Mechanical Engineer

FANGYUAN (Darrell) SONG MECHANICAL ENGINEER

203-***-**** Work Authorization H1b

*******.*******@*****.*** www.linkedin.com/in/fsong

Harrison, NJ, 07029

KEY QUALIFICATION

+ 5+ years' experience in product development from concept to launch;

Capable of sheetmetal, casting, thermoplastic, mold cavity and tooling

design.

+ Solid modeling skills in history-based CAD system: Pro/E, Solidworks

including top-down design method, surfacing, assembly configuration, 2D

drawing, routing, mechanism and animation.

+ Adaptive in multi-CAD environment with direct modeling(Synchronous)

technique; Quick geometry manipulation and reuse.

+ Working knowledge in FEA package (ANSYS, Hypermesh) in mesh preparation,

stress analysis, and topology optimization.

EMPLOYMENT

MECHANICAL ENGINEER / AUTOMANN USA / Somerset, NJ /2010.9-Present

Multi-task and prioritize tasks based on project timing, budget

constraints, and product enhancements; design review with internal and

external cross-function team; streamline product development workflow.

+ Promote PDM system for better integration and data management across

engineering team;

+ Create fully parametric models from point clouds by laser scanning saving

modeling time up to 50%, rapid prototyping through local lab and CMM

inspection planning;

+ Casting design for suspension components: complex surface modeling

technique for transition area; Associated cavity design: parting line,

runner and water line. Perform wall thickness analysis, flow analysis,

draft angle check-up and runner optimization;

+ 2D drawings dimensioning as per ASME Y14.5(GD&T) and tolerance stack-up

analysis;

+ Interact with suppliers to solve technical concerns, reduce cost and

implement DFM and DFA strategies; Issue ECR/ ECO for design changes and

propose corrective actions (CAPA) for quality issues; APQP documentation

and PPAP submissions.

MECHANICAL DESIGN ENGINEER/JINGCHENG HEAVY INDUSTRY /Beijing, China/ 2006-

2008

Used Pro/E as a primary design tool on a daily basis; prepared design

solution meeting functional, dimensional specifications, improving product

performance; provided monthly written reports outlining tasks performed;

+ Created robust 3D model at both part and assembly level; Interference

check and mechanism simulation (DMU) of turntable and extending leg

assembly of chassis; Pro/Piping for hydraulic and Po/Cable for electronic

schematics;

+ Detailed 2D drawings at part level and assembly level; BOM generation and

cost analysis.

+ Solved design challenges by engineering calculations and behavioral

modeling (BMX) with less design iterations; FEA verification by

Pro/Mechanica: solid tetrahedral element with higher order and local mesh

refinement to achieve better convergence.

+ Interfaced with suppliers to ensure that sub-components complying with

quality and delivery standards.

EDUCATION

M.S, Mechanical Engineering, University of Bridgeport, Bridgeport, CT, GPA

4.0, Dec 2010

B.S., Mechanical Engineering, Beijing Technology and Business University,

Beijing, China, 2006

SKILLS

+ Pro/ENGINEER Advanced user ( Mechanica, ISDX, BMX, Mechanism)

+ ANSYS Workbench/Abaqus CAE Intermediate user in structural and thermal

analysis.

+ Rapidform XOR3 XOV2

+ Hypermesh/Optistruct mesh generation/size, shape, topology optimization

+ Star CCM V6 external air flow analysis, thermal analysis, solid fluid

interaction

+ MS Office SharePoint, Project, Excel Pivot table

+ English & Mandarin

PROJECT HIGHLIGHTS

Dual axis solar tracking system design (9/2010-11/2010)

+ Collected load info through dynamic analysis then transferred into

Mechanica(FEA)

+ Design optimization by adjusting design variables based on FEA result

+ Validated deformation and stress results by partially coupled

Fluid/Solid interaction

Stress analysis of turbo blades by FSI (Fluid-Structure-Interaction)

(6/2010-7/2010)

+ Fully simulated rotational behavior of turbo blades in the design

process

+ Couple elastic solids to fluids in one way direction at steady mode

Simulation of the External Flow around a Vehicle (3/2010-5/2010)

+ Extracted the drag force and lift coefficient associated with flow

over geometries

+ Visualized flow through streamline and velocity scalar

Lunarbotics Mining Competition (09/2009-05/2010

+ Contributed to major concept design and 3D CAD work

+ Collaborated with teammates to fabricate prototype model

Fixture Design in Pro/Manufacturing (10/2009-11/2009)

+ Strengthened the seamless compatibility from design to manufacture.

+ Simulated 5-axis surface tool path in Pro/NC & Vericut.

+ Performed post processing and converted to G-code cutting in Haas Mini

Mill.

Endoscopic clip application devices (07/2009-08/2009)

+ Engineered a precise clip feeding mechanism by dynamic analysis in

Pro/Mechanism

+ Injection molding and rapid prototype methods (SLA, SLS and FDM).

+ Updated surface modeling skills in ISDX module by creating upper &

lower housing.

+ Animated demonstration for product showcase and rendered in Hypershot.

High speed Automation Wire Assembling System (09/2008-11/2008)

+ Improved the speed and repeatability of a continuous system with

minimal maintenance.

+ Performed BMX analysis to solve engineering problems with less design

iterations.

+ Organized large assembly plus simplified representations.

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