State University Engineer

SAKETH REDDY MUTHYALA

**** ****** **** **, ****** Hills, Michigan, 48326 Phone: +1-313-***-**** Email: ********.******@*****.***

SUMMARY

Mechanical Engineer with 4+ years of experience in the field of Computer Aided Engineering (CAE) in structural analysis, crashworthiness and product development

Hands on experience on performing linear and nonlinear finite element analysis on chassis, automotive door assemblies and body in white (BIW)

Expertise in simulating test scenarios for a given boundary conditions by utilizing LS-DYNA, HYPERMESH, and ANSA

Worked on post processing of results for fatigue and durability using FEMFAT calculations, and conducted design of experiments on specific parameters by utilizing kriging model code in MATLAB

Have excellent communication, interpersonal, problem-solving skills and working in cross-functional teams

PROFESSIONAL EXPERIENCE

Graduate Research Assistant

Wichita State University, Wichita, KS. December,2015 – Present (2 years)

Developed model set-up for Component level tests, sled tests, and full- scale barrier impact tests

Positioned 95th, 50th, 5th percentile and ES-2RE Dummies for various crash scenarios and evaluated injuries

Conducted component level tests such as free motion headform tests for interior impact& upper interior head impact protection in vehicle interior part’s target points by following FMVSS201-U regulations

Experienced in debugging huge DYNA deck files in case of negative volume problems, node shoot out, contact penetrations, hourglass, energy abnormalities, simulation quality checks

Modelled lap and shoulder-lap seatbelt finite element models, seat belt routing and seat squash

Worked on post-processing of results for dummy injury parameters, effective crush calculations, intrusion measurements for IIHS structural, NHTSA rating systems and created detailed reports and power point presentations

Software Used: LS-DYNA, ANSA, HYPERMESH, PRIMER, and CATIA V5

CAE Engineer

DesignTech Systems Ltd, India. June,2012 – October,2014 (2.4 years)

Assisted in developing FEA models and performing static and dynamic analysis

Conducted FE Analysis to predict the failure in components and assemblies under extreme loading conditions

Analyzed strength and durability of pintle hook and torsion bar of chassis and on automotive door components and assemblies by conducting door sag, door over opening, door belt squeeze, and door oil canning analysis

Involved in fatigue and model analysis on Body in White for different load cases like torsional & bending stiffness, side foot analysis, brake pedal & dash board deflection tests, floor sag, roof oil canning, and fender dimpling

Analyzed CAE results and recommended for modifications, optimized designs by conducting several CAE analysis iterations and created a detailed report files and power point presentations

Participated with design and development teams, supported for 2D, 3D layout drawings, prepared bill of materials

presented analysis results to engineering peers and management

Formulated ECR, ECO, ECN documentation with good interpretation and application of design for manufacturing and assembly (DFMA) and geometric dimensioning and tolerances (GD&T) standards

Software Used: LSDYNA, ABAQUS, MSC NASTRAN

EDUCATION

Master of Science in Mechanical Engineering. January,2015 – December,2017

Wichita State University, Wichita, KS. GPA: 3.8/4.0

Bachelor of Technology in Mechanical Engineering. September,2008 – May,2012

Jawaharlal Nehru Technological University, India. GPA: 3.5/4.0

MASTER’S THESIS

Improvement in Crashworthiness of a Vehicle for Side Impact Occupant Protection using IMPAXX and Polyurethane High Energy Absorbing Foam Materials.

Wichita State University, Wichita, Kansas.

Validated and analyzed stress- strain behavior of IMPAXX and Polyurethane foams by conducting FE drop tower tests

Simulated free motion headform tests, it was observed that head accelerations were dropped up to 90% and 87% by using IMPAXX and Polyurethane foams

Evaluated and compared the dynamic response of Toyota-Yaris (2012) FE model, positioned with finite element model of ES-2RE Dummy at driver seat with a shoulder-lap seatbelt by using FMVSS 214 and IIHS safety standards

Modified B-pillar design by padding validated material models of IMPAXX and Polyurethane foams in to the cavities

Observed that C.G. acceleration was dropped by 15%, Internal energy was improved by 2% and slight reduction in B-pillar intrusion by utilizing IMPAXX and Polyurethane foams of side impact test in accordance with FMVSS 214

Up to 19% and 23% of reduction in C.G. acceleration, 2% increment in Internal Energy was observed using IMPAXX and Polyurethane foams of side impact test in accordance with IIHS safety regulations

Calculated B-pillar intrusions and IIHS seat structural ratings were labeled as “Average”

Analyzed injuries of ES-2RE dummy and the results indicated that Head acceleration, Head Injury Criteria, Chest severity Index, and pelvic accelerations were slightly reduced

Software Used: LS-DYNA, HYPERMESH, and PRIMER

ACADEMIC PROJECTS

Fatigue analysis and design optimization of Rear Tow Hook.

Wichita State University, Wichita, Kansas

Modified design of rear tow hook as the assembly model didn’t meet the acceptance criteria

conducted fatigue strength analysis to modified rear tow hook with vertical up, vertical down, pull and push loads for normal and abuse loading conditions in ABAQUS and used NASTRAN as a solver

Analyzed stresses induced in individual components and whole assembly for all given loading conditions

Concluded that the modified design met all the required criteria with an increased fatigue life and recommended further study to reduce critical stresses generated near weld regions in assembly

Design and Finite Element Analysis on Automotive Bumper Bracket.

Wayne State University, Detroit, Michigan.

Performed static stress analysis of an automobile bumper bracket for given boundary conditions in HYPERMESH and used OPTISTRUCT as a solver

Reduced maximum stress concentration on a bumper bracket up to 10%, without altering thickness of design

Numerical Analysis of crack propagation and life time estimation.

Wayne State University, Detroit, Michigan.

Performed linear fracture analysis in ANSYS using APDL code (Ansys Parametric Design Language), for a rectangular plate with a hole for a given initial crack and boundary conditions

Calculated stress intensity factor and observed fracture behavior at different loading conditions

Estimated crack growth and predicted product life

Modeling Crash Response of an Aircraft Occupant on a General Aviation Passenger Seat.

Wichita State University, Wichita, Kansas.

Analyzed crash sled tests with a Finite element lap belt on 50th percentile hybrid Anthropomorphic Test Device Dummy by using MADYMO

Followed Federal Aviation Regulations under part 23, 25 and 27 for general aviation craft, transport aircraft, and rotorcraft

Compared Head displacement, Head Injury Criteria, and Lumbar Spinal Injuries, with and without bulkhead

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