SUBASH SHANMUGAIAH

Seeking Product design/CAE/Manufacturing engineering positions

*** ***** ******, ************, ** 46202; +1-317-***-****; ac2hyr@r.postjobfree.com Objective: Master student with experience in design, analysis and manufacturing of mechanical systems using various CAD/ CAM modules as well as a significant knowledge and experience in automotive industry. Seeking a Co-op/Full time. Education:

• Purdue School of Engineering & Technology (IUPUI) Dec 2017 Master of Science in Mechanical Engineering GPA: 3.6

• Anna University Dec 2015

Bachelor of Engineering in Mechanical Engineering GPA:7.2 TECHINCAL AND SOFTARE SKILLS: SOLIDWORKS, ANSYS, CATIA-V5, CREO PARAMETRIC, AUTOCAD, SIMENS NX, LS-DYNA, HYPERMESH MATLAB, LABVIEW, SIMULINK, MS-OFFICE,C++.

Work Experience:

R&D CAD/CAM Intern

Advanced Renewable Power, Carmel, Indiana April 2017- Aug 2017 Design and Modal/ Random Vibration analysis on a battery and rack module

It involved the design of trailers, axle and rack module in Solidworks.

Performed tolerance stake up, GD&T, DOE to study parameter relationships, scatter diagram to analyze the trend.

Performed DMAIC (FMEA, Root cause analysis to determine the reason for higher stress). Design being verified and validation for strength, vibration, vehicle dynamicity (FEA) etc. Performed DFM, DFA for better manufacturability and cost reduction. Automobile Technical/ Quality Intern

MPL Ford, Puducherry, INDIA June 2015-Aug 2015

Base engine testing, 02 sensor diagnostics, Vehicle problem diagnosis and their modes of failure.

Performed 5s, control charts to monitor performance, Data Analysis (Pivot table, pie charts, histograms), DMAIC (warranty and root cause analysis, FMEA for different failure modes).

Provided CAD design change (OEM models) suggestion to the plant supplier quality team with adequate results. Product Design and Validation – Final year Project TATA MOTORS Jan 2015 –April 2015

Designed various sub-system of engine parts to major automotive companies including TATA Motors, Chrysler and Jaguar – Land Rover etc. Designed and assembled of clutch, propeller shaft in Pro-E.

Designed suspension and braking systems for TATA Ace.

Designed and modeled the vehicle suspension & wheel envelope design mechanism as a part of initial screening.

Performed DFMA, GD&T and DFMEA of certain aggregates. Ranked 5th in product design among 40 colleges in Chennai. Product Design/CAE – Part Time

Harrison Technical Solutions, Chennai, India Jan 2013- March 2015

Product Design- Pump, Valves, Medical Devices, Propeller, Engine parts, Gearbox, Suspension/braking parts, Clutch, Fixtures, DC Rotor, Plastic Products, Sheet Metal, Working Tools etc. Performed DFSS on certain aggregates.

Product Validation (FEA), conducted DFM, DFA, GD&T, DVP&R, Tolerance Stake up etc.

Topology Optimization for previously design components using DOE, correlation, six sigma statistical analysis etc.

PDM of CAD design, CAE analysis, tool, manufacturing process. Manufacturing Engineer Trainee

Harrison Technical Solutions, Chennai, India Jun 2013 – March 2015

DFM design of die casting, injection molding, sheet metal products for the ease of manufacturing and cost reduction.

Determined root cause and corrective action for manufacturing defects. Prepared PPC for sheet metal operations.

Performed PDCA to reduce takt time to 9%.

Lead projects like die casting housing, sheet metal bracket, injection molding casing from prototyping to high volume manufacturing including plastic analysis, calculation of fill time, gate length and area for die casting.

Lean manufacturing utilizing lean principles like 5s, kaizen, Kanban in plastic blow molding and sheet metal manufacturing.

Practiced MRP, MSP, OEE calculation, downtime analysis. Collaborated with a team of 4 for continuous improvement.

Prepared product layout for continuous flow of material, less handling, motion and transportation.

Design of automated Manufacturing systems- CNC autoloader, PLC programing for pump mixer. PROJECT/ PAPER/ JORNAL:

Design and Fabrication of electromagnetic disc braking April 2014 The model was designed in catia with stress and vibration Analysis was performed in Ansys Workbench. Performed DFM, DFA, GD&T ( composite tolerancing ). Checked dimensions for 6 sigma capability. Journal: Design of vision based bottle cap inspection system Jan 2015 To use machine vision for identifying bottle caps which are not properly sealed and matlab was used for image processing. Paper: Ballistic performance determination of similar and dissimilar welded joints April 2015 Model was designed in AutoCAD and analyzed in Abaqus. Thermodynamics Project: HVAC of Office Building

The design of chiller, cooling tower, pump, AHU, Work Building in solid works. Demonstrated the working of chillers and their working circuits. Calculated the Chiller Cooling Capacity. Calculated the flow rate of pumps with varying RPM. Plotted in excel for mass flow rate v RPM. Studied the common types of refrigerant compressors. Performed Load calculation of a floor. Applied Mechanics CAE:

Static, Fatigue, Buckling, Thermal:

Design of steering system and fatigue analysis on the steering knuckle(Fatigue Analysis)

Transient structural analysis of Engine to determine the von mises stress

Heat Transfer of Cylinder Head

Heat Sink Thermal Analysis (Thermal Analysis)

Electric analysis of current through a copper wire(Electric Analysis

Study of static, fatigue, buckling failure of a model under certain boundary conditions Studied the plastic deformation. Determined fatigue failure and buckling under static pressure load. Explicit Dynamics:

Design / crash analysis on a car bumper

Explosion of aluminum box

Drop Test (Ansys workbench) of a phone case on a concrete, steel, aluminum floor etc. CFD: Simulation of car radiator

Simulation of airflow over a car (CFD Cfx)

Thermal insulation and heat loss in pipes (CFD FLUENT) Differentiated the fluid domain and interfaces to study the heat loss.

HVAC simulation with solar radiation (CFD Fluent) Work Building simulated for optimal ventilation under the working conditions of convection, radiation etc.

Shell and heat tube exchanger analysis(CFD FLUENT) Designed a Boiler and multiple tubes in solid works. Selected the appropriate fluid domains and interfaces. Analyzed the temperature of the hot and cold liquid after simulation.

Centrifugal Pump Simulation(CFD FLUENT)

The design involves a impeller with vane blades, housing, shaft, bearing etc. Flow rate and outlet pressure was given as input to determine the inlet pressure, head gain and efficiency . Design changes were made to avoid flow reversal. Studied the relationship between temperature, pressure and volume. Proficient knowledge in the working and design of centrifugal pumps. Automobile engine architecture in cameo systems modeler (Systems Engineering) Complete architecture of the engine components with its working was modelled in cameo. The engine was made to idle at 800rpm and fuel consumption was calculated every second. Teamcenter (PLM) CAE Integration – Efficient Product Development, Assign Workflows, Modify design, CAE Analysis in NX to meet design change requirements.

Idle Speed Engine Control and misfire detection (SIMULINK) Idle speed engine was model in SIMULINK.

An algorithm was developed for misfire detection . Worked with PID and state space controllers.

Modelled 4 gear transmission with state space logic for controller.

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