2026 ASEE Annual Conference & Exposition

Numerical Simulation Challenge: a College-Industry Cooperation to Engage Students and Enhance Learning in Computational Fluid Dynamics and Finite Element Analysis

Presented at Mechanical Engineering (MECH) Session 18: Computational Engineering, CFD, and FEA Education

Undergraduate students in Mechanical Engineering are progressively introduced to numerical simulation tools throughout the curriculum. Starting in the sixth semester, students learn the fundamentals of the Finite Element Method (FEM) and Finite Volume Method (FVM) through analytical concepts and MATLAB-based implementations for simple structural and fluid dynamics problems. In subsequent courses, FEM and FVM are applied to basic and intermediate engineering case studies using commercial CAE software. Building on this background, a senior-level elective course entitled Computational Simulation in Mechanical Engineering was designed to provide an integrated industry-driven experience in Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA), enrolling approximately 20 students per year. The same student cohort participates across two consecutive semesters, addressing a real industrial problem from both fluid and structural perspectives. The challenge involves cooperation between academia and an industrial partner specializing in mixing and processing equipment and is structured in four stages: (i) an introductory lecture delivered by an industry engineer presenting the design challenge, (ii) individualized follow-up meetings with student teams, (iii) submission of a technical report containing simulation results and proposed design improvements, and (iv) final evaluation and presentation of selected projects. Students work individually or in pairs to develop complete numerical models under academic supervision and industry mentoring. Performance is evaluated using a structured rubric combining academic criteria (model formulation, assumptions, boundary conditions, mesh quality, and technical communication) with industrial criteria (agreement with a validated reference model and feasibility of proposed improvements). Final grades are assigned on a 0–10 scale (approximately aligned with the A–F grading system) based on the submitted reports, and the highest-ranked teams are invited to present their results to industry engineers. To assess student engagement, a post-activity questionnaire was administered at the end of the second semester of the challenge. Across four years of implementation, at least 88% of participants reported that the industry-integrated challenge enhanced their learning of CAE tools. This paper presents the structure of the challenge and discusses student and industry perceptions of this academic–industrial collaboration.

Authors

Dr. João de Sá Brasil Lima Mauá Institute of Technology [biography]

Bachelor's at Mechanical Engineering (2011), PhD in Mechanical Engineering (2017) and Post-Doctoral (2019) at Polytechnic School of São Paulo University, in the Energy and Fluids field. Associate Professor of Mauá Institute of Technology (CEUN-IMT) and Coordinator of the Mechanical Engineering Course. Researcher in the Renewable Energies, Enviroment and Sustainability reseach group. Coordinator of the Renewable Energies Specialization. Has interest in fluid dynamics, optimization, CFD, bioengineering and engineering education. Valuer of engineering courses for Quero Educação/Estadão. Author of questions and reviewer for ENADE - INEP/MEC. Author of didatic books dedicated to students of elementary and high schools and college.
Prof. Alexandre Sampaio de Lima Malagodi . Luminus Engenharia [biography]

Engineer, Entrepreneur, and Professor with experience in computational simulation, industrial engineering, and technological innovation. Holds a Bachelor’s Degree in Control and Automation Engineering, an MBA in Project Management, postgraduate specializations in Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD), and is currently pursuing a Master’s Degree in Chemical Engineering at University of Campinas as an invited student. Currently serves as Professor at the Instituto Mauá de Tecnologia and at the ESSS / Ansys Institute. Founder and Director of Luminus Engenharia da Inovação LTDA. Previously developed a 17-year career at SEMCO Tecnologia em Processos, progressing from Junior Designer to R&D Engineering Manager. Research and professional interests include CFD, FEA, Fluid-Structure Interaction (FSI), turbomachinery, aerospace applications, HVAC systems, optimization techniques (DOE), pressure vessels according to ASME standards, industrial automation, and applied engineering innovation.
Marcelo Otávio dos Santos http://orcid.org/https://0000-0002-2357-6593 [biography]

Mechanical Engineer, Researcher, and Professor with over 25 years of experience in mechanical design, manufacturing processes, and applied research, integrating industrial expertise with academic innovation in advanced manufacturing technologies. Currently serves as Professor and Researcher at Instituto Mauá de Tecnologia (IMT). Holds an M.Sc. (2012) and Ph.D. (2018) in Mechanical Engineering from the University of São Paulo (USP), and recently completed two postdoctoral research programs at the same institution. Research interests include Computational Simulation (FEA/CFD), Additive Manufacturing, and Artificial Intelligence applied to engineering. Previously worked for more than a decade at B. Grob do Brasil S.A., developing manufacturing systems and machining solutions for the automotive industry. Author of peer-reviewed publications in international journals and conferences, with contributions to advanced manufacturing, smart manufacturing, and engineering education.

Download paper (1.32 MB)

Are you a researcher? Would you like to cite this paper? Visit the ASEE document repository at peer.asee.org for more tools and easy citations.

» Download paper

« View session