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Engineering Injection Molding

Location:
Cary, NC
Posted:
May 05, 2016

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Resume:

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



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