Mechanical Engineer

VIDHYA SAGAR R. ARUMALLA

*** **** ****** **, *******, GA 30324.

Mobile: 864-***-****

email: ********@*****.***

Summary

• Over 3+ years of experience in CAD modeling and Finite Element Analysis (FEA).

• Over 3+ years of experience in C\C++, MATLAB.

• Proficiency in software's: CATIA V5, Pro/Engineer, SolidWorks, AutoCAD, ANSYS, ABAQUS.

• Well versed with the concepts of Product Design & Development, CAD modeling, Finite Element Analysis (FEA), Six Sigma, Vibrational Structure Analysis, Engineering

optimization and passionate to work in these areas.

• Well-developed leadership and decision making abilities with excellent communication skills.

• Strong team player with excellent organizational skills and can work independently with

minimal supervision.

Experience

2008 - 2010

Graduate Research Assistant

Mechanical Engineering Department, Clemson University Clemson,SC

• Optimal Packing of Soft-Deformable Objects (U.S. Army Project)

o Developed a new packing algorithm to effectively pack multiple rigid-deformable objects using

evolutionary algorithms in C\C++ environment.

o Incorporated collision dynamics and improved shape morphing algorithm to effectively handle

possible multiple rigid-deformable interaction scenarios.

• Agent Based Approach to Thermal Packing Optimization (U.S. Army Project)

o Minimization of the overall temperature under the hood of a car is the objective.

o Performed CFD simulations over a reduced CAD model of the car under-hood using ANSYS

FLUENT.

o Modeled flow through the porous media for grille and radiator and also modeled the radiator by

implementing the “Ungrouped Macro Heat Exchanger Model” in ANSYS FLUENT.

• Battery Thermal Packaging Design: CFD analyses were conducted on sample cell arrangements in

the battery pack. The effects of various coolants (air, glycol, and mineral oil) with varying flow

rates for different heat generations of the battery core were investigated.

• Computed non-linearity index using Fast Fourier transform (FFT) to identifying the possible

optimal, sub-optimal and robust designs of the engineering design (ex: trusses, beams).

• Coupled Eulerian-Lagrangian (CEL) analysis have been carried on the Lunar Tweel®for an

improved traction by controlling the contact pressure patch, and the tread profile in Abaqus

Explicit.

• Use of Taguchi methods (orthogonal arrays) for optimizing geometric parameters of Tweel® to

reduce vibrations during high speed rolling. The displacement of set of nodes taken from the

Abaqus Explicit analysis are given as input to the FFT and obtained the frequency of vibration.

Jan-Dec 2007

CAD/CAE Intern

L&T IES Chennai, India

• Interior Part Design: Cup Holder and Glove box of Maruti Suzuki Splash in CATIA V5:

CATIA Workbenches used: GSD, Part Design, Assembly Design, Drafting

o Injection Molded Plastic parts Design and Modification

o Design Optimization for the finalized concept

o Generated manufacturing drawings specifying ASMEY14.5M, GD&T standards

• Structural Analysis of a Die Cast Back Rest Automotive Frame :

o The Back Rest is modeled in Pro/Engineer; structural analysis is carried out in ANSYS 10.0.

o The loads are applied as per the European government regulations and additional loads which

are predicted in the event of crash.

• Thorough quality check of 3D models, 2D drawings as per client's specification in Pro/Engineer.

• Created Manufacturing, Specification and Installation drawings as per the client requirements.

• An effective member of the Design review team.

2006 - 2007 R&D in Autonomous Systems

M.V.G.R. College of Engineering India

• Investigated problems encountered by existing AGV (Automated Guided Vehicles).

• Developed a solution procedure to overcome the existing problems.

• Designed a working model "RAIL TRACK INSPECTOR" with an improved guiding method.

• Awarded a prestigious location within the R&D Department.

May-July 2006 Mechanical Engineer Intern

Nuclear Power Corporation Of India Ltd. Kalpakkam, India

• Analyzed temperature distribution of end cap welds near the Heat Affected zone in ANSYS10.0.

• Evaluated optimal parameters for end cap welds by varying parameters during experiments.

• Analyzed temperature distribution of end cap welds near HAZ (heat affected zone) using both

experiment results & simulation packages.

Academic Experience

Finite Element Analysis :

• Finite element coding in MATLAB for problems ranging from linear time independent to non-

linear transient for beam, shell, axis-symmetric, plane stress, plane strain, 3-d elements.

Geometric (Large deflection), Material and Contact non-linearity's are encompassed in the non-

linearity of the problem.

• Computed Stresses induced in a metal during a metal forming process using ALE methods in

ABAQUS.

• Performed Structural analysis of the casted locomotive frames and vibrational analysis on an

automotive body structure.

• Studied the accuracy, stability and convergence of various explicit and implicit numerical

schemes that are employed in the Finite Element methods through some physical problems.

Design Projects

• Applied DFA, DFM guidelines and FMEA techniques to redesign the existing components like

headlight casing and electric shaver. Solidworks 2008 is used to remodel the geometry.

• Designed a low cost transportation system for 2 people with cost minimization as objective

using six-sigma standards as the part of the course project at Clemson University.

Optimization using modeFRONTIER, iSight-FD and other commercial optimizers:

• Weight Minimization of a 4-speed Gear box: Investigated and developed mathematical model.

Implemented various multidisciplinary optimization (MDO) routines: all-at-once (AAO),

interdisciplinary feasibility (IDF), and multidisciplinary feasibility (MDF) and collaborative

optimization (CO) techniques using commercial optimizers modeFrontier and iSight-FD.

• Comparative study of deterministic and non-deterministic optimization methods on a practical

engineering problem (for a 10 bar truss problem).

Shape Optimization of a Flywheel for maximum energy density

• Created a flow diagram to integrate the optimizer iSight-FD with the CAE software ABAQUS

for optimization.

• Developed a shape optimization code in MATLAB that included Finite Element Analysis of

flywheel in cylindrical co-ordinates.

• Results obtained from the commercial optimizer iSight-FD are compared to the output from the

MATLAB, and an error of 0.0001% is observed.

Technical Expertise

• Programming languages : C/C ++, MATLAB, FORTRAN 77, PASCAL, BASIC.

• CAD and FEA Packages : SolidWorks, CATIA, Pro/Engineer, AutoCAD, NX(Unigraphics),

ABAQUS, ANSYS, HyperMesh.

• Software : iSIGHT-FD, modeFrontier, Optistruct, MSOffice, Adobe.

Relevant Coursework

Advanced Design Methods, Material Selection for Design, Introduction to Finite Element Analysis, Advanced Finite

Element Analysis, Theory of Elasticity, Integration through Optimization, Modern Control Engineering, Continuum

Mechanics, Engineering Optimization, Robot Manipulators, Design for manufacture (DFM), Meta-heuristics, Experimental

Statistics-Sampling, Design for Six Sigma.

Education

2010

Master of Science, Mechanical Engineering

Clemson University Clemson, South Carolina

2007

Bachelor of Technology, Mechanical Engineering

Jawaharlal Nehru Technological University India

Certifications

• Engineer In Trainee (EIT) - Certificate ID : 18022.

• Certified SolidWorks Associate (CSWA) - Certificate ID : C-RMHYQTQND2.

• Certified SolidWorks Professional - Core (CSWP) - Certificate ID : C-QYWTXCZ9B4

• Certified SolidWorks Professional-Advanced Sheet Metal Specialist-ID: C-SRXSR77HJZ

• Six Sigma Green Belt Certified by Expert Rating - ID: 2574759.

Professional Memberships

• American Society of Mechanical Engineering (ASME), member.

• American Institute of Aeronautics and Astronautics (AIAA), member.

• SAE International (Society of Automotive Engineers), member.

Accomplishments

• Organized and Volunteered in 11th International DSM Conference on October 2009, at

Clemson University.

• Presented "Research issues related to Packing Optimization" at ARC May 2009

conference held at Ann Arbor, Michigan.

• Presented poster "Ascertain the Magnitude of Non-Linearity of a Design Space", at

ASME-DETC August 2008 conference held at Brooklyn, New York.

• Qualified for final round and secured 6th in the event of Grid Navigator at KSHITIJ-07

an International Tech Fest organized by IIT Kharagpur.

• Secured first prize in the event Design of Safe Handling Systems at the tech fest at

Gayatri College of Engineering(2006).

• Disassembled and reassembled a motorbike in least time and stood "First" in

"Automobile Workshop" at International Technical Festival SHAASTRA-2005.

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