Mechanical Engineering Design

SUSHANT MALAVE

*** **** ****** ******, #* Detroit, MI 48201 313-***-**** ********@*****.*** in.linkedin.com/in/snmalave EDUCATION

Wayne State University Detroit, MI August 2015 – May 2017 Master of Science, Mechanical Engineering – Solid Mechanics GPA- 3.3/4.0 Shivaji University Kolhapur, IN July 2010 - August 2014 Bachelor of Engineering, Mechanical Engineering GPA- 3.5/4.0 SKILLS

CATIA V5 Pro/E AutoCAD DOE DFMEA Microsoft Project NASTRAN LS DYNA Siemens NX GD&T 5 Whys DFSS DVP&R Solidworks Optistruct HyperMesh RELEVANT COURSE-WORK

Finite Element Methods (FEA/CAE), Manufacturing Processing Mechanics, Applied Mechanics, Crashworthiness and Occupant Safety, Multidisciplinary design optimization, Mechanical Systems Design, Design of Machines-I & II, Vehicle Dynamics, Operational Research, Metrology & Quality control, Value Engineering, PROFESSIONAL SUMMARY

2+ years CAD & CAE experience in Product design & development, Project Management, CAD modeling, Vehicle Crash, MBD, NVH, Structural & Fatigue analysis.

2D drawing & 3D CAD modeling experience using tools like CATIA V5, Pro/E, UGNX, AutoCAD & Creo.

Experience in various engineering materials including Silafont36, Catasil 37, AHSS, Aluminum, Magnesium, Composites and their possible Light-Weighting Optimization approach in Automotive BiW structure.

Knowledge of Multidisciplinary design optimization using soildThinking Inspire & Optistruct.

Knowledge of Six Sigma, Control plans, MSA, SPC, DFSS, GD&T, DOE optimizations studies etc. EXPERIENCE

FEA/CAE Engineer Lear Corporation, Detroit, Michigan USA May 2016 – March 2017.

Worked on the Programs T1-xx, HYLF, CUSW, ZA03 etc. for seating systems e.g. Frontal & Rear impact using Hybrid III 5th & 95th percentile dummies, Seatbelt Anchorage, Headrest Strength as per the OEM standards.

Worked on modeling & analysis for Occupant Safety, Seating system using Oasys PRIMER & LS-DYNA.

Managed DFMEA, DVP&R, and DRBFM documents while working closely with other documents.

Worked with engineering and manufacturing team to search and resolve problems with existing designs.

Interpreted test data and perform correlations with Physical Tests using CAE tools such as Oasys D3PLOT.

Prepared detailed CAE Reports. Prepared lessons learnt documentation, Guidelines for utilization. CAD-CAE Trainee Engineer IKSC Knowledge Center Private Limited Pune, IN July 2014 – June 2015.

Created 2D assembly drawings using AutoCAD & 3D models of vehicle & seat components using CATIA V5.

Prepared BOM, managed DFMEA, DVP&R & DRBFM activities within cross functional team.

Learned to analyze, design & build business / technical solutions that deliver clients goals.

Meshing of BiW components, Guidelines, Quality Checks, material, Removal of Penetrations etc.

Performed CAE (Computer Aided Engineering) simulations to evaluate performance of different parts.

Performing DFSS/DOE studies on multiple iterations to find the optimized designs as per client norms.

Linear Static, Nonlinear Static, Dynamic (Explicit) analysis using RADIOSS, ABAQUS & Optistruct. CERTIFICATIONS

Diploma in Product Design & Analysis CADD Center training services Kolhapur, IN July 2013 – Jan 2014.

Learned CATIA V5, AutoCAD user interface, 2D Drawing, 3D part modeling, wireframe & surface modeling.

Learned editing parts in assembly, Bill of materials (BOM), real time rendering, tolerance dimensioning, GD&T rules, Maximizing / Minimizing material condition of a feature of a size & concept of bonus tolerances.

Worked on live industry projects involving modeling & application of DFMEA, DVP&R, APQP & GD&T.

Overview ANSYS for mesh optimization, static, modal, buckling & thermal analysis and its post-processing. MAJOR PROJECTS

Design of seat structural components considering collision performance for FMVSS, ECE standards.

Designed and modeled seat parts like side cushion members, seat back members, seat upper & lower tracks considering performance for SBA, sled test & luggage retention test specifically. .

Worked closely with CAE and manufacturing team for manufacturing constraints and cost effectiveness.

Obtained initial CAE results for stress concentrations areas & modeled all components using CATIA V5.

Prepared detailed FEA report by all obtained data & correlated with NHTSA physical test of respective vehicle.

Design of B-Pillar & its center reinforcement and its crash analysis comparison with composite material.

Prepared Function Analysis System Technique Diagram (FAST) at initial level to understand design aspects of B-Pillar & understood importance of B-pillar in Side impact, Roof Crush & ODB impact.

Gathered input information of Material data. Formability studies & Die try out

Improved section stiffness, avoided cracks & added vertical beads to control the spring back of the ‘U’ channel and for dimensional control.

Finalized reinforcement section based on DOE results, cross section moments on inertia required.

Worked closely with CAE and Manufacturing team for any updates with above parameters.

Modeled designs using CATIA V5 and sent CAD data to dimensional teams.

Compared AHSS vs Composite material crash simulation results for same design profile.

Side Impact analysis of Ford Taurus, Ford Explorer & Chevrolet Silverado as per FMVSS214.

Prepared model with Moving Deformable Barrier with velocity 50kmh & 90 side Impact angle with vehicle.

Observed permanent deformation of LH door, B-pillar & rocker panel at different intervals of simulations

Plotted accelerations curved at vehicle compartment e.g. A-Pillar B-Pillar top, middle & bottom sections.

Compared B-pillar profile (Pre-crash & Post-crash) to calculate lateral distance from vehicle centerline.

Prepared detailed FEA report by all obtained data & correlated with NHTSA physical test of respective vehicle.

Performed multiple Iterations with new designs of Intrusion beams and find best design using DOE.

Forward & Rearward 35 MPH sled test analysis of Seat with Bio-RID II & Hybrid III dummies

Prepared model with Bio-RID II & Hybrid III dummies for different seat positions e.g. FFFU/FFFD/FRFU/FRFD

Calculated Resultant Acceleration (HIC 15), Head to HR contact duration & Neck Shear-Tension forces.

Observed dummy behavior & compared above values with Dynamic & Geometric rating requirements.

Obtained stress-strain data for structural integrity criteria, also suggested suitable design & material changes.

FEA Structural & Fatigue analysis of vehicle chassis.

Prepared model with shell mesh & beam elements for attachment e.g. fuel tank mountings, engine mountings, transmission mounting, etc. Spring elements was used for suspension stiffness of the vehicle.

Analyzed for different load cases like low acceleration, braking, banked road, and road bumps.

Observed stress & deflection distribution & stress vs force over the chassis.

Using Stress-Life method fatigue analysis was performed on same FE model.

Radiation noise analysis.

Predicted the radiator noise from powertrain model for various loads like engine load which includes inertia load, combustion load, gear mesh load & chain mesh load.

Engine loads from various RPM is obtained from LMS motion view & those loads are applied at bearing location of the engine & frequency response analysis is done to check the surface vibrations of powertrain.

Fuel Tank Material Sensitivity Study.

Conducted study to understand effect of Fuel tank Material and Modeling methods on Vehicle Idle frequency.

Compared results using different solvers such as Nastran, AMLS, OptiStruct and Hypermesh.

Coordinated with Supplier, Management & CAE teams to implement the best practice.

Bending & modal FE analysis of vehicle powertrain.

Calculated modal frequencies of powertrain to check matching with engine excitation frequency

These calculated results we used in initial design phases to understand dynamic characteristic of powertrain.

For frequencies below target value, performed multiple iterations in order to improve it.

Fatigue analysis of aluminum alloy wheel under radial load.

Prepared FE model with 10 node tetrahedral structural solid element & applied proper boundary conditions.

Wheel constrained in all DOF at PCD and hub portion & applied pressure over the rim part.

Assigned S-N curve to material for safety factor & damage of wheel.

Calculated total deformation, alternative stress & shear stress.

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