Design Engineer

DIVYAPRAKASH KUMAR

**** ******** **** *** *****• Westland, MI - 48185

313-***-**** •k. **************@*****.***

SUMMARY

• A delivery focused Mechanical Engineering Graduate seeking opportunity with an automotive company utilizing my MCAD-Wire harness, Design, Packaging and EDS skills for the benefit of both mutual growth and success.

• 6 years of experience with 2D and 3D Design software.

• 1 year of an overall work experience with Wire Harness design and packaging using Catia V5, Teamcenter/Vis mock up.

EDUCATION

Master’s in Mechanical Engineering Aug 2016 - May 2018 Wayne State University, Detroit, USA Current GPA: 3.41/4 Bachelor of Engineering – Mechanical Engineering Aug 2012 - May 2016 SRM University, Chennai, Tamil Nadu, India GPA:7.72/10 COURSE WORK

Computer Aided Design and Analysis, Finite Element Methods, Manufacturing Process Techniques, Crashworthiness and Occupant Protection – (FMVSS 208, 216 & 301), Design Optimization, Six Sigma (Green Belt Certification). SOFTWARE SKILLS

Design: CATIA V5 - (Certified Diploma holder in Product Design and Analysis), SOLIDWORKS, Unigraphics NX9. PLM: TEAMCENTER, VIS MOCKUP.

Analysis: HYPERMESH V13, ANSYS 15.0.7, LS-DYNA, ABAQUS V6.14, IPS. MS Office – Word, Excel, Power-point, Access, Outlook. PROFESSIONAL EXPERIENCE

ESG Automotive Inc, USA, FORD MOTOR COMPANY-Product Development - Dearborn. EDS Package Engineer - Power and Signal Distribution (October 2017 – Present)

• Working with CATIA V5, Vis Mockup (BUCK), Teamcenter to Design Wire harness and making package proposals on daily basis.

• Support to incorporate Electrical Modules into Vehicle Systems.

• Worked on Design of Wire Harness and Packaging EDS Components for MUSTANG 2022MY (Engine Compartment-Power Distribution, Body and Battery cable packaging). Currently working on the LINCOLN MKC 2022MY (Body and IP Packaging) and the BRONCO 2021MY (Door and Headliner Packaging).

• Design and development of Brackets to support EDS package using Catia V5.

• Vehicle Pre-Production EDS package and design of wiring architecture.

• Stress/Strain Analysis and Crash study of Wire Harness using IPS Software.

• Lead/Participate in issue resolution activities during development.

• Establish and monitor DVP&R and track corrective action.

• Prototype possible cost saving or development issue with supplier. Internship- Design and Development Engineer, Rubicon Lifts, Chennai, India.

• Design and Development of guide rail brackets and End truck for Light-duty EOT Crane using Catia V5.

• Experienced in Design of Sheetmetal, Plastic and Molding parts involving bending, stamping and casting process.

• 2D Drafting and 3D Modelling and responsible for Feasibility study and packaging study

• Updating the design and co-ordinating with cross functional teams.

• Prepare BOM, Assembly and Detailing with good knowledge in GD&T.

• Supported DFMEA and DVP&R process and documentation. ACADEMIC PROJECTS

Undergraduate:

• Design and Fabrication of Student Formula Car (Design, Build, Test and Analysis) for the SUPRA-SAE competition, I was in-charge for Design of the Roll cage considering all the safety specifications as per SUPRA SAE INDIA and Design and packaging of Braking system and vehicle wire harness using Catia V5.

• Strength Evaluation and Fabrication of Natural Fiber Reinforced Polymer using Sugarcane Bagasse for Industrial applications, it involves Design and stress analysis of the fabricated products using UG NX9 and ANSYS.

• Design and fabrication of power generator using vibrations.

• Design optimisation of Wind turbine blades using. Graduate:

Finite Element Methods:

• Performed Stress Analysis for the Bracket to optimize the design and reduced the stress by ten percent using Hypemesh.

Manufacturing Process Techniques:

• Design of Superplastic forming(SPF) Simulation using Catia V5 and ABAQUS software.

• Modify the design to reduce the Von Mises stress for the given Piston and determine its maximum axial deflection.

• Design and Fatigue life analysis of FLIP-CHIP packages. Crashworthiness and Occupant Protection in Transportation System:

• Performed Frontal, Roof and Rear Crash Analysis of vehicle following FMVSS 208,216 and 301 regulations using LS-DYNA and Hypermesh.

• Deformation and Energy Density flow Analysis using LS-Prepost, Hyperview and Hypergraph.

• Dummy injury criteria study such as HIC and chest deflection, with and without seatbelt and Airbag.

• Analyzed the behaviour of critical components of vehicle such as Hood, Fender, Rail and did optimization study.

• Determined the crush impact force to reduce the physical impact to dummy by implementing structural reinforcement.

• Frontal Crash analysis of a SUV body frame with steel and replacing it with composite material to compare their performance.

Fundamentals of Six Sigma:

• Defect reduction of Steering gear product using Six Sigma methodology.

• The process involves the DMAIC (define, measure, analyze, improve, control) approach in eliminating the defects caused by identifying, quantifying and removing the variation caused by special causes to bring the process under control and to improve it.

CERTIFICATIONS & INVOLVEMENT

• Certified Diploma holder in Product Design and Analysis.

• Member of Society of Automotive Engineers (SAE) and Society of Automotive Engineers India(SAE-INDIA).

• Have been selected to represent St. Andrews Club (Somerset Cricket Club) in Western Premier Cricket League at United Kingdom.

• Captained Wayne State University Cricket team in the 2017 American College Cricket tournament.

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