SUSHEEL KUMAR
MORRISVILLE, NC acunjt@r.postjobfree.com
• Proficient in mechanical design, 2D & 3D modeling and strong knowledge of engine components. Certified Catia V5 Designer.
• Strong background in metal fabrication, especially in casting and machining processes.
• Team player with good communication skills and a self-motivated fast learner.
• Available to start work immediately and open to relocate
Willing to relocate: Anywhere
Authorized to work in the US for any employer
WORK EXPERIENCE
MAKS Industries LTD. Hyderabad, India (Automotive Industry) June 2012 - Nov 2013
Role: Mechanical Design Engineer
Designed new and used parts (Brake Spider Casing, Cylinder Head, Pistons, etc.) to work together and suit customer specifications while keeping costs low
Worked with New product development and transformed products from development to production
Create easy to comprehend 2d drawings for vendors to manufacture
Upgraded two dimensional engineering drawings into 3D models in Solidworks to allow faster assessment and more accurate layouts of machines
Prepared bill of materials (BOM). Developed and recommended changes in product design for manufacturing process
Communicate with customer and implement any desired changes in Design. Also allow a line of communication so both parties are on the same page
Resolved manufacturability problems associated with product design and completed engineering change order
Suggested innovative solutions to customer performance required to meet quality standards and cost effective. Maintained project files as per ISO standards
Worked with the process development team to improve product quality with metrology using stage gate process
Executed manufacture engineering, production control, Lean principles and equipment engineering
Developed and analyzed Statistical Process Control (SPC) and product specifications to ensure quality of the received products
Rane Engine Valves, Hyderabad, India.
Role: Mechanical Intern Nov 2011-April 2012
Designed engine valves for 2 stroke & 4 stroke engines by using SolidWorks and AutoCAD by considering GD&T
Prepare sheet metal and tool design and 2D drawings for machine fabrication and assembly
Assist engineering department with the facilitation of design and manufacturing unit.
Performed various machine shop operations, including milling, lathe work, grinding, welding, etc.
Helped reduce wasted time and organized a specific cell in the manufacturing line by using Lean Manufacturing techniques
PROJECTS
Title: Design of High performance Turbo Charge Oct 2014
Prepared Conceptual Design of Turbo Charger parts, defined dimensions and ensured that products are manufacturable
Introduced multistage compressor into turbocharger to increase pressure ratio
Calculated pressure increase due to secondary compressor. Which directly effect engine power and performance
Developed 2D & 3D models of Centrifugal Compressor, Compressor housing, Shaft, Bearing etc. in Part drawing in Pro-E & Solid works
Performed drafting to generate blueprints for manufacturing purpose and assembled Turbo Charger parts
Result: Due to secondary compressor 5% increase in engine power
Title: Finite Element Analysis of a Flat Plate using ANSYS Work Bench March 2014
Performed Model, Static Structural, Harmonic Response and Flexible Dynamic Analysis on a Flat plate
Frequencies, deformation and von Mises stresses were evaluated and compared with material ultimate stress
Prepared technical report and presentation for resultant simulation.
Title: Finite Element Analysis on Contact Surface using ANSYS Software
Prediction and analysis of maximum deflection, maximum stress points and point of contact between surface of two cylinders when cylinders are placed in a closed box with internal pressure inside the cylinders
Independent Study project, Gannon University, Finite Element Analyst
Simulated deformation and stress points on cylinder specimens for internal pressure and compression tests to estimate the deformation shape, stresses and strain distribution properties using ANSYS to verify the analytical method with 4 different models
Regenerated specimens sketches with detailed manufacturing dimensions using Solidwork.
Re-conducted experiments to eliminate the inconsistence and justified the analytical methods and simulations
Title: Design and Analysis of Industrial Turbine Blade expose to Critical Stresses, Temperatures and Forces Oct 2014
Gathered blade specification from the internet and Designed 2D & 3D drawings of turbine blade in Solidworks
A Feasibility study was done on manufacturing techniques of the turbine blade
Calculated centrifugal force which is generated due to rotation, bending force due to the momentum of the fluid, bending stresses and safe centrifugal stress
Performed finite method analysis on turbine blade in ANSYS software. Recorded von misses stresses, bending stresses, critical temperature and compared with hand calculation
Title: Application of Carbon Fiber Composite Material on Artificial (Prosthetic) Limbs (Research Project) Sep 2014
Studied toughness, flexibility and strength need to withstand all forces while using artificial limb
Performed destructive testing on carbon fiber composite material and collected test data
Gathered different manufacturing techniques to manufacture artificial limbs in lower cost
Compared carbon fiber limbs with other conventional limbs made of wood and metals
Title: Design and CFD Analysis on Cessna 172 aircraft wing
Gathered NACA 2412 airfoil specifications and other details of the Cessna 172 wing to design in CAD software
Built 3D model of the Cessna 172 wing in Catia V5 software and then imported into ANSYS Fluent to do CFD analysis
Performed CFD volume analysis on the Cessna 172 wing and gathered total lift and drag data producing by wing
Regenerated wing sketches with detailed manufacturing dimensions in Catia V5 for scale wind tunnel Model
Manufactured Cessna 172 wing with reduced scale model and then tested this model in a wind tunnel and gathered lift and drag data.
Compared with the data gather from wind tunnel tests with the data of CFD simulation in ANSYS Fluent. The resultant data of both analyses were nearly equal
Title: Design, Analysis and Manufacturing of a Solid Rocket Motor (Project Leader) April 2012
Designed 2D & 3D convergent-divergent nozzle and Rocket parts in Solidworks and Catia V5
A Feasibility study was conducted with the Rocket parts under different conditions. After completing design and material selection cost analysis was performed
Chemical analysis was done to achieve higher combustion efficiency for rocket fuel
Built full vehicle CFD model of rocket for aero thermal analysis. Performed aero-thermal analysis on rocket motor and nozzle
Flow analysis and thermal analysis performed in CFD and ANSYS. Determined series of operations needed to manufacture
Developed required process and documentation for fabrication of parts. Interacted with fabricator for efficient production
Validation of the project was done after assembly of rocket parts. Prepared technical report and presentation
EDUCATION
Master of Science (Mechanical Engineering) GPA 3.30
Gannon University, Erie, PA Aug 2015
Bachelor of Science (Aeronautical Engineering) GPA 3.20
J.N.T. University, Hyderabad, India May 2012
TECHNICAL SKILLS
Mechanical softwares: CATIA V5 (2 Years) AutoCAD (6 Years), Autodesk Inventor (3 Years), Solidworks (4 Years), Pro-E(2 Years), NX (1 Year), Team Center, ANSYS (3 Years) & CFD (Gambit &Fluent) (1 Year)
Programming languages: C, MATLAB
Editing packages: MS-WORD, MS-EXCEL and MS-POWERPOINT
Mechanical Knowledge: Hydraulics, Pneumatics, Injection Molding processes, SPC, DOE, Mechanical systems, Machine tools, Quality control, Manufacturing processes, ASME Standards, CNC Machining and Programming, Materials, Surface behaviors, Plastics, Plant layout, Tribology Mechanism, Mechanical Systems, ASME and ANSI
HARDWARE SKILLS
Work Experience (3 Years): CNC Machining, Lathe Machine, Milling Machine, Drilling Machine, Welding (ARC & Gas welding), Foundry and Sheet Metal
Strong Knowledge: Machine Tools, Materials, Hand Tools, Fixture, Gauges and Jigs
COURSES
Engineering Analysis
Internal Combustion Engines I & II
Project Management
Reliability Engineering
Thermodynamics
Manufacturing technology I & II
Finite Element Method
Engineering Materials
Risk Management
Production Drawing
Turbo Machinery
Strength of Materials
STRENGTHS
Possess excellent self-directed, time management skills, highly motivated and organizational skills
Ability to solve complex problems by scientific rules and methods
Extensive Knowledge in designing tools, machine design, GD&T, IC engine, Transmission System, Manufacturing Technology, Plastic Injection Molding, PLC programming, Sound Scientific Principles, Rotary Forging, CNC Metal Spining, Connectors, Root Cause Analysis, Fault Tree Analysis and Product Failure Mode Effective Analysis (PFMEA), Engine components, Operations of Gas Handling operations, Control Plans, Risk Analysis, Design for Six Sigma (DFSS), Lean Principles, APQP, Automation Control Systems Hydraulic Actuations & Statistical Analysis.
Excellent knowledge in dimensional tolerance, quality inspection methods and control charts
Excellent knowledge of mathematical concepts with good command over verbal and written communication
Ability to work under pressure and handle multiple tasks