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Engineer Development

Location:
Akron, Ohio, 44302, United States
Posted:
May 31, 2017

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Donald W. Cummings

** ***** **** ********* *****, Ohio 44302-1064

Tel.: (330) ***-**** Cell: (330) ***-**** Email: ac0klw@r.postjobfree.com

BACKGROUND SUMMARY

** *****, ********* ******** **********, 26 years, Stress/Structures/FEA Engineer Experience

Aircraft Primary Structures/Stress/FEA Experience – Wing Ribs, Pressurized Deck, Composite Fuselage, Fuselage Splice Joint, Windshield Divider, Composite Pressurized Cabin Bulkheads, Fuselage Main Frames, Special Fittings, Longerons, Main Landing Gear Cylinders, Nose Gear Cylinders.

Aircraft Secondary Structures/Stress/FEA Experience – Wing Trailing Edge, Deck Support Fitting, Seat Tracks, Composite Exterior Access Doors, Intercostals, Miscellaneous Brackets & Fittings, Aircraft Wheels & Brakes.

Aircraft Engines Structures/Stress/FEA Experience – Combustors, Combustor Fuel Distribution Systems, Nacelles, Cowling & Shrouds, Engine Mounting Brackets & Pylons, Lift Fan Housing, Gearbox Housing, Turbine Exhaust Case, Thrust Reverser Structural Components, Fuel Pump Main Drive Shafts.

Aircraft Brake Control Systems Components Experience – Brake Control Valves, Shut-Off Valves, Shuttle Valves, Pressure Transducers, Park Brake Handle, Hydraulic Accumulators, Wheel Speed Transducers.

Spacecraft Primary Structures Analysis – Service Module Flange Ring, Liquid Propellant Fuel Tanks

Ground Based Test Equipment – Engine Test Stands, Rocket Test Chambers, High Speed Flow Test Nozzles

Fatigue & Damage Tolerance Analysis: Modified Goodman Methods, Miner’s Rule, Rainflow Cycle Counting Methods, Load Life, Stress Life, & Strain Life Methods. LEFM Methods including crack initiation prediction and crack propagation life.

FEA Programs Experience, Approx.25 yrs. - ANSYS (rel.4.0 thru 12.0), ANSYS Workbench (rel.17.0), ADINA, ABACUS (rel.5.8), MSC NASTRAN (rel.70.7, 2017), Cosmic NASTRAN, NISA II (rel.5.0 thru 7.0), and MSC PATRAN (rel.2.0 thru 2017), FEMAP 9.2.

Analytical Programs Experience, Approx.25 yrs. - MathCAD (rel.3.0 thru rel. 14), MS Excel, Lotus 123. Boeing Specific Programs - IAS, CSW, GKJOINT.

Standards Experience, Approx.25 yrs.: F.A.R. Part 25, RTCA DO-160, MIL-STD-810, A.N.S.I., A.S.T.M., A.S.M.E. Pressure Vessel Code, Section VIII, Divison 1, D.O.D./U.S.Navy Structural Design Basis (SDB) for Pressure Vessels, I.S.O. 9000, and A.A.R. Standards.

PROFESSIONAL EXPERIENCE

Meggitt Aircraft Braking Systems, Akron, Ohio, Apr. 2011 to May 2017

Sr. Engineering Specialist/FEA Engineer

FEA stress analysis of aircraft brake components including complex brake housings, brake components, and wheels using ANSYS Workbench. Primary author of stress reports for these components.

FEA stress analysis of Roll Test Axles and Brake Test Axles used for wheel and brake dynamometer testing, using ANSYS Workbench. Primary author for related stress reports.

Fatigue & Damage tolerance analysis of Test Axles, Brake Housings, Brake Components, and Wheels. Primary author for related FD&T reports.

Review of vendor stress reports for Brake Control Systems Hydraulic Components to shown compliance with structural and dynamic requirements from the airframer.

Establishment of FEA dynamic analysis guidelines to be followed by vendors to meet Mechanical Shock, Vibration, and Acceleration requirements of DO160 and MIL-STD-810.

Set-up and running of Strain Gage Roll Tests of main and nose wheels. Processing of strain data to predict CFD and life. Primary author for related reports

Westinghouse Electric Company, Westinghouse Energy Center, Monroeville, Pennsylvania, Mar. 2009 to Nov. 2009

Sr. Consulting Structures/FEA Engineer, AP1000 Advanced Light Water Reactor

Displacement & Acceleration Response Spectrum Analysis, using ANSYS, of Control Rod Drive Mechanism (CRDM) Guide Funnel Extension Assemblies.

Flow Induced Loads Analysis, per ASME Code, for the Control Rod Drive Mechanism (CRDM) Guide Funnel Extension Assemblies due to internal reactor coolant flow.

Primary author for the AP1000 Design Loads Report (calc note) documenting all analysis calculations and results for these reactor internals. APP-MV01-Z0C-028, “AP1000 Reactor Vessel Head Extension Tube Design Loads”.

Lockheed Martin Space Systems Company & NASA George C. Marshall Space Flight Center, Michoud Assembly Facility, New Orleans, Louisiana, May 2008 to Sep. 2008

Sr. Consulting Structures/FEA Engineer, Orion Space Vehicle, Service Module

Spacecraft Primary Structures Analysis – FEMAP Finite Element Modeling of the Service Module Flange Ring, Fairing Hinge Mechanism, and Carbon Fiber Composite Fairing.

Project level review of stress reports on theses above mentioned and other service module components.

Hawker Beechcraft Aircraft Company, (Formerly Raytheon Aircraft Company), Wichita, Kansas, Feb. 2007 to Jan. 2008

Sr. Consulting Structures/FEA Engineer, Hawker 4000 Program, MRB Stress & Structural Integrity Support

Development and approval of repair processes and corrective actions to disposition MRB tags on carbon fiber primary & secondary structures composite parts, including composite fuselage, wing, and empennage repairs.

Stress analysis support by hand calculations, and or FEA, to substantiate structural compliance with FAA regulations to the FAA structures DER representatives.

Development of spreadsheet tools using hand calculations for wet lay-up repairs of composites, to replace lost strength and stiffness, to disposition MRB tags.

Development of spreadsheet tools using hand calculations for MRB structural substantiation analysis related to airframe repairs.

Extraction of loads from MSC Nastran FEA models using Patran for analysis support and disposition of discrepant parts.

Preparation and review of MRB stress reports of all major components of the aircraft to support disposition of discrepant parts. Review and disposition of SVR’s, (Supplier Variation Requests)

Boeing Aircraft Company, Integrated Defense Systems, Philadelphia, Pennsylvania, May 2006 to Oct. 2006

Sr. Consulting Structures/FEA Engineer, Boeing 787 Program, Chinook CH-47H Helicopter

Aircraft Primary Structures/Stress/FEA - Structural substantiation analysis of primary airframe, primary bulkhead, intercostals, braces MRB tags for the CH-47H Chinook Helicopter final assembly line. MSC Patran/Nastran Finite Element models for structural optimization analysis of Wing Ribs for the 787 aircraft. Models included combined composite and metal structures.

Aircraft Secondary Structures/Stress/FEA - Structural Substantiation Analysis templates for the 787 Pressure Deck Structural Fittings, Fixed Trailing Edge Main Structural Members. Static analysis, Fatigue, and Damage Tolerance analysis, per Boeing Standards BCM1 & BCM2.

Pulling of loads from existing FEA models using MSC Patran & FEADMS.

Middle River Aircraft Systems, Middle River Apollo, Maryland, Jan. 2006 to May 2006

Sr. Consulting Structures/FEA Engineer, 747-8, Thrust Reverser, CF34-10 & CF34-11 Engine Thrust Reverser Programs

Development of MSC Patran/Nastran 3-D finite element models for the 747-8 program thrust reverser major structural components. Analysis of composite honeycomb / skin structures, models included coupled thermal mechanical analysis.

Preparation and development of large scale MSC Patran/Nastran 3-D finite element models for the CF34-10, CF34-11 engine programs thrust reverser major structural components.

Rolls-Royce North America, Inc., Indianapolis, Indiana, Oct. 2005 to Jan. 2006

Sr. Consulting Structures/FEA Engineer, F-35 Joint Strike Fighter, F-135 Engine Program, STOVL Lift Fan

Aircraft Primary Structures/Stress/FEA - Development of ANSYS 2-D finite element models for the JSF F135 Engine Lift Fan Gear Box. Models included non-linear contact and coupled thermal mechanical analysis.

Development of APDL macros and ANSYS input files to automate the FEA process.

Hendrickson Trailer Suspension Systems, Hendrickson International, Canton, Ohio, May 2005 to Sep. 2005:

Sr. Structures/FEA Engineer, New Truck Suspension Development:

Development of ANSYS 3-D finite element models for structural analysis of truck and trailer suspension systems. Non-Linear models including contact and plasticity.

Development of Excel spreadsheets for determination of loads on the structural models. Development of APDL macros and ANSYS input files to automate the FEA process.

Northrop Grumman Integrated Systems, Bethpage, New York, Jul. 2004 to May 2005:

Sr. Consulting Structures/FEA Engineer, NC-130H AWACS Test Platform Aircraft, Radar Air Cooling & Conditioning System Add-On Modifications, Ram Air Duct & Heat Exchanger, Radar Air Piping Systems, EMIRS Program Cargo Door Modification

Aircraft Primary Structures/Stress/FEA – Modifications to Fuselage Main Frames & Cargo Door, Design & Installation of Intercostals.

Modifications to the NC-130H Mercer University MSC Nastran finite element model to support and verify aircraft structural loads, and determine structural response with the proposed structural modifications.

Review of the original Lockheed C-130 stress reports to provide loads, and loading conditions, for the F.E. model. Preparation of hand calculations to determine loads on the finite element model. Associate Author & Preparation of stress report for NAVAIR.

General Electric Company, Transportation Systems Division, Wind Energy Group, Erie, Pennsylvania Sep. 2003 to May 2004:

Sr Consulting Structures/FEA Engineer, 1.5 MW Wind Turbine, Planetary Gearbox

Development of ANSYS 3-D finite element models, Wind Turbine Planetary Gearbox Components, Gearbox Test Stand. Development of Excel spreadsheets, for determination of loads on the structural FEA model.

Lord Corporation, Erie, Pennsylvania Mar. 2003 to Apr. 2003:

Sr. Consulting Structures/FEA Engineer, Boeing, Cessna, & Pilatus Aircraft - Vibration Damping Engine Mounting Assemblies

Preparation and development of ANSYS 3-D finite element models for aircraft engine vibration & shock mounts including contact and plasticity. Engine mount programs for Boeing, Cessna, and Pilatus.

Stress based fatigue analysis of metal engine mount components. Comparison of finite element model results with qualification test results show model robustness, and prove design integrity.

Aeronca, Inc., Division of Magellan Aerospace, Middletown, Ohio Nov. 2002 to Feb. 2003:

Sr. Consulting Structures/FEA Engineer, GP-7200 Engine Program, Exhaust Nozzle Structures, Engine Cowlings

Preparation and development of MSC Patran/Nastran 3-D composite finite element models for the GP-7200 composite engine exhaust nozzle and plug. Analyses include 3-D modal, linear static, thermal, coupled thermo-mechanical.

Development of Excel spreadsheets, for determination of loads on the composite structural model.

MRB stress / structures support to manufacturing and assembly.

United Technologies Corporation, Pratt & Whitney Aircraft Engines, East Hartford, Connecticut Jul.-Aug. 2002

Sr. Structures Engineer/FEA Engineer, F-35 Joint Strike Fighter Program, F-135 Engine Program, Turbine Exhaust Case

Development of ANSYS 3-D finite element models for the F135 turbine exhaust case, and components. Analyses include 3-D modal, linear static, thermal, coupled thermo-mechanical. Stress and strain based fatigue analysis of metal engine exhaust components.

Development of ANSYS macros for the automated creation of finite element models for stressed skin panels.

Provided advisement on various metal alloy selection for TEC components. Also advised on exploratory materials substitution efforts to achieve weight reduction.

Direction of design engineers working on the turbine exhaust case to solve complex design problems of weight, space, and interference based upon finite element results.

General Electric Co., G.E. Aircraft Engines Division, Combustor Center of Excellence, Methods & Analysis Group, Cincinnati, Ohio Mar. 2001 to Dec. 2001

Consulting Structures/FEA Engineer, F-404, F-414, GE-90 Engine Programs, MRB Stress Analysis Support, Product Development Stress Support

Development of ANSYS 3-D finite element models for jet aircraft engine combustor components, assemblies, and systems. Analyses include 3-D modal, linear static, thermal, coupled thermo-mechanical, forced response, and response spectrum analysis.

Comparison of test data with finite element results to support failure analysis. Preparation of design reports and presentations. Stress and strain based fatigue analysis of metal engine components using GE proprietary software.

BF Goodrich Aerospace, Landing Gear Division, Cleveland, Ohio Jul. 2000 to Dec. 2000:

Stress/FEA Engineer; Product Development Stress Support, Embraer Landing Gear Programs; MRB Stress Analysis Support, Boeing 747 Main Landing Gear Program

Development of ANSYS 3-D finite element models of main and nose landing gear outer cylinders and pistons to support landing gear design, and MRB activities.

Development of various MathCAD applications, using hand calculations, to support the F.E.A. effort and other analytical landing gear analysis.

BWX Technologies, Inc., Nuclear Equipment Division, Barberton, Ohio, Jul. 1999 to May 2000

Stress/FEA Engineer; Product Development Stress Support, CVNX Naval Nuclear Steam Generator

Development of ABACUS 3-D finite element models for elastic, perfectly plastic, limit load sizing analysis of the steam generator primary head, tube sheet, & divider plate.

3-D linear static analysis of the steam generator the transition t-shell, separator plate and cans.

3-D shock & 3-D vibration analysis of the steam generator the transition t-shell, separator plate and cans.

Development of various Mathcad applications to support the F.E.A. effort and parametric studies.

Aerospace Design & Fabrication, Inc., Cleveland, Ohio, Sep. 1998 to May 1999

Aerospace Design & Fabrication, Inc. is a contractor to The National Aeronautics & Space Administration (NASA), Lewis Research Center, Cleveland, Ohio. Consulting Stress/FEA Engineer

Development of ANSYS 2-D axisymmetric thermal-mechanical finite element analysis of a hypersonic test nozzle at mach 6 & 7 flow conditions. 3-D finite element structural analysis of the RBCC (Rocket Based Combined Cycle) Test Rig Combustion Chamber. 3-D finite element analysis of the PSL (Propulsion Systems Laboratory) Engine Thrust Test Stand under engine operating conditions.

Analysis of fiber-epoxy composite LOX & LH fuel tanks for Trailblazer ETO vehicle using NASA’s ICAN composite analysis program.

EDUCATION

The University of Akron, Akron, Ohio, M.S., Mechanical Engineering, 1991.

The University of Akron, Akron, Ohio, B.S., Mechanical Engineering, 1988.

The University of Akron, Akron, Ohio, Minor, Applied Mathematics, 1990.

PROFESSIONAL REGISTRATIONS AND AFFILIATIONS

E.I.T. Ohio, 1988; Member, The American Society of Mechanical Engineers; Member, American Institute of Aeronautics & Astronautics; Member, ASM International; Member, Society of Allied Weight Engineers; Member, ANSYS Users Group, Western Pennsylvania



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