Optimizing EV Lubrication and Thermal Management Systems with Particleworks

In today’s electric vehicle technology race, optimizing EV lubrication and thermal management systems is a critical factor in determining the durability and performance of the drivetrain (E-axle). However, conventional CFD simulation methods often struggle with complex moving components. Particleworks—a meshless fluid simulation solution from Prometech—serves as the “key” that enables engineers to effectively overcome these challenges.

1. Challenges in Optimizing EV Lubrication and Thermal Management Systems

Unlike internal combustion engine vehicles, electric vehicle (EV) drivetrains—specifically the E-axle—integrate the electric motor, gearbox, and power electronics into a single compact unit. This architecture introduces two major engineering challenges:

• Churning losses: An improper lubrication oil volume can create excessive fluid resistance, leading to unnecessary energy losses and reduced battery efficiency.
• Localized hotspots: Electric motors operate at extremely high rotational speeds, generating significant heat. Effective EV thermal management requires oil to be precisely delivered to critical areas such as the stator windings.

Using conventional mesh-based CFD methods to simulate oil splash behavior inside gearboxes is highly time-consuming and prone to convergence issues. This is why the MPS (Moving Particle Simulation) method used by Particleworks has become a global industry trend.

2. Particleworks: A Meshless CFD Simulation Solution

Particleworks completely eliminates the meshing step—an activity that typically accounts for up to 80% of the time required in conventional CFD workflows.

2.1 Accurate Oil Splashing Simulation

Using the MPS algorithm, Particleworks tracks the behavior of individual oil droplets as gears rotate at tens of thousands of revolutions per minute. This enables engineers to optimize lubrication systems by visually analyzing how oil is transported from the gearbox sump to critical components.

2.2 Optimized Electric Motor Cooling (E-Motor Cooling)

The software allows direct simulation of oil jetting onto winding heads. Manufacturers can evaluate heat dissipation performance and fine-tune oil nozzle positioning to achieve optimal EV cooling efficiency, while reducing the risk of short circuits caused by overheating.

3. Why Should Enterprises Choose Particleworks for EV Optimization?

Global automotive leaders trust Particleworks for its outstanding competitive advantages:

• GPU-accelerated computing: Leveraging NVIDIA CUDA optimization, simulation speeds are tens of times faster than traditional CPU-based calculations.
• Seamless software ecosystem integration: Easily imports data from CrownCAD, NX, and CATIA without complex geometry preparation.
• Solid component thermal analysis: Particleworks calculates heat transfer coefficients (HTC) and maps temperature distributions onto solid surfaces, enabling accurate evaluation of overheating risks.

4. Deploying Particleworks in Vietnam with SDE Tech

Mastering simulation technology is a key enabler for Vietnamese enterprises to enhance their competitiveness within the global electric vehicle supply chain. SDE Tech is proud to be the strategic partner delivering Particleworks solutions in Vietnam, providing comprehensive support including:

• In-depth consulting: Addressing EV lubrication and thermal management optimization challenges tailored to specific engineering requirements.
• Training and knowledge transfer: Enabling engineering teams to become proficient with the software in the shortest possible time.
• Infrastructure support: Advising on optimal GPU workstation configurations to ensure smooth, high-performance simulation workflows.

5. Frequently Asked Questions about Particleworks in the EV Industry

To help enterprises better understand the capabilities of Particleworks in optimizing EV lubrication and thermal management systems, SDE Tech has compiled the most frequently asked questions:

5.1 Can Particleworks calculate the temperature of solid components?

Absolutely. Through its convective heat transfer functionality, Particleworks accurately calculates the Heat Transfer Coefficient (HTC) and maps temperature distributions onto solid surfaces. This enables engineers to identify potential hotspots early and adjust designs proactively.

5.2 What hardware configuration is required to run Particleworks?

Unlike traditional CFD software that often requires large server clusters, Particleworks is optimized for GPU computing using NVIDIA CUDA. With a single high-end GPU workstation, users can perform highly complex simulations at exceptional speed.

5.3 What support does SDE Tech provide when deploying Particleworks?

SDE Tech goes beyond software licensing by accompanying enterprises throughout the entire implementation process, including structured technology transfer training, simulation consulting tailored to real-world engineering challenges, and 24/7 technical support.

In the era of rapid electric vehicle expansion, adopting advanced simulation technologies such as Particleworks is a strategic move for Vietnamese enterprises to strengthen their market position and integrate more deeply into the global value chain. Are you looking for an optimal EV lubrication and thermal management solution for your project? Let SDE Tech partner with you to bring breakthrough designs to life.

Register for a consultation and solution demo here: https://forms.gle/XxYem17oxYyw4AKF8

SDE Digital Technology Co., Ltd. (SDE TECH)

Email: sales@sde.vn
Hotline/Zalo: 085 256 2615 – 0909 107 719