CFD ANALYST

RAHUL SURIANARAYANAN

********@*********.*** 810-***-**** www.linkedin.com/in/rahul-surianarayanan Open to relocation

SUMMARY

Graduate automotive engineer with 2 years of experience in powertrain modeling, testing and optimization using data acquisition devices, CAE tools and computational fluid dynamics (CFD) at LHP Engineering Solutions and Kettering University

Professionally trained in engine calibration, gasoline engine management systems, control strategy development, CAN communication, MIL and HIL testing and possess in-depth knowledge in IC engines, hybrid powertrain systems, drivetrain, combustion, emissions, vehicle dynamics and OBD II

Worked as a full-time automotive technician for Pratham Motors, India – Extensive hands-on experience in vehicle service, diagnostics, repair and validation

Software Skills: MATLAB, Simulink, LabVIEW, MotoHawk (Code Generation tool), MotoTune (Calibration tool), CANKing, AVL Fire, AVL Fire M, Converge, ANSYS, CarSim, Pointwise, SolidWorks, CATIA V5, MS Excel

Hardware: Woodward ECUs, Kvaser CAN, OBD II, VBox PerformanceBox, HIL (LHP DTE)

PROFESSIONAL TRAINING

“Fundamentals of Controls Systems – Gasoline” SAE Certificate of Mastery Aug. 2017 – Sept. 2017 LHP Engineering Solutions, Pontiac – Michigan

SAE J1939 CAN

Code Generation Training

Engine and Controls Training (Speed Governing; Control Model; System Diagrams, Wiring, and CAN)

PID Controllers and Calibration

Engineering Process Training (Agile SCRUM)

Business Soft Skills (Business etiquette, leadership, stress test, team building)

WORK EXPERIENCE

Graduate Research Assistant - CFD Analyst - Kettering University Jul. 2016 – Present

Modeled 3D direct injection diesel and dual fuel engines in AVL Fire incorporating appropriate turbulence and spray models to comply with emission standards while delivering industry level results

Investigated the potential of direct injection CNG systems for dual fuel engines to achieve diesel-like performance (high efficiency and low-speed torque) and eliminate knocking

Focused on the effect of spray configuration, swirl motion and piston bowl design on emission characteristics

Designed a wave piston (patent of Volvo) for a diesel engine to allow the fuel/flame jet to re-enter the piston center that helped break the inherent NOx-soot emissions trade-off

Resolved the problem of poor air-fuel interaction near the center of deep bowls through a deflector ring design

Automotive Technician - Pratham Motors Pvt. Ltd, India Jun. 2014 – Aug. 2014

Gained hands-on experience in powertrain, suspension, and brakes repair/services

Noted customer complaints and conducted necessary inspections on the vehicle

Diagnosed vehicle malfunction and recommended appropriate services

Performed quality checks and validation of the vehicle through on-road testing

AUTOMOTIVE AND CONTROLS PROJECTS

Vehicle Performance Testing

Created EREV model, vehicle energy model and battery capacity model using backward Simulink method for a 2017 Audi Q7 to evaluate battery capacity and performance

Evaluated the battery SOC and DOD swing for Audi Q7 in FTP-75, UDDS and US06 drive cycles

Performed warm motoring, cylinder cut-out tests to find friction and pumping losses of a 3.8L Buick V6 Engine

Evaluated the best fit acceleration, top speed and fuel economy for a ‘94 Saturn SL2 based on final drive ratio and rolling radius combinations

Calibrated OBD II data to calculate road load forces, rolling resistance and coefficient of drag acting on a 2013 Nissan Sentra during a coast down test

Managed on-road acceleration tests using an inertial dynamometer (Vbox PerformanceBox)

Performed wind tunnel test on a scaled truck model with tailgate up and down to find coefficient of lift and drag

Manual and automatic transmission tear down sessions to gain insight – CVT and dual-clutch

Driveline Characteristics Study of Kettering University’s FSAE Vehicle (Yamaha Y450F Engine)

Determined available wheel power from a chassis dynamometer test

Measured torque and power output of the engine are plotted against vehicle and engine speed

Study of shift RPMs and slope of N/V ratio

Bosch Dv – e5 Electronic Throttle Position Controller using a Linear Potentiometer

Utilized Simulink blocks to develop a control model for an electronic throttle controller

Calibrated the electronic throttle position and pedal position using MotoTune

Tested and validated controller while varying the pedal position using MotoHawk

Development of Minimum and Maximum Governor Control Models

Developed minimum and maximum governor models in Simulink for controlling engine speed

Simulated controller model on Hardware in Loop (HIL) to test and validate engine states and logic

Calibrated and tuned the engine using MotoTune

Tested final engine control model on GM Ecotec 2.4L gasoline engine at different load conditions

Development of Gasoline Engine Speed Control System

Designed engine PID controller, plant model, and Engine Position Tracking (EPT) system for a gasoline engine

Developed a state machine for stall, crank, run, and overload states and calibrated engine for different states

Executed gain scheduling and feed forward look up table for lower response time and stabilized engine speed

Implemented different techniques to improve PID controller model (Gain scheduling, saturation, anti-windup)

Distributed Control System for Electronic Throttle and CAN Communication

Developed a feedback PI electronic throttle controller (ETC) using Simulink and MotoHawk blocks

Calibrated the control system using MotoTune, Tested and validated the controller using throttle valve

Learned about the instabilities encountered in feedback PI control system and ways to eliminate them

Controlled remotely the ETC using CAN Communication

Development of a Control System for an Electronic Fuel Injector

Selected piston position and crank shaft RPM as simulation parameters

Calibrated the control system using MotoTune

Simulated the control system for different engine speeds and tested on the fuel injector

ACADEMIC PROJECTS

CFD Evaluation of Fuel Injection Techniques in a DI Diesel Engine to Reduce Emissions

Visualized and simulated the optimum spray angle and nozzle hole diameter for uniform air-fuel mixing in AVL Fire

Achieved a 70% drop in NOx PPM when using the split injection technique

Vehicle Dynamics Portfolio for a 2005 Ford 500

Simulated acceleration, braking, tire patch forces, ride dynamics, low-speed steering and high-speed steering conditions on CarSim and compared the results to mathematical model tabulated on MS Excel

Examined the vehicle’s suspension, control arms, brake calipers, tie rods and dampers using a car lift

Mini Sled Impact Evaluation

Replicated an impact of a car using paper cup to create a crush profile on a pneumatic mini sled

Developed a mathematical model to find the initial and final velocities of the cup using calibration curves

Repeated the same operation using an accelerometer and TEMA (Video analysis software)

Investigation of a Variable Diameter Drill Tool

Structural loads, vibrational loads and thermal stresses acting on the tool are calculated using a MATLAB code

The tool is modeled on NX and simulated using the calculated loads

Design and Analysis of Hybrid Rocket Engine Nozzle

Designed exit nozzle on CATIA V5 to obtain the desired thrust for given conditions at the inlet and throat

Pressure, temperature and velocity contours in the nozzle were presented based on ANSYS Workbench analysis

Design and Fabrication of an Automotive Differential

Fabricated using PL4 - Lathe, milling machine and gear-hobbing machine

Demonstrated the distribution of speeds by allowing the shaft axles to rotate at different speeds

Supported the weight of the differential using ball bearings

EDUCATION

Master of Science in Automotive Systems, GPA: 3.43 Sept. 2015 – Jun. 2017 Kettering University, Flint – Michigan

Bachelor of Engineering in Mechanical Engineering, GPA: 3.18 Jul. 2010 – May. 2014

Hindustan University, Chennai – India

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