NIKHIL S. KATTA

ac2dqm@r.postjobfree.com 850-***-****

Performance driven Engineer seeking a challenging position with growth opportunities in the field of Automobile engineering. Strong theoretical and practical knowledge in design and manufacturing engineering. Experience in design and development of aerospace components and performing design changes to improve quality.

Core Competencies

Design Engineering

Control systems

Thermal Engineering and Design

Manufacturing Engineering Finite Element Analysis (FEA) Multi Project Management

Education

Master of Science in Mechanical Engineering. 2016

Florida State University (FSU) Tallahassee, FL

Bachelor of Engineering in Mechanical Engineering 2013

Jain University Bengaluru, India

Software Skills

CAD Modelling: CATIA V5, AUTODESK Inventor, Solidworks, PTC CREO

Analysis: ANSYS – Fluent and Workbench, Hyper mesh, Abaqus, COMSOL, Labview, MATLAB- Simulink, Minitab

Professional Experience

Executive Engineer Jul 2013 - Jul 2014

JS Precisions Bengaluru, India

Created 2D/3D-models of bolts, sheet metal parts, and production drawings with enough data to ensure that the part could be manufactured or gauged for functionality

Applied casting, machining principles, limitations and GD&T to component designs

Developed control plan for the production process and performed component dimensional inspections to prepare quality reports.

Estimate man hour, prepared BOM, DFM and DFMEA with precision to reduce the manufacturing time by 25% and audited internal processes according to ISO-9001

Visited our client sites, reviewed the progress of projects and maintained a good relationship with our clients

Experience in working with multi-Project environment involving several production processes and machining tools, quality control, sheet metal and forgings for the Aerospace industry

Teaching Assistant, Propulsion systems Jan 2016 - May 2016

Department of Mechanical Engineering, FSU Tallahassee, FL

Conducted office hours to assist 45undergraduate students with weekly assignments and course topics.

Corresponded with on Blackboard providing feedback on homework and examination, proctored examinations.

Assisted class instructor in photocopying, scanning and other tasks to support teaching.

Intern Jan 2012

Gedee Technical Training Institute Coimbatore, India

Hands-on experience by performing assembly and disassembly of Ford v6 Engine, and 6-speed rear wheel drive automatic transmission system and car door locking system.

Acquired knowledge of maintenance procedures, tool management and safety practices followed.

Research Assistant, Guide: CS Ramesh Feb2013 – Jun 2013 PESIT Bengaluru, India

Performed thermal expansion and conductivity testing on turbine blade materials by determining the temperature gradients by competitive cut bar method and analyzed the test data for eight different coating thickness.

Researched on the thermal expansion and conductivity effects of nickel spray coating concentration.

Follow up the tests that ran on previous shifts and prepared test reports.

Report results of testing and defects discovered, follow up on failed tests to ensure that the underlying problems are resolved.

Major Academic Projects

Casting simulation of Aluminum Alloy for wheel rim in Click2Cast package Jan 2016 - May 2016

Reviewed a process for casting automotive wheel rim (8.5”) by gravity sand casting.

3D Modelled the gating system utilizing Solidworks.

Simulated mold filling and solidification of Al-95.5%, CU-5% alloy casting.

Improved the gating system to reduce turbulence, increased the molten metal pouring temperature from 6800C to 7000C to eliminate Partial filling of the casting.

Increased the number of the risers from 3 to 4 to reduce macro porosity.

Process design to cast an Exhaust Manifold Oct 2015 - Dec 2015

Reviewed suitable alloys and designed a process for casting exhaust manifold by investment casting technique using HK 40 stainless steel alloy as the material.

The challenges involved in this process were carefully addressed.

The potential defects related to the casting products and methods to avoid these defects were also discussed.

Other relevant issues related to the casting process and material selections along with environmental concerns were addressed.

Development and characterization of Al6061TiB2 insitu composites for automotive pistons

Jan 2013- Jul 2013

Simulated the casting of Al6061TiB2 billets using Click2Cast package and optimized the gating system.

Utilized induction furnace to melt master alloy and base alloy at 800oC and obtained casted billets.

Produced castings were machined and subjected to hot extrusion process at 525oC to obtain extruded rods.

Evaluated the microhardness, wear and thermal conductivity properties of the extruded Al6061TiB2, extruded and forged Al6061TiB2 and master alloy.

Performed FEA analysis of thermal conductivity and verified by conducting thermal conductivity test on polished samples using custom test-setup.

Results confirmed a negligible change in thermal conductivity of Al6061TiB2 extruded-cum-forged component compared to the Al6061TiB2 extruded.

Simulation and Analysis of SI Engines for determining MBT timing and suppressing Engine knock

Jan 2015 - May 2015

2.4L Naturally Aspirated Engine and a 2.0L Turbocharged engine were simulated in Matlab-Simulink environment and are analyzed for various input parameters.

The MBT timing for the 2.4L Naturally Aspirated engine was determined by parameters such as spark plug timing, EGR rate and Compression ratio and analyzed by comparing the ISFC and IMEP.

The engine knocking tendency for the three parameters was investigated closely.

The effect of boost intake pressures on the MBT timing for the 2.0L turbocharged engine was analyzed and ideal MBT timing and minimum engine knock for each boost pressure intake was determined.

The effect of ISFC and IMEP on engine performance with respect to boost pressure was analyzed.

Further to obtain better power, torque and fuel economy at high boost intake pressure, the effect of EGR was considered to obtain a better MBT timing and the performance was compared to the 2.0L Naturally Aspirated engine to conclude the findings.

Failure analysis of Takata Passenger Airbag Inflator using COMSOL Aug 2016 - Dec 2016

FEA analysis of heat generation and combustion, stress concentration and stress wave propagation

3D modeled a BMW-TAKATA passenger airbag inflator on Solidworks and simulated the hot air-flow out of the

inflator holes.

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