Meticulous CAE Engineer who excels at juggling multiple tasks and working under pressure. Broad industry experience includes Trucks & Off Highway, Automobile, Recreational Vehicles, Industrial Products with strong leadership skills.HIghly Experienced, Technical, Team oriented Leader with excellent project management skills who works effectively with all levels of employees in cross-functional teams.
Highlights
Expert in ANSYS APDL, WB, Design Modeler, Space Claim (8 Years)
Proficient in Altair Products (Hypermesh, Optistruct, Radioss Non Linear Implicit & Explicit) (4 Years)
Proficient in Abaqus Implicit & Explicit (2 Years)
Proficient in Fatigue Life calculation softwares like FE Safe, N-Code (1 Years)
Proficient in Pro-E & Windchill (2 Year)
Good Experience on both chassis components & Engine components along with sub system & full system level Analysis
Good at different Project Management and leadership activities like: Process Improvement, Quality Management, Data Management, Productivity Improvement, Time management, Project Development and Life Cycle
Education
NATIONAL INSTITUTE OF TECHNOLOGYSURAT, GUJARATExpected in 2003 – –Bachelor of Engineering:Production Engineering - GPA:
with distinction – 74% (Aggregate 64%)
Accomplishments
Total 9.5+ Years of Experience as CAE Engineer in different domains
Currently Working as Onsite CAE Lead Engineer & Offshore Project Manager since 1.5+ Years in Polaris Industries, USA
1.5+ Years worked as CAE Onsite Lead in Volvo, France & India
3 Months worked as CAE Onsite engineer in Husky Injection Molding Systems Ltd, CANADA
4+ Years worked as CAE Engineer/Project Lead/Project Manager for different domains like: Recreational Vehicle (All Terrain Vehicle, Snowmobile, Motor cycle, Off Road Vehicles), Construction Equipment, Trucks, Nuclear Industries, Heat Exchanger, Automobile, Turbines, Pumps ETC
2.5+ Years worked in New Product Development area in Machine Tool, DG Set, Boilers ETC
Key FE Analysis/Product Development Projects Handled
Component, Sub System & Full System level FE Analysis on Automobile & Recreational Vehicle Engines (2-Stroke, 4-Stroke)
FE analysis on Piston & Con rod with sequential loading, Pre-stress Modal analysis of full engine, Tolerance Stack up analysis at Trans Joint, Interference Fit simulation, sequential Assembly loading simulation, Run different fatigue loadings to find fatigue life with manual calculation
Map CHT results of full engine from CFX or Fluent to ANSYS WB/APDL and find Total & Harmonic Cylinder bore distortion analytically
FE Analysis (Static, Vibration, Torsion Vibration, Vibration Fatigue, Transient Vibration) & Validation of different components of engine like: Engine shaft, Pump shaft, Connecting Rod, Flywheel, Crank Shaft etc
Sub structuring of Engine to consider engine stiffness in Different full motorcycle analysis (Modal, Static, Dynamic)
Component, Sub System & Full System level FE Analysis and design life calculation on Automobile & Recreational Vehicle Chassis and other structural components (Suspension parts, Swing Arm, Accessories ETC) using ANSYS & N-Code Packages
Worked on ROPS and some other quasi static Analysis for different cabins of Construction Equipment, Agricultural Equipment, Recreational Vehicle along with Correlation with physical test
Worked on Non Linear Buckling Analysis along with Correlation with physical test
Worked on FOPS and other Explicit analysis like: Drop Test, Simplified Crash Simulation, Simulation of Deep Draw Operation ETC
Sub Modeling of wheel, Chassis, Drive line assembly to perform detailed study and optimization of different component with Full system level loadings
Perform and handle different optimization projects on Optistruct
Develop different Automation tools in ANSYS WB/APDL or VB Application for Cylinder Bore distortion, Fatigue Life Calculation, MNF File creation in ANSYS WB, Contact generation in ANSYS APDL/WB, QC, Different result interpretation etc...
Perform Creep analysis on riveted joints
FE Analysis/ Fatigue Life Calculation/ Correlation of FE Results with Actual Test/ Product development/ Design Calculations/ Design Iterations for Off highway vehicles like Backhoe Loader, Excavators, Wheel Loader, Skid steer, Special Purpose Vehicles like different cranes, Expendable boom etc.
FE Analysis of Structural components of different Industrial Products, Medical Equipment, Securities system, different Structural Components (Main Frame, Drive Shaft etc) of wind turbine
FE Analysis & Meshing of different components of Truck & Car
Design, Validation & Fatigue life calculation of Nuclear Vessels, Boilers, Pressure Vessels, Turbine
FE Analysis of Pressurizer (Nuclear Plant Component) as per ASME SEC III and FE Analysis of different boilers as per ASME SEC VIII
Design and FE Analysis of different components of Machine Tool - CNC & Conventional machines, Alternator
Worked on Design Calculation on Math CAD
Worked on Kinematic Analysis with Working Model & Design View & Pro Mechanism
Have good Hands on Pro-E and Windchill experience for CAE & Design Project Need where CAE has major role to play
Key Achievements as Project Manager
Being in Service Industries 4+ years of total experience in Project Management
Handled and grown more 3+ accounts from 0 to 5+ team size
Handled and grown 1 account from 0 to 10+ team size
Implemented different QMS Processes in project for continuous & long term account growth
Followed CMMI Level 5 and QMS Processes for 2+ accounts with team size 6+
Always work on customer satisfaction
Spend 4000+ hours only in project management
Experience
Ford Motor Company Us - CAE Engineer Chicago, IL, 01/2006 - Current
Onsite CAE Lead & Offshore Project Manager (07/11 – Present)
Execute & Coordinate Project on ATV, SXS, MOTORCYCLE, SNOW MOBILE chassis Programs and Engine Programs
Responsible for 1st time pass & On Time Delivery
Responsible to build Software (ANSYS, Altair & N-Code) and Product Capability
Handle offshore team responsibility as Remote Offshore Project Manager
Project Lead/Manager (05/08 – 07/11)
Lead a team of seven to execute & co-ordinate projects in Truck & Off highway, Industrial Products, Automobiles etc.
Different Explicit analysis done on LS DYNA and Abaqus Explicit. Eg: Drop test, Snap Analysis etc…
Design and validation of Pressurizer - Nuclear vessel as per ASME Sec III Design Code and customer input specification
Handled big models having 5 million DOFs and extensive nonlinearity in terms of geometry, material, Bolt Pretension, Contacts etc.
Done ROPS and FOPS of an Excavator cabins as per standards. Also validated FEA results with actual test.
FE Validation of expendable Boom
Optimization of Pump (Target : 20% weight reduction) using ANSYS Workbench with different functionality and design criteria
Transient thermal, coupled field and structural analysis of LP inner casing of turbine.
Onsite CAE Lead (01/11 – 04/11)
Initiate technical discussions with client at their all locations & understand their need for Structural validation of new business family.
Design and Validate different components & Assemblies of Injection molding machines for new product line/Family using FE Analysis.
Interpret results for different load cases, find fatigue & yield safety factor for components, perform Design Modifications as per need and validate those modifications.
Work as Onsite Co-coordinator and get work done from Offshore Project Team.
Review & Interpret work done by offshore team and discuss results with Customer for design improvements and modifications.
Prepare project specific technical documentation like Scope of Work (SOW), Understanding Documents and Technical Proposal etc.
Guide and develop offshore project team as per client requirement.
Onsite CAE Lead (01/07 – 04/08)
Key participation in development of new structural validation team at New Customer site, Bangalore
Key participation in developing a relationship with customer. Visited Customer site at France for 2 months on business visa for business development activities and understand customer methodology for structural validation of different components to validate a prototype.
Worked at customer site - France for 1 year on work permit.
Done structural validation in terms of fatigue life calculation of different components.
Extrapolate fatigue life theoretically.
Handled whole project life cycle. i.e., Receive 3D model from design center > Meshing > creation of load cases as per standard> FEA calculation before test> Find high stress regions> gauge placing> Static & Field test> …> Validate the final modified design.
Used advanced ANSYS techniques like: APDL, Sub modeling, Sub structuring, Design Optimization, Adaptive meshing etc.
Developed different macros in ANSYS to remove errors from the model and to finish the task in seconds instead of days.
CAE Engineer (02/06 – 01/07)
Worked on earth moving machineries like: Excavators, Backhoe Loaders, Skid Steers and Wheel Loaders for FE Validation Projects
FE Validation of Engine components like : Connecting rod, crank shaft, Flywheel etc
FE Analysis of different components of Truck
Done meshing on different components like: Chassis, Arm, Boom, Bucket, Attachments, and Cabin etc. using Hypermesh.
Done different type of analysis like: Linear and Non Linear structural analysis, Dynamic analysis.
C32 Engine + LSA50.2/LSA69.2/LSA47.2 Alternator - MODAL ANALYSIS - Free - Free condition/ Constrained Condition/ Free - Free condition without Rail, Radiator, Control Box and Pipe/ Free - Free condition with the use of spring element as a Bearing.
Find permissible limit of Max.
Use of balancing weight on a fan to get rotor assembly balanced for more than 10 alternator fans.
Check structural integrity of rear Bracket, Front Bracket and Counter Flange for the new developed product.
Cost reduction project on Fan. GOAL: Reduce cost of fan/hub by redesigning single piece in to 2 pieces: a HUB casting with attached plastic FAN) Cost reduction project on Terminal Box (GOAL: Reduce cost of Terminal Box - Sheet metal design by making it in one piece with considering minimum hardware in design.
Product development of CNC- Vertical machining center using pro-engineer- It covers Modeling, Assembling, Detailing of all components, Making of Assembly Drawings with exploded views, Apply Model Check, Mechanism Design Extension & Mechanism Dynamic Option for checking quality of parts, Design Optimization & to ensure better performance of machine.
Dynamic Analysis of Spindle.
Convert fabricated BASE & COLUMN of CNC- vertical machining center in to casting component.
Structural analysis, Sensitivity Analysis, design optimization of bed & column of VMC using PRO-MECHANICA.
Generated standard parts for ease in modeling & assembly using concept of nested family table, PRO-Program etc.
Attachment design for mounting milling head.
Parametric modeling & gear automation using pro-E wildfire & c-language.
Work on ERP package for different requirements.
Remove vibration from BFC-15 (milling machine) during cross movement.
Troubleshooting & modification in CNC & conventional milling machine.
Plug Power Inc. - Mechanical Engineer Newark, NJ, 06/2003 - 05/2004
Cost reduction Project on Package Boiler. We have designed boiler main shell, gusset plate as per ASME code and IBR standards.
I-DEAS 10NX used to perform static linear and thermal analysis and correlation achieved by performing actual hydro test.
Using above results we have optimized boiler main shell design and reduced thickness of gusset plate so that we have achieved remarkable cost reduction of 18000INR per 1 Boiler.
Product development & design of CNC tables, Fixtures for holding big diamonds during cutting operation & mountings for holding optics - It covers Modeling, Assembling, Detailing of all component and making of Assembly drawings with exploded view.
Affiliations
Certificate Course in IDEAS (CAD House, 2002)
Attended 2 Days ANSYS advanced Workshop for Solver Technique and MBD (ANSYS, 2008)
Attended 3 Days ANSYS advanced Dynamic analysis Training (ANSYS Pune, 2007)
4 days basic training on PATRAN/NASTRAN (SVNIT, 2002)
Additional Information
Presented a Paper in ANSYS India User Conference 2008 on APDL & Sub modeling (ANSYS, 2008)
Active member in collage technical and cultural festival organizing committee
Member of Collage Training and Placement Committee (SVNIT, 2002-03)
Presented a seminar on Rapid Prototyping (SVNIT 2003)
1 Month Training at KRIBHCO.LTD, HAZIRA IN NDT Department (2001 - 02)
1 Month Training at INFAB.LTD, SURAT IN FABRICATION Department (2000 - 01)
1 Month Training at TEXFAB.LTD, SURAT IN FABRICATION Department (1999 - 00)
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