Engineering Design, Cae, Fea, Fea Analyst, Hypermesh, Solidworks

Shantanu Sabade

317-***-**** **************@*****.*** Indianapolis, IN46202 linkedin.com/in/shantanu-sabade-9b901387

Product Design Simulation Reporting & Analysis Finite Element Analysis Model (FEA) System & Component Design CAE Tools

Improving manufacturing capability by aligning product design: Increased system efficiency by 5% by implementing design and material changes. Carried out CAE analysis to determine stresses, deformation in centerbolt and compression in rotor. (ANSYS).

Performing simulation analysis: Evaluated rotor strength at max clamp load to verify whether rotor has sufficient strength to withstand application loads by performing FEA analysis (ANSYS).

Provides product development & engineering support: Modeled and assembled gearbox components by finalizing product size and material type. Determined maximum stress and prevented system failure by conducting CAE analysis in ANSYS.

Skills: Dynamics, CAD Modeling, Mechanical Systems, Client Support, Fatigue & Durability Analysis, Linear & Non-linear Analysis, Catia V5, V6, Creo, Solidworks, ANSYS Workbench, Hyperworks, Hypermesh - Optistruct, LS Dyna, Inspire solidthinking.

Professional Experience

VCT Product Engineer (CAE Engineering Co-op) at BorgWarner Morse Systems 1/18 – 7/18

Facilitated design and FEA analysis of a key VCT component, a phaser, for large-scale automotive clients such as Jaguar, Ford, and Mahindra. Collaborated with a team of 7, assisted with testing and creation of prototype parts, and prepared customer reports.

Improved product performance by 15% by securing an actuation rate of 150 deg/s. Gathered requirements, used the VCTISM tool, and analyzed interference fits (ANSYS). Changed rotor thickness, adjusted swept volume, and tested multiple bias springs.

Determined overall product success rate by performing EOL and flow testing. Prepared detailed teardown analysis reports.

Analyzed deflection of a sensor wheel tab by performing FEA analysis. With load applied, max deflection was 10 microns at tab and 1-3 microns in rest of areas. Stresses induced were very low (5-6 MPa). (ANSYS)

Carried out CAE analysis to study housing deflection and end plate gaps. Outer plate deflection greatly exceeded 20 micron design guide limit. Inner plate deflection well below 15 microns design guide limit. (ANSYS Workbench)

Design and FEA Analysis Intern at Epsilon Composite Solutions 6/17 - 8/17

Conducted structural analysis of a sandwich and rib-stiffened composite water tank cover. Determined a cost-efficient and secure design by conducting FEA analysis for 3 cases. Indicated 5% reduction in stresses and 18% reduction in displacement.

Reduced computational time by 2 hours by selecting best-fit mesh size. Evaluated panel structural integrity under G-loads, external force, and pressure. Tools: Catia V5, Hypermesh-Optistruct, 7 Plies Laminate, Independent Feature Modeling Techniques.

CAE analysis and Manufacturing Intern at Endurance Pvt. Ltd. 8/14 – 5/15

Increased Crankcase productivity from 19.5% to 21.5% by reducing cycle time and saving space. Worked with a team of 5, created 3D models and bill of materials, and improved dimensional stability.

Cut down cycle time by 15% and saved cost by decreasing the number of tools by 5. Identified areas of low-stress concentration, performed topology optimization to reduce weight and stiffness, and validated design changes by conducting FEA analysis.

Tools & Processes: Creo Parametric 2.0 and Catia V5, AUTOCAD, FeatureCAM, Ansys, Tool Deflection Principles, ASME Y 14.5.

Engineering Projects

FEA Analysis and Topology Optimization of Bell Crank: Reduced bell crank weight and increased stiffness by conducting topology optimization. Verified results by performing component level FEA analysis. Tools: CatiaV5, ANSYS.

Shaper Tool Head Mechanism: Modeled, assembled, and analyzed a shaper tool. Tools: CAD, Creo, and Hypermesh-Optistruct.

Topology Optimization of Skateboard: Modeled a skateboard and performed stiffness calculations of Abs, plastic, and wood. Conducted static linear FEA analysis. Tools: CatiaV5, Hypermesh, MATLAB, Solidthinking.

Off-shore BOP Platform: Identified a corrosion-resistant and maintenance-free deep water structure material by conducting a comparative study. Performed FEA analysis; indicated better performance of the composite material compared to steel.

Bird-Airplane Modeling and Crash Analysis: Designed an aircraft wing with improved resistivity to bird strike according to the FA’s safety regulations. Performed FEA analysis to determine optimum case. Tools: ANSYS 18.0 & CATIA V5.

Other Projects: Clutch System Design & Assembly & Explicit Dynamics Project.

Education

MS Mechanical Engineering GPA: 3.4, Purdue School of Engineering and Technology, IUPUI May 2018

Bachelor of Engineering GPA: 3.7, University of Pune 2015

Certifications: Hypermesh 12.0 (2016), Design Automation using CAD Software – Creo 2.0 (2016), ANSYS Workbench 13.0 (2014).

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