Mechanical Engineer

AJAY DUSANE

+1-848-***-**** ************@*****.*** https://www.linkedin.com/in/dusaneajay Highland Park, NJ

SUMMARY

An enthusiastic ever learning engineer with solid command in FEA, CFD, and 3D CAD tools; background in product design and development, solid mechanics, kinematic and dynamic simulation, and programming languages; possessing strong problem-solving skills, skilled multi-tasker and a team player, experienced in project management; seeking a full-time position as a Mechanical Engineer.

EDUCATION

M.S. Mechanical Engineering, Rutgers University, New Brunswick GPA: 3.81 2018

oRelevant coursework: Supply Chain Engineering, Continuum mechanics, Computational Mechanics of Solids (ANSYS APDL and Workbench), CAD (Python), Optimal Design (modeFrontier), Advanced Mathematics, Robotics and Control.

B.E. Mechanical Engineering, University of Pune, Pune GPA: 3.70 2014

oRelevant coursework: Applied Thermodynamics, Solid Mechanics, Strength of Materials, Heat Transfer, Machine Design, Vibrations, Industrial Fluid Power Systems, Fluid Dynamics, Turbomachinery, Reliability Engineering.

TECHNICAL SKILLS & CERTIFICATIONS

FEA/CAE/CFD

CAD

Programming

Optimization

Certification

COMSOL, ANSYS

Solidworks, AutoCAD

Matlab, Simulink

modeFrontier

DFMEA, Six Sigma

Autodesk Moldflow

CATIA, PTC Creo

Java, Python

Creo, Solidworks, GD&T

PROFESSIONAL EXPERIENCE

A) CAE Research Engineer, Rutgers University, (Feb 2019 – July 2019)

Developing a wireless electromechanical structural health monitoring system as a part of the NASA project, which includes creating a piezoelectric-based sensor coupled with inductive coils for strain monitoring in structures.

Created an ANSYS (FEA/CAE) model simulating the electromagnetic behavior between the inductive coils.

Assisted in the performing stress calculations, creation of new test methods and protocols, and developing fixtures. Executed experiments validating the numerical model. Employed Bode analyzer for response measurement and Arduino for relay control.

Developed a search algorithm in MATLAB and Simulink to determine the location (x, y, z coordinates) of the sensor.

Also aiding in creating paper-based touch and leak detector for structures(pipes) and developing a fluid-structure interaction (FSI/CFD) model for a soft amphibious robot. Experienced in 3D printers, laser cutters, machine shop, and precision metrology equipment.

B) AutoCAD Designer, Momentum Solar, (May 2018 – Feb 2019)

Designed and optimized layouts of the residential solar projects balancing competing engineering requirements and calculate the annual solar production. Revised designs according to customer requests and state fire safety codes.

Drafted detailed drawings, including elevation plans, electrical line diagrams (one-line and three-line), in AutoCAD, prepare design package, generate the bill of materials (BOMs) and routinely carry out engineering change orders (ECNs) and revisions.

Identified potential areas of improvement for the faster and efficient design process and carried out necessary changes, resulting in the overall improvement in the quality of designs and reduction in lead time by 20%.

Coordinated with Marketing, Sales, Installation, and Customer Service for timely completion of turnkey projects.

Worked in a fast-paced, rapidly evolving, collaborative environment, under minimal supervision, facilitating the rapid expansion of the company, and increased customer satisfaction.

C) Graduate Research Assistant, Rutgers University, (September 2016 – Dec 2017)

Created molds, test specimens, and fixtures using soft lithography and additive manufacturing (3D printing). Developed a linear viscoelastic model for silicone rubbers through static and dynamic experiments in wet tissue lab.

Constructed complex cross-sectional geometry of jellyfish-like fin based on an actual robot in Solidworks.

Created a 2D axisymmetric transient FEA/CFD model of jellyfish-like locomotor in ANSYS, mimicking complex jellyfish flapping motion. The numerical model simulated qualitatively similar behavior to the experimental one.

Assisted in developing an Arduino controls platform for the silicone jellyfish-like locomotor in MATLAB.

Gained experience in handling laser cutter, 3D printer, simulating non-linear materials and composites, particle image velocimetry (PIV), static & dynamic structural analysis, vibration analysis, modal analysis, Computational Fluid Dynamics (CFD), conducting performance and validation tests, maintaining calibration of lab equipment, and cluster computing.

D) Intern, Kumars Autotech Pvt Ltd, (June – Nov 2014)

Designed valves, fixtures, & pumps in Solidworks, with GD&T and tolerance stack-up analysis and worked with product planners and to conceptualize and refine product designs.

Experienced in material and product testing procedures using valve test rigs.

Gained valuable insight into equipment design and process development and knowledge of Good Manufacturing Practices (GMP).

E) Intern, Tata Group of Companies, (May – June 2012)

Investigated potential product failures using Design Failure Mode and Effect Analysis (DFMEA) and made proper maintenance recommendation. Implemented 5S method for improved efficiency and reduced lead time.

Participated in root cause analysis procedures. Gained hands-on experience in auto-vehicle assembly.

ACADEMIC EXPERIENCE & PROJECTS

A) Thermal and Structural Analysis of Electrical Busbar

Modeled the Joule heating effect due to current flow through busbar in Solidworks. Created a CAE/FEA model in ANSYS simulating the thermal stresses induced due to Joule heating.

Investigated the cooling due to natural and forced convection on the structure of busbar.

B) Control of Four DOF Robotic Manipulator Arm

Derived a dynamic model of four DOF planar serial link manipulator arm in MATLAB using Newton-Euler formulation.

Designed a (Proportional-Derivative) PD controller for the position regulation of the end effector.

C) Structural Optimization of External Fuel Tank

Modeled simplified 3D CAD model of the external fuel tank of Space Shuttle in Solidworks. Performed structural analysis in ANSYS.

Optimized the structure in modeFrontier for lesser weight and higher volume by applying MOGA-II.

Gained experience and knowledge in 3D modeling, design of experiments (DOE), and different optimization techniques.

D) Development of Computer-Aided Design (CAD) features using Python

Created a CAD feature for splitting and composing Hermite surfaces in Python as per the user input.

Programmed a zoom, pan, and move feature found in commercial CAD packages using OpenGL.

Developed an intuitive understanding of software development and testing.

PUBLICATIONS

A) Ferri, Dusane, et al., “Modeling of Paired Inductive Coils with a Crystal Oscillator for Wireless Measurements of Strain,” in progress.

B) Dusane, et al., “Analysis of Active Suspension of Half Car Model using Matlab-Simulink,” IJESRT, 2014.

CO-CURRICULAR ACTIVITIES

A) National ABU Robocon 2013, Runner-up

Member of the cross-disciplinary team tasked with the creating pneumatically operated manual and autonomous robots.

Responsible for the design and manufacturing of chassis and frame of the robots. Experienced in handling CNC, Milling, and welding (TiG) machines. Gave key inputs to the design of electrical components, including PCB design.

Oversaw the project from the concept to the competition ready deliverable.

B) METEOR Robotics Workshop 2013, Organizer and Presenter

The workshop included training sessions and hands-on assembly session of robotic kit.

Presenter for ‘Mechanical Engineering in Robotics’ session. Delivered a lecture on the basics of the robotics design for an audience of more than 800.

Developed excellent presentation and audience engagement skills.

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