmanpura (near Jama Masjid, Sambhajinagar), and Sangli (Shubham Emphoria, Vishrambag). Call 7039169629 or WhatsApp 7774002496 to check batch dates.

FAQs

What is the difference between steady-state and transient thermal analysis in ANSYS?

Steady-state thermal analysis finds the final equilibrium temperature distribution under constant heat input — it answers how hot the component gets at operating load. Transient thermal analysis tracks temperature as it changes over time, answering how fast a component heats up or cools down from a given starting temperature. Both analyses are covered in Episode 3 with real-world examples from power electronics and automotive applications.

What industries use ANSYS thermal simulation and which companies hire thermal engineers?

Key industries using ANSYS thermal simulation include automotive (EV battery cooling, engine thermal management), electronics (PCB and IGBT thermal validation), HVAC and appliances, aerospace, and power generation. In Maharashtra, key employers include Bosch Engineering Centre Ranjangaon (A1/A2), KPIT Technologies Hinjewadi, Bajaj Auto Waluj (Plot G-137), Whirlpool Pune, and Tata Technologies Hinjewadi.

What salary does a thermal engineer earn at companies like Bosch or Bajaj Auto?

Fresher thermal/CAE engineers in Pune earn ₹4–₹7 LPA at companies like Bosch, KPIT, and Tata Technologies. In Sambhajinagar, freshers at Bajaj Auto and Endurance Technologies earn ₹3.5–₹5.5 LPA. Senior thermal engineers with 6+ years see ₹15–₹25 LPA. Source: AmbitionBox, PayScale India 2025–2026.

Is Episode 3 suitable for beginners with no prior ANSYS experience?

No prior ANSYS experience is needed for Episode 3 if you have completed Episodes 1 and 2 of the Foundation to Expert series. Episode 1 covers the ANSYS Workbench interface and geometry setup; Episode 2 covers meshing and static structural analysis. Episode 3 introduces a new physics type (thermal) and builds on the same Workbench project workflow established in the earlier episodes.