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Principal Mechanical engineer FEA stress ANSYS

New York, New York, United States
December 29, 2017

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Joseph J Carbone

**** ***** *** ****, ***********, PA 215-***-**** Mechanical Engineer

More than 20 years of experience solving structural analysis problems for the aerospace industry. Expertise in managing and performing engineering analysis of military and commercial products focusing on engineering stress design, structural dynamics, transient response, fatigue testing and dynamic model simulation. Excellent record of completing projects within schedule and budget, developing innovative cost saving solutions, and creating new products as a product development leader. Partner in cross-functional team environments. TECHNICAL SKILLS

• ANSYS Workbench and APDL

• AFGROW(Air force crack growth program)

• ANSYS Explicit STR


• Workbench ANSYS/LS-DYNA

• Workbench Structural Nonlinearities

• Solid Edge, ProE, CATIA V5

• Pro Mechanica

• Pro Thermal


• MATLAB/Simulink & M-Files

• Workbench ANSYS Heat Transfer

• Workbench ANSYS Dynamics




Designs, builds and delivers Helicopters, defense and aviation-related systems. Revenue: 4.24 € billion EUR Structural Dynamics Engineer (2017- Present)

• Performed structural dynamic, Transient response, dynamic landing loads modeling and simulation in support of design and verification of AW609 Tilt rotor program. ORBITAL ATK, Corinne, UT (2016 – 2017)

Designs, builds and delivers space, defense and aviation-related systems. $4.6B,12000 Employees Mechanical Engineer IV

• Responsible for Thermal and Dynamic structural modeling of metallic and composite solid rocket propulsion components

• Performed structural dynamic and Thermal modeling simulation in support of design and verification of space vehicle rocket nozzle propulsion systems.

• Contributed as a team player in the evaluation and processing of full scale launch vehicle modal test and correlates finite element models with modal test.

• Built finite element models and evaluate critical load cases and passed to associated customer.

• Analyzes design features and determines best structural analysis approaches, methods or practices.

• Modeled and assessed rocket propulsion systems structural integrity and related composite components due to ground non-flight, ignition and propulsion test.

• Prepared and made presentations summarizing structural assessment and test results to internal and external customers.

• Reviews results of analysis tasks and determines if they are complete, correct and integrated with project objectives.

• Follows all existing processes and procedures and makes recommendations for process improvements.

• Modeled structure for dynamic capabilities and evaluated results due to operation and ground transportation excitation loads.

• Performed material tests data analysis to establish dynamic model material input properties.

• Prepared analysis models, test reports and memos documenting structural assessment results.

• Performed analysis to assist disposition of discrepant hardware and hardware anomalies.

• Interacts with Design, Development, Quality, Safety, Thermal, Materials and Operation engineering, to maintain program continuity.

JOSEPH J CARBONE 215-***-**** page 2 ENGINEERED ARRESTING SYSTEMS CORPORATION (ESCO), Aston, PA 2002 – 2016 Manufacturer and designer of aircraft emergency arresting systems. $80M, 150 Employees Principal Project Engineer III (2010-2016)

• Supported 25 product development and engineering personnel in structural design, analysis and testing with finite element analysis for civil and military vehicle launch and recovery systems.

• Supervised and guided 3 analysis and 2 design engineers in developing unmanned aerial vehicle (UAV) shuttle carriages and launcher systems.

• Performed detailed finite element analysis (FEA) and documented stress analysis on large product assemblies using ANSYS Workbench and ANSYS APDL (Ansys Parametric Design Language) that supported proposal, prototype and production systems.

• Managed $500K budget for qualifying arresting gear tests at Naval Air Weapon Center Lakehurst. Principal Project Engineer II (2002-2010)

• Responsible for managing arresting gear program budgets of $1M and schedules to support prototype build and testing at Naval Air Weapon Center Lakehurst NJ.

• Developed Finite Element Model (FEM) in LSDYNA to determine dynamic shock loads for assembly stress analysis.

• Mentored 3 engineers in ANSYS FEA for results comparison with traditional hand calculation.

• Developed FEM of reinforced concrete in ground structures that supported aircraft rollover and tire impact.

• Directed 5 designers to make hardware changes based on FEA calculated and test measured results. TRIUMPH CONTROLS INC, North Wales, PA 1999 - 2002

Designs and manufactures mechanical / electro-mechanical control systems for fixed and rotary winged military and commercial aircraft. $30M 120 Employees

Senior Stress / Dynamic Test Engineer (1999-2002)

• Performed laboratory sine sweep tests to determine the “go ahead” for random and shock tests. Modified existing designs to remove 10% weight and improve reliability and operational performance.

• Led activities associated with qualifying structures to withstand laboratory shock vibration tests and stress. Directed 3 test personnel placing strains gauge instrumentation to record load cycling stress results during qualification tests to compare with stress model.

• Performed traditional stress hand calculation on metallic an composites according to the methods of Bruhn, Niu, and Peery.

CURTISS WRIGHT FLIGHT SYSTEMS, Fairfield, NJ 1997 - 1999 Manufacturer of mechanical and flight control systems. Senior Stress / Vibration Engineer

• Managed the purchase of $65K laboratory strain gauge instrumentation to support laboratory test articles for flight control power drive units and actuators. Performed FEA simulation in ANSYS APDL for thermal, dynamic and mechanical stress analyses on flight control systems.

• Represented Curtiss Wright as a Subject Matter Expert to customers for problems related to structural dynamics, stress, and vibration. Interacted with customers and suppliers to achieve technically sound and functionally superior products.

GENERAL DYNAMICS ELECTRIC BOAT, Groton, CT 1995 - 1997 Designs, manufactures and supports the lifecycle of submarines for the United States Navy. Senior Shock and Vibration Engineer

• Responsible for building FEMs of submarines for in-water structural vibration modes and frequencies.

• Modeled and applied to the submarine system FEA model underwater explosion shock with the US Navy’s Under Water Explosive Shock (UNDEX) program to determine system critical stresses.

• Interpreted and applied shock requirements specified in MIL-S-901D and MIL-STD-167 to vibration shock model of ship mounted equipment.

JOSEPH J CARBONE 215-***-**** page 3 NORTHROP GRUMMAN (Formerly Grumman Aerospace Corporation) Bethpage, NY 1992 - 1994 Manufacturer of Air Force and Navy aircraft.

Consultant Structural Dynamics Engineer

• Simulated aircraft carrier catapult launches and arrested landings generating shock transient response loads for structural design stress and fatigue assessment.

• Correlated aircraft finite element model to ground vibration survey measured modal test data.

• Modeled aircraft main and nose landing gear use to determine airframe design shock loads. GULFSTREAM AEROSPACE CORPORATION, Savannah, GA 1990 - 1992 Manufacturer of business jet aircraft.

Consultant Structural Dynamics Engineer

• Built aircraft main and nose landing gear models to determine dynamic shock loads applied to a FEM for stress analysis.

• Modeled entire aircraft FEM models and analyzed load response due to random, tuned and discrete gust vibration excitation.

• Defined and created load fatigue spectrum due to nose wheel turning and towing ground load and aircraft Ground Air Ground (GAG) load cycles.

NORTHROP GRUMMAN, Bethpage, NY 1982 - 1989

Manufacturer of military jet aircraft.

Structural Dynamics Engineer

• Built entire aircraft airframe structural FEM and generated transient response loads due to catapult launches and arrested landings.

• Responsible for aircraft main and nose landing gear modeling and correlating model to drop test.

• Measured and calculated wind tunnel model mass properties and integrated data into FEA flutter models. PROFESSIONAL CONSULTING SERVICES

Stress Engineer Consultant 2002 – 2012

• Provided project specific consulting services on an ad hoc basis for a mechanical control systems manufacturer.

• Wrote environmental test plans for component qualification for new and existing products.

• Conducted detailed stress analysis of metallic and composite structural components of cockpit controls to the methods of Bruhn, Niu, and Peery

• Correlated and analyzed FEM structural models to meet the requirements of MIL-STD-810 and RTCA/DO-160.


BS Mechanical Engineering - Hofstra University, Uniondale, NY Certificates - UNIGRAPHICS, ANSYS apdl, Project Planning Scheduling & Control, Fastening Technology and Bolted Joint Design, ProE, ANSYS/LS-DYNA, Solid Edge, MATLAB/Simulink, ANSYS Workbench-Dynamics- Nonlinearities, Heat transfer, CATIA SmarTeam-R23- PART & ASSEMBLY-SHEETMETAL-TUBING, Airline Hydraulics: Introduction to Pneumatics

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