Mechanical Design Engineer

LOKESH KUMAR BAILAPUDI

**** *** ******, *****: 313-***-****

APT 405, DETROIT, MI 48201 Email: ***********.*********@*****.***

https://www.linkedin.com/in/lokesh-kumar-bailapudi-7a706a138/

CAREER PROFILE

Detail-oriented Mechanical engineer with 3 years combined experience as a powertrain design & development engineer, mechanical design engineer and product development engineer.

Solid command of technologies, tools and best practices in designing mechanical equipment using AutoCAD 3D & inventor, CATIA V5, Unigraphics NX 10.0 &14.0 and Engineering drawing.

Strong knowledge on plastic product design, sheet metal and surface design. Clear Understanding or reading of blueprint/Schematics of 3D CAD drawing.

Hands-on experience and knowledge on mechanical assembly processes, mechanical test & test equipment.

Trained (certified) in Autodesk Fusion 360, HyperMesh & Six sigma (green belt).

Self-starter and a quick learner with the ability to work as part of a team in a fast-paced environment with minimal supervision.

WORK EXPERIENCE

WAYNE STATE UNIVERSITY MAR 2017 – APRIL 2018

Graduate Research Assistant (GRA)/ Graduate Teaching Assistant (GTA)

Product Development Team – Design and Release Engineer (Plastic Fabrication)

Designed & developed speculum for Bio-medical department (medical device). US Patent has been applied for the design.

Designed various CAD models of speculum by using Siemens Unigraphics NX 10.0 and maintained industrial tolerance standards as design and release engineer.

Constructed DFMEA, Pugh analysis, DVP&R (Design Verification Plan & Report), Product Costing Plan. Documented all the reports according to industrial standards. Became the go-to expert on evaluating design models for ISO, DFM and form-fit-function compliance.

Constructed prototypes of speculum by using CubePro polymer 3D printer and submitted to bio-medical department for testing. ABS (Acrylonitrile – butadiene – Styrene) & PLA (Poly Lactic acid based Co-Polymer) were the two biodegradable polymers used for printing prototypes.

Researched and documented the Injection Molding based manufacturing procedure for mass production.

Graduate Teaching Assistant for ME 5040: Finite Element Method I and ME 2420: Mechanics of Materials.

Demonstrated various types of finite element analysis like linear static, non-linear, dynamic and crash analysis involved in both solid and fluid mechanics. Taught Mechanics of material and Altair HyperWorks subject for undergraduate students.

SRI VENKATESWARA GEAR WHEELS SEP 2015 – MAY 2016

Mechanical Design Engineer – CATIA V5

Assisted senior design engineer in designing a gear box with turning gear mounted on gear box for total gear set as per requirement of BHEL (Bharat Heavy Electricals Ltd.).

Constructed various gear type (Spur, helical, bevel, worm, and time pulley) and gear boxes (like planetary gearbox and helical gearboxes) CAD models using CATIA V5. Applied design techniques to reduce the design time by 30%.

Self-motivated, worked independently under high pressure to make delivery within timeline.

Constructed FEA (finite element analysis) model using Ansys V15R for various gear types to calculate the high stress point and severity at failure locations. Calculated and documented critical stress area, life cycle, and reliability.

Delivered gear macro geometry, strength evaluation, and tooth modification proposal for gearbox development by using advanced calculations.

Managed product through the life cycle using Siemens PLM software; and maintained quality of drawings, BOM and specifications.

Responsible for Feasibility report, 2D, 3D data making, GD&T Check, Design Release, Supplier interaction, Convergence with the Styling, Supplier and Purchase and BOM maintenance.

Assisted senior manager in Standardizing CAD drawings/blueprints, schematics and specification sheet format across the sub-contractors to improve communication between manufacturing and design teams.

SAHARA FORCE INDIA FORMULA ONE MAY 2013 – AUG 2015

Powertrain Design & Development Engineer

Powertrain Designed & development engineer responsible to design and develop an internal combustion engine based powertrain for formula one race car for Sahara Force India F1.

Designed Powertrain using Kawasaki Ninja ZX6R 2002, rear sprocket, Mondeo drive flange, Honda type R SD differential.

Derived state variable equations for fixed gear operation, upshift and downshift and identified control variables.

Estimation of shift time, Torque hole parameters and clutch torque curves for Torque and Inertia phases of 1st to 2nd gear shift.

Designed Matlab and Simulink based powertrain simulation and estimated torque, power requirement, final gear ratio and drivetrain ratio.

Closely worked with Chassis design team to develop powertrain mount systems. Calculated 6 DOF movements of the powertrains, counted for in the engine compartment dimensions.

Explicitly used Team Centre PLM software for communication between chassis development, wheel and brake development team.

Completed the production of vehicle in estimated budget of £30,000.

EDUCATION

Wayne State University Aug 2016 – May 2018

Master of Science, Mechanical Engineering GPA: 3.71/4.0

University of the Highlands and Islands Aug 2012 to Jul 2015 Bachelor of Engineering, Aircraft Engineering (Honors First Class (Distinction)

TECHNICAL SKILLS

CAD Software Tools: AutoCAD & AutoCAD Inventor (7 years), CATIA V5 (5 Years), ProE CREO (5 years), Unigraphics NX 10.0 & NX 14.0 (5 years), and SolidWorks (5 years).

CAE Software Tools: Siemens Teamcentre, Altair HyperWorks (Certified Altair trained developer) (3 years), ANSYS V18 R (5 years), Abaqus (3 years), and LS-Dyna (2 years).

Controls & Automation Simulation Tools: Matlab & Simulink (5 years), LabVIEW (2 years), Automation Studio 5.0 (2 years)

Other Tools: Six Sigma (Green Belt), Project management, Reliability Workbench, and DFMEA.

Application & Coding: Microsoft Office (MS Word, Excel, PowerPoint, Project management, and publisher), FORTRAN, C++, and Java.

RELAVENT PROJECTS

Crash Analysis for Ford E-Series Van

This project aimed to identify the capacity of the Ford E-Series van structure to absorb kinetic energy generated in various types of crash (like Frontal, rear, side and roof crash) as tested by NHTSA (National Highway Traffic Safety Administration) using FMVSS 208, 301, 214 & 216a (Federal Motor Vehicle Safety Standards) respectively and IIHS (Insurance Institute of Highway Studies).

Various test criteria like Full Width Frontal Crash, Frontal Offset Crash (40% wall impact), Small Overlap Frontal Crash (25% wall impact), side to pole, and rear vehicle to vehicle are conducted using LS-Dyna Software by impacting vehicle with both rigid and deformable wall.

Analyzed overall vehicle deformation, crash pulse, barrier forces, structural deformation forces, trends in kinetic energy and internal energy of various system in vehicle.

Design and Development of Bell Mouth Intake Duct for Allison 250 C-10D engine

Designed and developed CAD model of typical Bell Mouth Intake duct using CATIA V5.

Stress analysis, air flow rate and fluid streamline flow were generated and studied using ANSYS – Fluent Workbench.

Optimization was carried on and successfully increased the rate of air intake by ten percentage without failing the EASA specifications.

Design and Development of a B737 Flight Simulator

Designed and developed a fully functional B737 Flight simulator.

Using advanced 3D Design software (AutoCAD), nature of the workload and the forces on the control systems were studied.

The CAD model along with sourced technical data was used as a basis for carrying out design validation using stress analysis tools (Autodesk Inventor 2013) and simulation through MATLAB & Simulink.

Contrasting between the precision positioning table and the proposed assembly design, a total savings of £436 (approximately USD 550) was projected.

Contact this candidate