SUMMARY:
• Six Sigma Green Belt certified Mechanical Engineering graduate currently working in the ‘Product Development & Global Technology (PD>)’ group at CATERPILLAR Inc.
• 15+ months experience in automotive design. Systems designed for include- Powertrain (conventional & electrified), Engine Installation, Frame structures, Chassis mounts, PT Cooling and Vehicle Packaging
• Experience in using parametric part design, FEA simulations (stress & thermal) for design validation, GD&T and application of design principles/theories-Taguchi Robust design, TRIZ & statistical methods for life predictions
• Over 7000 hours of CATIA V5 experience. Ability to integrate manufacturing / tooling capability into design (stamping, casting & injection molding) and PT simulations / control / calibrations for optimized performance
• Professional experience in application of APQP (DFMEA & DVPR) in NPI programs for requirements/specifications development, risk analysis & mitigation and development of vehicle level testing & validation plans
SKILLS:
CAD- CATIA V5, Creo (ProE), SolidWorks, NX8.0, AutoCAD
Part Design, Sheet metal & Surface Modeling
● Machining Process- Stamping, Casting & Injection Molding
ASME Y14.5M GD&T
APQP, DFSS, DFMEA, DVP&R, DFSS, DFM, DFA
FEA (Nonlinear) - ANSYS, Abaqus, RadTherm
Simulation-MATLAB, Simulink, LabVIEW
Probabilistic Design, Prototyping & Testing
Multivariable Design Optimization
Component Testing (Hardware-in-Loop)
EDUCATION:
Master of Science, Mechanical Engineering Arizona State University GPA: 3.47/4.00 May 2015
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Bachelor of Engineering, Mechanical Engineering Anna University GPA: 8.40/10.00 May 2013
PROFESSIONAL EXPERIENCE:
Product Development Engineer (APQP) June 2015 - Present
Caterpillar Inc., Decatur, IL
• Work involved concept evaluation, design modification, cost prediction, material selection, design risk-prediction-evaluation-mitigation for NPI projects- Reversing Cooling Fan, Auto articulation, Next Gen Cab integration
• Worked on development of modified design for engine installation components (mounts, fuel/cooling lines, hydraulic hoses, exhaust pipes, mufflers) in Creo 3.0
• Utilized sheet metal design for the brackets and GD&T in creation of drawings. Tracked and updated related BOMs
• Conducted DFMEA, DVP&R & QFD at vehicle level (L7) and system level (L4)-powertrain, engine install, light fabrications and articulation systems of Motor Graders and Large Mining Trucks using APQP guideline
• Analyzed the ISO requirements (inc. ISO-9001), design concepts, guides and warranty claims (historical and field data) before arriving at the recommended control plans for risk mitigation and noise factors management.
• Special project: piloting & replacement of STPs with Simulation based Controls (SCS) across all system FMEAs
RESEARCH EXPERIENCE:
Assistant Team Lead-Powertrain Design & Chassis Integration August 2014 - May 2015
EcoCAR3, Arizona State University – Organizers: GM & DOE
• Finalized the powertrain architecture after performance calculations, analysis & selection of multiple powertrain components (1.8 L I4 engine, AC-150 EM, 80*3.6V/60Ah battery pack).
• Developed the electrified powertrain & engine install design (electric motor, adapter coupling, control module, exhaust piping, battery pack, PT cooling), mounts, electrical HV/LV routing and vehicle packaging in UG NX8.0
• Performed material selection, specifications development, strength calculations and integrated the vehicle dynamics model developed in Simulink for optimized energy consumption and acceleration (0-60 mph in < 6s)
• Generated drawings & BOM of the mounts and coupling after analysis of fabrication feasibility (casting/stamping)
• Conducted detailed FEA simulations (stress/thermal/modal) and iterated all custom designed components for optimized performance characteristics (life predictions, 50:50 weight distribution and overall cost targets)
Design Engineer-Powertrain & Thermal Management System (project with ASU) March 2014-December 2014
Torque Trends Inc., Surprise, AZ
• Developed, validated and packaged the Electric Vehicle powertrain (EM, controller, coupling, shaft, knuckle, speed reduction gear box), mounting brackets and battery package on the chassis in CATIA V5
• Conducted performance / strength calculations and weight distribution studies in CATIA V5 with emphasis on safety, 50:50 weight distribution and high acceleration performance (0-60 mph
DESIGN / OPTIMIZATION OBJECTS:
SAE Baja-Roll Cage Design and FEA for All-Terrain Vehicle (ATV) Fall 2012-Spring 2013
• Selected material & designed the roll cage / knuckle for an ATV aimed at low cost and high strength-weight ratio
• Modelled the frame CATIA V5. Validated its strength under head impact, roll over and heave loads in ANSYS
• Modified the design based on FEA simulation results for optimized safety, performance and handling
• Achieved 11% weight reduction over previous version of the roll cage. Fabricated the design using pipe bending
Six Sigma Design of Test Fixture Tool (Statistical Methods), Arizona State University Fall 2014
• Modified the structure of a fixture used for compressive load testing, employing statistical methods for high reliability
• Evaluated its failure probability (0.003) allowing six sigma variance on input (DFSS) using Monte Carlo & FORM
• Modelled the finalized design in CATIA V5 and validated the strength through FEA simulations in ANSYS
DFMA-Autonomous Vehicle & Ball Return Mechanism (Concept to Prototype), Arizona State University
Fall 2014
• Developed & evaluated concepts for an autonomous vehicle & ball return mechanism using TRIZ
• Responsible for design of the chassis, powertrain and electrified mechanism based on dimensional constraints
• Modelled & assembled the parts in CATIA V5. Analyzed compatibility between the selected components
• Prototyped, tested, modified the design to improve manufacturability reducing number of parts
• Documented the design with BOM, cost estimations, assembly drawings and tolerance allowances using GD&T
Design Optimization of a Connecting Rod, Arizona State University Spring 2014
• Optimized the dimensions of connecting rod subjected to hi...
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