Mechanical Engineer John J. Belle Stress/Dynamics/Heat Transfer Analyst

**** *********** ***. ****: 630-***-****

Wheaton, I llinois 60189 Home: 630-***-****

Email: acd2a8@r.postjobfree.com

Skills

Summa ry: E xtensive experience in detailed stress & fatigue analysis using linear and non-linear FEA methods

for metallic and composite structures employing beams, shells, solids, and gap elements, with hand analysis

capability (Perry, Bruhn & Roak). LCF & HCF Fatigue using miners rule. Dynamic analysis performed using

F EA methods to simulate steady state, random, sine on random, and t ransient vibration; including, shock, and

i mpact. Dynamic FEA models are calibrated to dynamic test results (modal frequency, mode shapes, damping

and response). Applied loads are checked against allowable loads specified in contract to determine Margins of

Safety (M.S.). Heat Transfer analysis performed by deriving heat t ransfer coefficients and applying them in a

t hermal/mechanical FEA model. Authorized MRB signature for Airborne Laser and Navy airplanes.

S t ructures Analyzed: • P ressure vessels (metallic & filament wrapped composite) • P rimary and Secondary

Structure (Metallic & Composite) • L aunch Vehicles • H ydraulic/Pneumatic pressure lines & fit tings (high/low

p ressure) • T urbo-machinery (rotating and static); Shafts, Turbines & Compressors • Avionics & Chassis • GSE •

Solid Rocket Nozzles (Flex-bearing & Nozzle) • L iquid Rocket Turbo-Pumps & Nozzles • Optical Benches • Optics

supporting structure • Optic positioning mechanisms • electro-mechanical drive systems • bearings • Epicyclical

gear sets • hydraulic pumps (high pressure fuel & hydraulic) • h igh-pressure common rail fuel injection system •

t urbo-chargers & super chargers • d ry-sump scavenge oil systems • Satellite Primary Structure (E-Beam welded

f rame) • M isc. E-Beam Welded Structure & Components (Ti-6Al-4V, AlBeMet, & Ph17-4)

L oading Conditions Encountered: • Static • E nforced Displacement, • T hermal/Mechanical • I nertial •

P ressure • Combined Loading; pressure + inertial + enforced displacement • Shock Transient • Sinusoidal •

Random • Sine + Random • Thermal Transient • Modal interference (Campbell diagrams) • Strength • C rippling

• B uckling • C reep • Fatigue (LCF HCF) • Naval Carrier Loadings • Corrosion

Analysis and CAD/CAE Codes: • A NSYS • N ASTRAN • A DINA • A BAQUS • PATRAN • PRO/ENGINEER •

PRO/MECHANICA • SDRC IDEAS • CATIA • UG • M atlab • C++ • Fortran • MS Visual Studio 2012 • Excel/VBA

• MS Project • L inux/Unix

Test and Evaluation; • Modal Testing and FEA Calibration • Strain Gauge • Temperature • F FT Evaluation •

Load Calibration

P rograms Worked On

• A tlas • Centaur • A tlas-Centaur • Shuttle-Centaur • T itan IV – Solid & Liquid Rocket Engines • C ruise Missile

Solid Booster • T rident I I (D5) Upper Stage Nozzle • Space Shuttle Solid Boosters (RDSM) • Space Shuttle

W ing/Elevon Repair (MRB) • YF-23 (ATF-Generator) • F-22 (20 mm Munitions Feed), • F-14D (MRB), F-35

(JSF-Lift Fan), • F/A-18E/F (20 mm Gatling Gun Mount), • E-2C (MRB) • C-2 (MRB) • A-6E (MRB) • 767

( MRB) • Gulf Stream GIV (MRB) • C-17 T1 & T2 (MRB) • Elevated Pressure Vessels (ASME Code) • Acoustic

Levitating Furnace (ALF) Space Experiment • J-69 Gas Turbine (for T37B) • RAH-66 Comanche (APU), • CA-

270 /295 LOROP Dual Band Reconnaissance Cameras • Rolls Royce BR700 9-stage High pressure test rig •

DARPA’s RASCAL M IPICC Mach4+ test rig • CMANPADS (Counter Man Assisted platform antiaircraft Device)

• C rIS Space Instrument for NPOESS JPSS • VTOL/VAATE (Technology Demonstrator) • YAL-1 (747

A irborne Laser MRB ~ Active Secret) • 7 495HR/HF Rope & Hydraulic Crowd Electric Rope & RH400 hydraulic

M ining Shovels • Amicus Apheresis (continuous Process dual speed blood separator) • U.S. Army Mobile Electric

Power SBIR Phase I “Small Piston HCCI demonstrator Engine for Man Portable Power” • DARPA/U.S. Army

A MCOM SBIR Phase I “Small Engines Designed for High Efficiency, High Power Density and Quiet Operations”.

Expe rience :

Belle Aerospace Corporation (BAC ~ Cage Code OV8G2), Wheaton, I L (Principle April 1988 ~

P resent

Use internal resources to develop proposals for potential clients for purposes of marketing and development of

I P for client use or U.S. Government applications. Application of stress and dynamic analysis methods are used

to ensure structural integrity and validity of successful technology development. BAC has had two small

i nnovative research (SBIR) contracts awarded from U.S. Government, for the development and proof of concept

of a high-speed, variable compression heavy fuel engine, with an integral starter/generator for use in compact

power generation and UAV engines. Development continues using internal resources for this small bore engine

for Department of Defense customers.

P roduct development continues on a compound-coupled planetary t raction drive gear bearing system solution

for heavy pulling of wire rope hoists and capstan cable drive systems applications (enclosed epicyclic

gear/bearing drives).

• D efense Advanced P rojects Agency (DARPA)/U.S. Army, Phase I – SB IR P rime Contract.

P rinciple I nvestigator & P rogram Manager for BAC. Continued development of BAC’s opposed piston

variable compression high-speed heavy fuel HCCI engine for 10 hp (7.5 kW) UAV applications and incorporate

i mprovements from previous development efforts. Demonstrate cold start and operation on straight JP-8 heavy

f uel for single cylinder/single piston demonstrator engine with heater improvements. Demonstrated variable

Page 1 of 5

Mechanical, Electro-Mechanical, Electro-Optical Design, and Structural Mechanics Testing

Mechanical Engineer John J. Belle Stress/Dynamics/Heat Transfer Analyst

compression opposed piston engine concept, and miniature glow plug hardware. Determine costs to build

development test engine for Phase I I effort as prime Government contractor (Cont. No. W31P4Q-09-C-0509).

• U nited States Army Mobile Elect ric Power, Phase I – SBIR P r ime Contract . P rinciple

I nvestigator & P rogram Manager for BAC. Developed and proved homogenous charged compression

ignition (HCCI) operation on an advanced hardware design developmental engine. Designed, sourced, and

assembled by BAC, Concept proven by empirical test at client’s facility in Ft. Belvoir, VA during Phase I final

report presentation. Prepare Phase I I proposal. Cont. No. W909MY-05-C-0008.

Primary contracts and consulting engagements through Belle Aerospace Corporation (BAC);

• B ucy rus, Special Projects, South Milwaukee, WI. Senior Structu ral

M echanics Analyst. Responsible for analyzing primary structure for typical expected fatigue loading events,

and defining design loads of large hydraulic an electric rope shove mining equipment. Additional

responsibilities include; capturing legacy design methods, developing test requirements for special project

hardware, development of dynamic design requirements for reliability testing, and guide selection of dynamic

testing equipment for dynamic t ransient and modal analysis, testing, and FEA correl.

• N orthrop Grumman Space Technology, Redondo Beach, CA Edwards AFB, CA Senior M RB

L aser Stress Analyst, with Material Review Board (MRB) signature authority for A ir-Borne Laser @

Edwards AFB. Resolve component integration problems to chemical Laser and A/C while insuring structural

i ntegrity and form/fit/function issues are addressed. Identify and resolve engineering problems associated with

system integration and function. A dditional Engagement as Stress/Dynamist Analyst and Site

W itness: Represent NGST’s interests at vendor’s facilities in Ft. Wayne (IN) @ ITT

Aerospace/Communications Space Systems during CrIS satellite instrument (NPOESS JPES) qualification

failure investigation, exoneration, and corrective action activities for the return to f light qualification status.

• N orthrop Grumman, Defense Systems, Rolling Meadows, I L S tress/Dynamist

A nalyst. P rimary Structure analysis for FAA type certification of the: Counter-Man-Assisted-Platform-

Antiaircraft-Device (CMANPADS). Perform random, static and dynamic environmental evaluations of avionic

chassis to insure stiffness and parameters and structural integrity is maintained during fatigue random

qualification testing.

• T eledyne Tu rbine Engines, Toledo, OH Designer, Heat T ransfer,

S tress & Dynamist. Conduct structural thermal design of a two stage free power turbine to provide shaft

power for a direct coupled lift fan (Secondary f low analysis, Disk Design, Stress & Modal Analysis). Provide

t hermal/mechanical design of two sets of scrolls and bellows in support of integrated VTOL/VAATE

demonstrator development ~ government contract FA865004D2400-002. A dditional engagement: H igh

speed tactical missile turbo-machinery, static structure thermal/mechanical analysis, design, and testing.

Determine hot and cold blade natural frequencies and compare with excitation sources. Shaft critical speed

analysis. Design for HCF, LCF, and rotor over-speed requirements. Develop “cold f low path” blade and hub

geometry from aero “Hot f low path” geometry. Calculate “cold” blade tip, and room temperature build

clearances. Size metallic and ceramic Recuperator heat exchanger. Hybrid Electric Vehicle (HEV) ~ 110,000

r pm, 55 KW Turbo-Generator. Design for high volume “automotive” production cost and performance goals.

Structural analysis and design of high speed Switch Reluctance Starter/Generator (S/G). Specify S/G rotor

materials and heat t reat process to ensure adequate strength and reasonable magnetic properties. Establish

and monitor vibration limits during hardware testing. Conduct failure analysis on hardware when warranted.

A dditional Engagement: J-69 man rated engine for T37B primary airforce jet trainer compressor rotor

t rade study. Evaluate peak bore stress and effect on rotor LCF. JETEC project, heat transfer and structural

analysis of various components. A dditional engagement: Concept design & analysis of small gas turbine

engines for; target drones, reconnaissance vehicles, and weapon missiles. Analysis of ceramic turbine disk,

removable ceramic turbine vanes, and ceramic to metal attachment methods using strain isolation techniques.

• P acker Engineering/Packer Technologies I n te rnational (Bank rupt), Naperville, I llinois.

Designer & Stress Analyst. P rovide litigation investigation direction for aviation related accidents for

clients retained by PE. Test system hardware to verify performance. Develop patentable technology for clients

w hile retaining Intellectual property r ights for PTI. Supply proposal effort for SBIR and broad agency

announcements as a Principle Investigator.

• A llied Aerospace (Now owned by ATK), GASL Division, Ronkonkoma, NY

Stress Analyst. Perform structural analysis using ANSYS of the M IPCC structure for DARPA’s

RASCAL Program. Develop reinforcement sizing for the high temperature (1200F) pressure vessel used to

simulate Mach +4, +100,000 foot altitude engine inlet conditions. Thermal transient analysis was used to

p redict expected heat loss.

• A llied Aerospace (Now owned by T r i umph Aerospace Systems), Newport News, VA

S tress/Dynamics/Heat T rans. Analyst. Structural analysis using ANSYS on rotor disks for Rolls Royce’s

new BR700 9 stage High Pressure Compressor test rig. Update full 2-D axi-symmetric engine rotor model;

perform hot to cold blade/disk growth profile calculations. Modify hardware as required to ensure positive

margins of safety to ensure structural integrity and adequate LCF (Low Cycle Fatigue) life. Prepare action

i tem responses to customer.

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Mechanical, Electro-Mechanical, Electro-Optical Design, and Structural Mechanics Testing

Mechanical Engineer John J. Belle Stress/Dynamics/Heat Transfer Analyst

• R ECON Optical, CAI Division (Now owned by B.F. Goodrich, Facility is closed), Barrington, I L.

S tructu ral/The rmal Analyst. Design, analysis, and manufacturing support of new dual band E/O

reconnaissance cameras used in Air Force and Navy military operations (U.S. and foreign sales). Design for

Carrier loading events using Shock Response Spectrum (SRS). Prepare Flight Safety analysis for Naval

Research Laboratory (NRL). Initiate design changes as result of analysis to meet structural integrity

requirements. Perform t rade studies to optimize structural stiffness and optical performance while reducing

t he weight of primary structure optical bench and Cassegrain. Perform Heat transfer analysis supported by

test data to show requirement for onboard mechanical refrigerator unit over current TE coolers to meet

envelope cool down requirement with limited power resources. Provide system requirements for an onboard

I MU for target GPS information relative to airframe and to change the isolator concept for long focal length

cameras to meet performance. Produce drawings in for prototype release. A dditional engagement: P roved

feasibility of Ultra-Low-Expansion (ULE) ceramic materials in fast scan mir ror concept definition for proposal

effort. Used Pro/Engineer and ANSYS™ FEA software to prove ceramic fast scan mirror electro-mechanical

concept could meet RFP requirements for articulation performance, optical surface deformation and function.

Used FEA methods, and close form solutions to demonstrate performance capabilities, and manufacturing

feasibility could be meet. Report results to the mechanical engineering department head and head designer

for two other specific projects. IR&D effort to develop cost effective commercial electro-mechanical, opto-

mechanical stabilization platform system for small CDD device. A dditional engagement: Optical hardware

definition and proof of concept through analysis of a high speed large rotating scan mirror design for IR

scanner. Cost reduction and reliability improvement through reduce part count. Integrate direct drive motors

and eliminate belt drive system for mirror rotation. Obtain ceramic material quotations and present design

l abor and hardware cost results to management. IR&D funded commercial product submission for potential

development. Proposal effort for multi-spectrum recon camera on UAV platform. Heat transfer analysis of

avionics for verification of cooling load.

• L ockheed-Ma r tin Armament Systems, Burlington, VT

S tructu ral Analyst. F-18 E/F 20 mm Gatling gun primary support structure cost reduction. Design

and analysis using ANSYS. Primary airframe structure that supports gun and munitions barrel was

redesigned from a multi-piece fabricated aluminum forging to a one-piece aluminum casting. Analysis

i ncludes evaluation of multiple load combinations simulating mission sorties for strength, stability, and

cumulative damage for fatigue evaluation (note: primary structure passed ultimate structural load test with

“ flying colors” and is currently in production on new F18 E/F Navy Aircraft). F-22 munition feed system,

p reliminary evaluation of injection molded thermal plastic carrier bucket for 20 mm Gatling gun ammunition.

• L-3 Communication, ElectroDynamics, Rolling Meadows, I llinois

D ynamist/Shock Analyst. Pyrotechnic transient shock analysis performed on the warhead initiator

module (WIM) for the JAVLIN reactive armor antitank missile. Comparison of time domain high frequency

t ransient shock response spectrum (SRS) to component drop test SRS to support client’s position of severe over

testing by prime contractor. Provide Client support at meetings with prime contractor.

• B axter Healthcare - Fenwal Division, Round Lake, I llinois S tress/Dynamist

& T esting Engineer. P roduct improvement for Amicus™ blood platelet collection separator by analysis (i.e.,

F EA static and dynamic analysis using ANSYS) verified empirically derived data (FFT used in modal and

dynamic evaluations, 1/3 Octave Sound Analyzer used in reducing noise). Produce Drawings in PRO/E for

p rototype release and incorporate product improvements into production. Disposable bearing patent applied

for through client. A dditional engagement: Define testing requirements, apply strain gages and conduct

structural dynamic testing on rotating hardware. Resize centrifuge Isolators by reassessing centrifuge’s actual

p roduction mass and distribution. Use FFT spectrum analyzer to determine disposable umbilicus and bearing

loads on rotating centrifuge hardware. Use empirical testing and FEA results, to define the disposable applied

bearing load and fatigue requirements. Modify bearing design to improve bearing life and reduce noise.

A dditional engagement: Define Amicus™ design requirements for continuous process centrifuge used for

collecting single donor blood Platelets used for Cancer patients. Specify testing equipment requirements used

for dynamic testing. Modal analysis performed on medical centrifuge structure followed by modal testing.

A nalytical to empirical correlation of results for mode shapes and frequencies were within 5% of first two mode

f requency and shapes. Use spectrum analyzer to empirically determine Fourier components of harmonic

loading and excitation sources for AMICUS blood platelet processing centrifuge. Apply Fourier coefficients to

dynamic harmonic analysis of isolated centrifuge mass to determine cyclic stresses due to imbalance for fatigue

evaluation.

• S undstrand ~ Aerospace, Rockford, I llinois

S tress/Dynamist. B uild FEA models using a combination of CAD meshers and ANSYS ™ . Perform full

harmonic analysis of Airbus A340 & A320 IDG (Integral Drive Generator) system (i.e., primary outer support

structure/pressure vessel) using ANSYS to verify passing of required qualification test. Provide recommended

changes to design.

• W illiam’s I nte rnational, Walled Lake, M I

S tress/Dynamist. Gear train dynamic stability and auxiliary attachment hardware dynamic analysis

for the supplemental power unit (SPU) on the Comanche helicopter development project. JETEC rotor dynamic

analysis and turbine material substitution analysis.

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Mechanical, Electro-Mechanical, Electro-Optical Design, and Structural Mechanics Testing

Mechanical Engineer John J. Belle Stress/Dynamics/Heat Transfer Analyst

• G en-Corp, Aerojet Tech Systems, Sacramento, CA

S tress/Dynamist. T itan IV Liquid Rocket Engine pump impellers detailed stress analysis and report for

stage on and two (Turbo-machinery 3-D Static and Dynamic Analysis). Evaluate manufacturing discrepancies

and recommend corrective action (Titan and Delta Liquid Rocket Engines). Delta ablative combustion

chamber structure, asbestos phenolic replacement analysis and report (Axisymmetric Composite Analysis).

• O ther P r ior consulting th rough BAC; • Novenco Fans I nc., Elgin, I L. • I n te rsonics I nc., Northbrook

I L.,

Consulting Cont racts not through Belle Aerospace Corporation;

• R olls Royce Corp., I ndianapolis, I N

Stress/Dynamist. Joint Strike Fighter (JSF) Lift Fan Vectoring Nozzle. Responsible for structural

i ntegrity of JSF lift fan vectoring nozzle. Nozzle is integral with primary Airframe keel beam structure (bottom

support of airplane). Define primary load combination methods (i.e., pressure + airframe mechanical +

actuator vectoring loading) with different applied Factors of Safety (F.S.), define fatigue analysis methods

using multiple load case combinations from mission rain-f low spectrum to determine linear damage fraction

( Miners sum) for demonstration of “Safe Life”. Present proposed analysis methods to Airframe and Propulsion

Team members (Northrop-Grumman, Lockheed-Martin, Pratt & Whitney, BAE).

• C hicago B ridge and I ron (CB I) I nc., Plainfield, I L T he rmo-Mechanical &

S t ructural Analyst. Evaluate pressure vessels, shells, and plate structures par ASME Boiler code Section

V I I I. Determine Thermal boundary conditions for thermal mechanical loads. Apply Finite Element Analysis

(FEA) methods to verify design is per ASME Boiler Code for mechanical and thermal/mechanical loading

conditions. Primary support structure for elevated water tank Stability analysis and test correlation report.

• G rumman Aerospace Corporation, Bethpage, NY M RB

S tress Engineer. Structural analysis engineer authorized engineering signature on the Material Review

Board (MRB) for DOD and commercial FAA programs, for f light hardware salvaging efforts. Structural and

Stress analysis of repairs to ensure structural integrity and adequate margins of safety throughout hardware

design life (static strength and required fatigue life). Programs responsible for: Space shuttle wing repair,

F14D, Mc Donnell Douglas C-17, Boeing 767, and Gulf Stream GIV.

• Westinghouse Electric Systems D ivision (ESD), L ima OH.

S tress/Dynamist. Evaluate and report stress levels for ATF (Advance Tactical Fighter YF23) converter

box using the qualification random vibration PSD (Power spectrum Density) input levels, and operating load

conditions. Failure analysis of the “high speed” rotor project (IR&D). Determine influence of failure causes:

a rmature stress, discontinuities in radial growth on filament end turn banding rings, end effects of rotor

g rowth, Low Cycle Fatigue (LCF), and shaft instability (critical speed).

• M o rton Thiokol, Space Operations, Brigham City Utah. L aunch Support

S tress Analyst. Space Shuttle Redesign Solid Rocket Motor (RSRM) project. Analysis use to conduct design

audits and determine design system loads on the RSRM and nozzle structure. Define instrumentation

requirements, select and locate instrumentation for f light and static testing of RSRM’s. Duties include

w riting/revising Level I I engineering requirements for “Operations and Maintenance Documents (OMDs)”, and

“Operations and Maintenance Requirements and Specification Documents (OMRSD)”, for Space Shuttle

RSRM’s.

D i rect Employment P r ior to BAC I ncorporation in April 1988

• U nited Technologies, Chemical Systems Division, San Jose, CA

S tress Analyst. Rocket nozzle group structural analysis of several solid fuel rocket/ramjet projects,

T rident I I (D5), Titan IV, Tomahawk solid rocket motor booster, Solid fuel rocket ramjet pulse motor and

S ICM technical proposal effort. Analysis included filament wound composites, metal matrix composites, high

strength isotropic metals, and incompressible visco-elastic materials subjected to extreme thermal and

mechanical loading conditions (nozzles and f lexbearings).

• G eneral Dynamics, Space System Division, San Diego, CA S tress

A nalyst/MRB Engineer. Shuttle/Centaur G and G’. Responsible for system load analysis and detailed hand

analysis of cryogenic f luid lines, components, mechanisms, and redundant fluid line support structure for

Shuttle/Centaur. Prepare final stress reports, and release of drawings. Integrate with vendors to provide

design loads, review analysis techniques, resolve manufacturing discrepancies, and provide manufacturing

support. Stress group representative in Critical Design Review (CDR) for NASA customers.

Education :

• M aster of Science, Finance with concentrations in Risk Management & Investments, Stuart Business School I IT,

Chicago, I L

• Bachelor of Science, Mechanical-Aerospace Engineering (BSMAE), I llinois Institute of Technology, Chicago, I L

• Associate in Science, Mechanical Engineering, College of Dupage, Glen Ellyn, I L

Volunteer Work:

• D owners Grove Sportsmen’s Club, Morris, I L Executive: Treasurer, 12/2013 to

P resent. Responsible for the financial affairs of a 501(C) Corporation with $2mil assets and $320k in revenues.

Establish cost center budgets, review and ensure audit functions and tax compliance. File income taxes,

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Mechanical, Electro-Mechanical, Electro-Optical Design, and Structural Mechanics Testing

Mechanical Engineer John J. Belle Stress/Dynamics/Heat Transfer Analyst

property taxes, and payroll liabilities with correct state and federal forms on t ime. Ensure deposits are

credited properly, and disburse funds to pay bills as approved by board.

• P hoenix I B FO & Black Phoenix Research, St. Charles, I L Partner and Network Engineer,

03/2011 – Present. Provide technical expertise in server configurations; configure network cut-through

switches, and provide general hardware support as a system administration. Install and configure hardware at

datacenter for proprietary high frequency t rading algorithms. Provide back office support for confirmed t rade

reconciliations.

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Mechanical, Electro-Mechanical, Electro-Optical Design, and Structural Mechanics Testing

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