NIJAGUNA B.R.

#**** *-**** ****, *** No. ****,

Wichita KS - 67207

Email: acup6l@r.postjobfree.com

Mobile: + 001 316-***-****

professional Summary

8+years of experience on Structural Analysis, Product design and validation.

Currently at client location on onsite deputation from Infosys (H1B work permit), working on validation of structural changes and manufacturing Non-conformities of Boeing Aircraft Programs.

Leading team which works on Structural Analysis of Aircraft structures, handling both FEA and Classical Hand Calculations.

Expertise on FEA of Linear and non-Linear applications.

Worked as T-300 Airbus signatory on A350 fuselage structure Concessions.

Technical Skills

Experienced in structural analysis/Sizing of aircraft frames, floor beams, skin stringers and Wing Front Spar.

Worked as signatory, lead team for Airbus concessions of frames, skin stringers and floor beams.

Experienced in working for Airbus tools like ISAMI, Boeing tools- FAMOSS, IAS, and FEADMS.

Experienced in working on core FEA using Abaqus 6.10, Hypermesh 9, Nastran2010, and Patran 2009.

Experience in Analysis of Door and latch systems, automotive brake systems, Handling Material and Boundary Non linear Problems.

Capable of handling FEA projects individually working with direct interactions of clients

Experienced in leading cross functional team handing and exciting new projects

Hands on knowledge in Welding Design standard (EN 15085), preparation DFMEA, RAMS calculation, REX, and core project activities.

Experienced in working with project management team for initiating and estimating tenders.

Experienced in interaction with customers and suppliers for negotiations and final approvals

Experienced in working with Advanced CAD tools like Catia V5 R17, AutoCAD 2008.

Educational Qualification

Academics

University

Year of Passing

Percentage

Msc ( Automotive)

Coventry university

2007

71.2 %

BE(Mechanical)

VTU

2005

68.5 %

PUC

Pre-university Board

2001

75.4 %

SSLC

Karnataka Education Board

1999

64.8 %

Working Experience

1)Organization : Infosys Limited

Designation : Engineering Lead

Period of Work : From 16th Apr 2012 to till date.

About Unit: Infosys is one of the leading service provides in field of Aircraft structural design and analysis, working with major aircraft manufactures. The team is committed to provide service support for all Structural analysis/sizing, hand calculations and CAE activity for aircraft structures, handling aircraft frames, floor and skin stringer structures for static and Fatigue calculations.

Work Profile: Currently working as Engineering Lead, handing multiple teams which works on sustaining activity for both single aisle and twin aisle aircraft structures. Work involves understanding the non-conformity, Task planning; scheduling and allocation, Identification of baseline analysis/ calculations carried out, Analysis of the non-conforming structure, Negative margin resolution, Analysis/Calculations Review and documentation through Strength Check Notes.

2)Organization : Tata Consultancy services ( TCS )

Designation : Technical Analyst – CAE

Period of Work : From 8th June 2011 to 12th April 2012.

About Team: TCS is one of the leading service provides in field of CAE, working with major automotive manufactures and Tier 1 suppliers of automotive systems. The team is committed to provide service support for all CAE activities for brake system, handling complex FEA predictions on structural, thermal and NVH activities majorly automotive assemblies involved.

Work Profile: Worked as technical Analyst Handling small team, working on for core CAE activity. Job involves understanding the nature of problem, setting up boundary conditions, geometric discretization (FEA modeling), Pre-processing work involves calculations on non-linear material data on true stress-strain plastic data, result validation co-relation with physical testing results and report generation for final discussions.

3)Organization : Faiveley transport India Private Limited

Designation : Senior Engineer Product Engineering

Period of Work : From March 2008 to April 2012.

About Company: One of the top railway/Metro systems manufactures working world wide for conventional and metro railway segments. Key systems manufactured in India are Locomotive brakes, Pneumatic Pantographs, HVAC systems. Door actuation systems, Brake Compressors, Couplers etc

Work Profile: Currently working as Senior Engineer in product validation team. Working for core design validation of railway brakes components, Pantographs HVAC, Couplers for Metro application.

Work Deputation: Was deputed to FT Czech Republic for a period of 3 months. Projects during this deputation were supporting Customer on Initial design validation of locomotive brake components. I was preliminary point of contact between FT India and FT Czech.

4)Organization : Hydro Power Engineering Systems

Designation : Design Engineer

Period of Work : June 2005 to March 2007

Work Profile: Worked as Design executive for a period of 18 months. Involved in designing of Hydraulic and Pneumatic “Special purpose machines”. Key role in designing actuation systems, Generation BOM, Welding design, Preparation of Production drawings, casting drawings etc. Active member of CFT, for phase to phase customer approval for total life cycle of the product.

Projects Handled:

FAIVELEY TRANSPORT INDIA

Project Title : CONCEPTUAL DESIGN ANALYSIS OF LX PANTOGRAPH

Project Description : Product Development & Structural Analysis

Roles & Responsibility:

Generation of conceptual design as per TD provided by customer

Co-ordination with CAD team for development of conceptual CAD model

Preparation of PO- drawings for initial interaction with the customer

Localized Equivalent materials. The final co-ordination with SISCOs for approval of localized materials.

Geometric meshing and Setting up benchmark for Final Element Analysis.

Pre-processing of model for Structural analysis for various loading conditions and contact constraints.

Post-processing of results and presentation to customer for FAI.

Design reviews as per customer feedback.

Validation of Conceptual design.

Product prototype development and follow ups.

Generation of Test parameters as per IEC norms. Preparation of test specification.

Project Title : FAILURE PREDICTION OF TRANSPORT PALLETS

Project Description : FE Analysis

Pallets are frame structures used to transport HVAC units. During the transport major failures of pallet frame support was noticed. This field failure was analyzed. And alternate design modification was recommended. The re-designed pallet frames are currently being used for various companywide transport requirement.

Roles & Responsibility:

Worked as lead engineer and was co-ordination between departments.

The preliminary phase of investigation was requirement gathering of different field failures.

Understanding the failure modes by visual inspection

Co-coordinating with welding experts for better understanding welding properties.

Finite element analysis of transport pallet assembly and co-relation of failure modes.

Recommendation of re-designing of transport pallets.

Finite element analysis of re-designed transport pallet assembly and validation.

Hydro Power Engineering Systems

Project Title : Design and Analysis of Hydraulic Mold Fixture

Project Description : New Product Development & FE Analysis

Description: The project was intended to provide mold fixture used for foam casting for seating systems. The aim of the project is to design hydraulic press system which is capable of providing 5kg/sq.cm of internal creaming pressure with down stroke force of 750 KN and must be able to tilt and close in radial travel. The project was very challenging since the need of customer is to pack the entire fixture in 1600L * 1400 B. All 187 components are designed and assembled using CATIA V5. The component is structurally analyzed using contact constraints at the mating positions. ABAQUS is used for analyzing the component.

Role: My contribution for the project was to generate 3D CAD model and simulate the whole assembly. I was also included in designing the hydraulic tilting cylinder, clamp cylinder, moving bolster. I was put to mesh the entire assembly and set the preprocessing part for analysis.

The project was carried out in R & D center of HYDRO POWER SYSTEMS for its client HARITA SEATING SYSTEMS.

Duration: 8 months Team: 4

TATA Consultancy Services

Project Title : Structural study for Over Mold design

Project Description : Non Linear structural study for Plastics

Plastic Molding of housing incorporates huge amount of tooling cost, for each variants separate molding fixture has to be structured, which calls for increase in molding cost for a family of plastic housings. The idea was to prepare common housing fixture and over mold the connector portion to the common housing mold which saves separate tooling cost for each variant of housing for same program.

The Objective of analysis is to test and compare the over molded housing assembly with full molded housings as per the end customer standard procedures and to validate the same by testing results.

Total of 3 analysis cases were considered from standard for 2 different over mold designs. The analysis includes calculation of plastic strain data from linear stress strain data.

Assembly consists of PCB, heat sink, Top cover, Bushing enclosures pin connecting housing assembly with PCB.

The major significance of analysis is of FE modeling complex geometries of housing and connecting each pin holes of housing with appropriate locations of PCB using RB3 connector elements in order to simulate load transfer. Each connector variant surface are carefully connected to common housing using contact constraints to capture the behaviour.

The Major challenging aspect of the project is to establish proper contacts between mating parts, with proper convergence.

Displacements and stresses were from all design variants are compared with single mold housing assembly.

Design recommendations were made in order to further improve the strength of over molded housing joints.

The project was concluded and approved by end customer for prototype development and testing.

To the further the same analysis is iterated for different plastic family for comparison.

Project Title : ESC Housing Transient Thermal Stress

Project Description : Internal pressure study with temperature distribution

ESC housing assembly is major sub assembly for slip control mechanism in automotive vehicles.

Housing assembly consists of Cast Aluminum cover with Plastic (Ultradur GF 40) housing. PCU and Heat sink are enclosed between housing and cover.

The objective of the analysis is to Study of temperature distribution from cover to housing coupled with CIPG (Cured in place gaskets) loading and internal pressure as per automotive manufacturer’s standard.

2 iteration for different housing material namely ultradur and stanyl was analyzed.

Total of 4 load cases were considered as per recommendations from car manufactures

Plastic strain data for all range of temperatures involving were calculated from linear stress-strain data.

Several design recommendations were concluded on post-processing the results.

Infosys Limited

Project Title : Sec 41 Frames Analysis

The objective of the project is to analyze whole aircraft frame structures. The Project comprises of following tasks.

Geometrical data extraction: The whole frame Geometric sections are extracted for each stringer location, with details of skin/stringer thickness at each stringer location. Various required geometrical parameters are measured and tabulated.

Load extraction: Loads from GFEM frame web and inner chord are biased to the outer chord to skin node and inplane loads for all load cases are extracted. Frames are only capable of supporting inplane loads such as frame axial, in plane shear and inplane moment loads.

Analysis: A typical Frame structure compromises of Frame web, inner chord, outer chord (Fail safe chord) connected to skin stringer through stringer clip and shear ties. The scope of the project is to analyses the entire frame to skin Joint for ultimate loads.

The typical analysis checks performed are web buckling check for shear loads and combined loads. Web buckling check is also performed for limit loads. Frame chords under goes tension/compression check, Beam column, Johnson-Euler column buckling check. Inner chord also is checked for Inter diagonal tension.

The scope of skin analysis is limited to inter rivet buckling, skin compression checks. In addition to the above checks, secondary structures like shear tie and stringer clip under goes buckling, fastener, and Ultimate shear flow capability checks.

Apart from standard frame analysis checks mentioned above, Frame to Floor frame joint check, frame splice joint check, are performed followed with clevis fitting checks for bending and fastener checks are performed for separate set of fitting loads with documentation of all the above in form of Strength check notes.

Project Title : Sec 41 A350 Concessions

Worked as T300 Airbus Signatory on A350-900 concession.

Responsibility lies in concession study, Understanding the manufacturing deviations, perform stress assessment and generate the margin of safety (MS) based on the material allowable using client specific tools, providing the real time solution and documentation.

Lead a team which works on stress assessment of Aircraft frames, Floor beam and cargo Beam structures. Also involved in concession reviews pertaining to Quality Notifications (QN’s), Lateral junction Panel (LJP) and Forward Lower shell (FLS).

Authorized signatory for stresses assessment activity for all concessions executed at offshore. Has also extended role as stress assessment reviewer for concessions raised on Forward Wing Spar (FWS).

Have independently developed Floor concession validation methodology, for static non-conformities, which also involves validation of seat rail strut, cargo beams and vertical strut validations.

Project Title : Single Aisle Final Floors Stress Analysis

Various passenger air travel service providers have separate priorities for seating arrangement, Request for separate/customized monuments. Location of each monuments varies based on end customer requirements. All the arrangements of seating and monuments affects loads on floor beam, seat track and floor panels, which needs to be validated. The main objective of the project is analyze all floor frame and its attachment. Standard monuments consists of Galley, Lavatory cabins and closets. The validation includes Floor Panel Shear, Floor Beam Analysis, Seat Track Analysis, and HolyBeam Checks for Floor Beam to Frame Joint Check. All the Analysis is performed for Emergency loading conditions (9G fwd,6.5G down,3.5G up,3G left,3G right,3G right+1.5G down,3G left+1.5G down). The details of the validation carried out is listed below:

Floor Panel Analysis: All floor Panels, from Sec 41 and 47 are checked for shear loads. Floor panels are analyzed for most critical fwd load case (9G Fwd). Since Loads are staggered all along the sections at all panels, one column of panel is considered as single simply supported beam along fore-aft Direction. Considering single beam at a time shear forces on the beam along its length is calculated followed by calculation of insert shear and panel shear.

Floor Panel Bending Due to Cart Wheels: Cart wheels seating on floor panel deflects floor panels imparting a bending moment on floor panels. A stiffness method based on matching deflections is used to calculate the effective applied load in longitudinal and transfer directions maximum bending intensity is calculated and used to determine margin of safety.

Floor Beam Analysis: Floor beams are analyzed for emergency loading conditions. The entire floor beam is divided in individual bays based on the designed stiffener and intercostal structure connected. Each bay is individually analyzed for upper chord tension check, Lower chord buckling/crippling check. The Johnson-Euler Column analysis method is carried out to determine the critical buckling and crippling margins for each column

Project Title : Boeing 787 Sustaining

Structural changes/corrections are part of aircraft program. As manufacturing of each line unit progresses, new design changes are proposed based on customer requirement/cost reduction. The major structural changes involves alternative material proposal on secondary structural components, changes in electrical and electronic equipment’s which impacts structural arrangement in aircraft and change proposals to bring commonality between different variants of aircraft program.

Stress analysis/ validation of these changes are performed in-line with procedures followed for Final aircraft Sizing. The sustaining activity also comprises of validating manufacturing non-conformities reported during assembly. The stress validation involves impact study of proposed changes; re-calculating load changes involved followed with re-analysis if the changes are significantly affected followed with updates on strength check notes baselined based on results obtained.

Personal Details

Sex / Marital Status : Male/ Married

Date of Birth : 22.03.1984

Passport No. : G7314348

VISA : H1B, Valid till Sep 2016. Petition can be extended. Linguistic abilities : English, Tamil, Telugu, Kannada, Hindi

Permanent Address : Door No. 402 Arneesh Residency,

MLA Layout, Kalena Agrahara,

Bannergatta Road, Bangalore 560076

DECLARATION:

I hereby declare that all the above information is correct to the best of my knowledge.

NIJAGUNA B.R.

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