Mechanical Engineering Engineer

Profile Summary

Masters in mechanical engineering with over 7 years of work experience in aerospace industry – over 3 years in finite element software development and over 3 years in design and product development of aerospace forging components

Masters and Thesis

Venue: Department of Mechanical Engineering, Indian Institute of Science, Bangalore.

Time period: Aug 2001 – Mar 2004 (2 years and 8 months)

(Done under external registration program when working for HAL)

CGPA 6.3/ 8.0.

Project title

A New Approach to Process Modeling and Simulation of Metal Forming

Description

Development of new mathematical material model of the stress-strain curve, for simulation of elastic-plastic deformation of metals at elevated temperatures

Application of material model and evaluation of material parameters for common aerospace materials viz. AA2014 (Aluminum alloy) and SS304 (Stainless steel) from experiments

Development of 4 node quadrilateral finite element with the new model, to simulate non-linear elastic-plastic deformation, applying the Newton-Raphson method;

Validation of the element using benchmark tests like plane strain and axi-symmetrical upsetting through experimental results.

FE Development Experience (Post MS)

SAFRAN Aerospace India Private Ltd (SAFRAN GROUP)

Time period: Oct 2004 – Present (4 years)

The work is on development of the finite element software, which is predominantly in C language and FORTRAN. The sources include the solver, pre and post processing tools. The team consists of five members catering to the dedicated client requirement of CAE software development. The client is a leading French based tire manufacturer.

Projects handled (a gist of important projects only):

Development projects:Calculation of global rigidity (stiffness) of a tire under ground contact using Boeing sparse solver (originally skyline solver) through numerical reduction Pre and post processing tools using Python coupled with interfacing with C libraries

Numerical projects: Convergence enhancement of rolling simulation through improvements in contact kinematics for (i) quasi-static process and (ii) stationary rolling process (ALE formulation)

Optimization/Migration projects:Parallelization of element stiffness matrix computation and assembly of element matrices with OpenMP pragmas to enhance performanceDynamic memory allocation and optimization of internal files to optimize memory consumption and performancePerformance improvement (for huge simulations) through binary files optimization and management Migration from text format to XML format of input file containing material properties and boundary conditions information – using libxml library – for extensibility and readability

Post Bachelors Experience

HINDUSTAN AERONAUTICS LTD., Foundry and Forge Division, Bangalore.

Duration: Feb 1998 – July 2001 and Apr 2004 – Sep 2004 (3 years 10 months)

Role: Design Engineer

Projects outline: Product design, tool design and process simulation of forgings for Fan module of CFM Engine (for Snecma Moteurs)Stress validation of forgings of control mechanism components like Bell Crank levers, control rods etc., for ALH (Advanced Light Helicopter)Tool design and process simulation of Landing Gear Components for LCA (Light Combat Aircraft)Product design, Stress validation, and process simulation of forgings for Transmission Components for ALHProduct design, Stress validation and process simulation of forgings for Rail Rotor Forgings Schweizer (Hughes) Aircraft CorporationProduct design of ADOUR and ARTOUSTE Engine mount components

Technical Skills

Programming Languages: C, MATLAB, FORTRAN, UNIX shell scripting

Operating Systems: Linux, HP-UX, Windows

Computer Aided Analysis Tools: ANSYS, ABAQUS, DEFORM

Computer Aided Design Tools: I-DEAS, Pro-Engineer

Other ExposureVarious aerospace certification environment – ISO9001: 2000, AS9100, EN9100 etcAerospace materials, properties and applications – Aluminum, stainless steels, mar-aging steels; Nickel and Titanium based super alloys etc.International and country-specific material and process specificationsDesign requirements and loadings (static, dynamic, fatigue and creep) related to structural fuselage, control mechanism, and transmission chain assemblies.Destructive and non-destructive testing of materialsSolid modeling and CNC code generation

Professional MembershipMember of Aeronautical Society of India.

Publications"Development of forgings in AA7449" in National Metallurgist's Day organized by Indian Institute of Metals

ReferencesProfessor Udipi Shrinivasa, Department of Mechanical Engineering, Indian Institute of Science, Bangalore. Ph: 22932331, Email: *****@*******.****.*****.****. Velpari M. S., Chief Manager, Development department, Foundry and Forge Division, Hindustan Aeronautics Limited, Bangalore. Ph 918*******. Email: *********@*******.***

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