Sr. Manager - CAE Vehicle Dynamics

GURDEEP SINGH PAHWA

E Mail: ********@*****.***/ ********@*****.*** ~ Contact: +91-996******* (M) / +91-996******* ®

Assignments in CAE Vehicle Dynamics, FEA Simulation & Methods Development/ Product Development with an

organisation of repute.

PROFESSIONAL OVERVIEW

A competent professional with 10.75 + years of fruitful experience in the field of CAE Vehicle Dynamics (MBD), CAE

Durability (FEA), 1d Methods Development, CAE Project Handling, Product and Process Improvement .

Presently working with Mahindra and Mahindra Ltd., Chennai as Sr. Manager CAE Vehicle Dynamics (Specialist) &

0d 1d Methods Development.

Competency in developing and executing quality plan.

Competency in creating Macros and Subroutine in Excel, MATLAB, TK Solver & ADAMS to reduce simulation time and be

error free.

Expertise in identifying areas of improvement through robust design simulation. Using DOE, Stochastic and Optimisation

techniques in MBD and FEA environment.

Well versed with CAE Vehicle Dynamics (Ride, Handling and Durability Simulation), CAE Durability (FEA), Tire Dynamics,

Tractor Dynamics, Drive Away Chassis (Chassis, Suspension, and Steering Design), Vibration, Mechanism, Linear, Non

linear and transient Simulation for Auto, Farm and Construction Division projects.

Handling & Contributing the Products Knowledge in Auto Sector (SUV’s, MPV’s, LCV’s, SCDC, Mini Trucks, Pick Ups,

Sedan, Hatchback…), Farm Sector (Tractor’s, Combine Harvester, …), Construction Equipment (Backhoe, Excavator &

Mechanism (Auto, Farm and Construction Equipment) through robust CAE tools.

Posses sound of knowledge of ADAMS (CAR Package) 13, ADAMS VIEW 13, ADAMS Chasssis 13, CarSim 8.2,MSC

NASTRAN 13,ALTAIR MOTIONVIEW/HYPERSTUDY/HYPERMESH/OPTISTRUCT,MATLAB/SIMULINK R2011a/AMESim,

LMS Isight, Heeds and Tk Solver.

Excellent communication, interpersonal, analytical & negotiation skills with strong organizational and team building abilities.

ORGANISATIONAL EXPERIENCE

Since Mar’04 with Mahindra and Mahindra Limited

Career Graph:

Mar’04 – Mar’05 Paid Trainee – CAE (Durability and Vehicle Dynamics)

Apr’05 – July’05 Executive Manager (Durability and Vehicle Dynamics)

Aug’05 – July’07 Deputy Manager (Durability and Vehicle Dynamics)

Aug’07 – July’11 Manager CAE Vehicle Dynamics (L7M)

Aug’11 – July’13 Manager CAE Multi Body Dynamics (L6M)

Since Aug’13 Sr. Manager CAE Multi Body Dynamics & Methods Development

(L5M)

Key Deliverables CAE Dynamics Department:

To ensure complete virtual validation for all vehicles, Tractors, Harvester and Construction Equipment in Multi Body dynamics

for gateway delivery.

Correlate dynamic simulations to tests & real world user feel in dynamics area.

Continuous Improvement in developing CAE Design Verification process, Design Guideline, Procedures and improve the

correlation level to achieve first time right dynamics performance.

Continuously improve dynamics simulation productivity through automation.

Evaluate and Purchase hardware, software & recruit people for dynamics CAE group.

Guide the vehicle design at concept phase, detail design & testing phase to achieve the vehicle dynamics and Durability

targets.

Key Deliverables Methods Development Department:

Capture mathematical modelling requirements from different CoEs .To create the models using 0D and 1D approach, So that

the key output parameters can be simulated using mathematical models.

Applying Research methods in the area of engineering data analytics and able to cater the requirement generated through

validation measurements as well as benchmarking exercises

Catering Auto Division and Farm Division to design first time right products by facilitating the designers to make more

rationale and systematic design choices at early stage in product development.

Collaborating with software vendor to drive architectural changes and customization in the calculations management system

Galaxy, to make it more user friendly and to enable internal customers to seamlessly access models from a central server.

Monitoring and controlling the quality of deployed models by continuously reviewing and drafting validation plans with

respective CoEs and IT and hardware resources in order to operate the above functions smoothly without any disruption.

PROJECTS TILL DATE

Auto Sector

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Key Contribution in CAE Vehicle Dynamics & Durability simulation for Mahindra Auto Sector on road projects like

XUV500, Scorpio Refresh, Xylo, Verito, Reva, Thar, Bolero Refresh, BMT, Maximo, Genio, Gio, Alpha and Tourister

Buses.

Correlation: Correlation of test data with ADAMS result are done for Vehicle Dynamics and Durability tests as follows:

Suspension K&C test, Steady State Circular tests maneuver, Double Lane Change maneuver, Single Lane

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Change maneuver, Steering return ability test, Steering effort test, Ackerman test, Acceleration levels on chassis and body on

(Highway, Long Wave Pitching, Pave tracks, and Pot Hole Hitting), Vehicle rigid body frequency, Suspension Natural frequency,

Power train rigid body modes, Fatigue Damage with test data for an SUV using ADAMS Car and LMS FALANCS Software.

Involved in Mahindra fatigue lab to establish correlation between Test to CAE to lab for vehicle ADT load cases on Pave,

Rough Road, Figure of 8, High Frequency etc and to derive the drive file used for Three and Four Poster rig for Suspension,

Chassis and Fuel Tank components.

Modeled and Optimize the Active four wheel steering (A4WS),ESP,ABS and Active Damper concept using co simulation

approach with ADAMS/CAR and Simulink for Steady state circular maneuver, Single lane change, Double lane, Fish Hook and

Turning circle diameter maneuver.

Predicted and optimize the steering effort for hydraulic power steering using co simulation approach with ADAMS/CAR and

EASY5 for Steady state circular maneuver and Single lane change maneuver.

Delivered on technology development projects like Semi Active suspension, ESP development (SIL), Process Manager

(Suspension Manager and Vehicle Dynamics Manager) and Rubber Bush shape optimization to achieve the desired stiffness

(using Abaqus and Heeds).

Involved in vehicle dynamics target setting activity and benchmarking for Kinematic and Compliance test, Vehicle Ride and

Handling parameters and Vehicle Architect design. (Done for CAR, SUV, SCDC, LTV, MPV category of vehicle) while considering

different suspension layout.

Worked on DOE, Stochastic, and Optimization study for Suspension K&C, Full vehicle ride and handling parameters and

Chassis, Fuel Tank (DAC) for Modal and Strength targets using Motion View/Hyper Study, ADAMS/CAR/ Insight and HM/MSC

Nastran/Hyper Study/Optistruct.

Predicted Ride Comfort with full vehicle flexible body using ADAMS/CAR/Chassis.

Derived Mahindra RIDE INDEX value on mixed road terrain for different vehicle categories.

Predicted Handling behavior with full vehicle flexible body using ADAMS/CAR/Chassis.

Predicted Ride and Handling behavior of full vehicle using ADAMS/CAR/Chassis.

Predicted and Correlated Fatigue Life for BIW, Chassis and Suspension components on various tracks using MSC

ADAMS/CAR/Durability.

Predicted Vehicle Natural Frequency Map.

Static and Dynamic Engine Mount stiffness optimization.

Rigid Body Frequency Response on Straight and Bumpy Analysis using ADAMS CAR.

Methodology developed for DOE and Optimization for K&C and Full Vehicle Ride and Handling simulation.

Suspension K&C Parameters Multi objective optimization Study using genetic algorithms (MOGA) with Motion View and

Hyper Study.

Static and dynamic load generation for FEA Durability analysis as per guidelines.

Kinematics and Compliance Analysis for Suspension using ADAMS CAR as per guidelines.

Predicted effort for automotive mechanism in vehicle like window regulator, door latch, hood etc.

Simulated door latch mechanism for 35 g Inertia loading condition as per SAE J839 standard.

Chassis Durability (Fatigue life estimation) correlation with test data (FEA).

Expertise in reviewing and performing Static durability ADT load cases for Chassis, Fuel Tank, Exhaust, Suspension

Components, and Hoods etc using MSC Nastran and Optistruct.

Farm Sector

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Key Contribution in CAE Multi Body Dynamics simulation for Mahindra Farm sector on road projects like Yuvraj,

Arjun and Harvester.

Correlation for Tractor TCD, Steering Effort and Ackerman with Physical data.

Correlation for Dynamic Acceleration on Torture Track, Pit Hole, Figure of 8, Rough Course Test Track)

Predicting the Static and Dynamic Stability for Tractor.

Soft Soil Simulation for tractor application.

Static and Dynamic Load generation for Full Tractor and Supporting the CAE Durability group for the same.

Clutch, Brake, Seat and Hood Mechanism simulation.

Optimize three point linkage hard points and support designers with ADDC mechanism model.

Construction Equipment

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Key Contribution in CAE Multi Body Dynamics simulation for Mahindra Construction Equipment sector on road

projects like EarthMaster Backhoe Loader.

Correlation for Backhoe and Excavator Enveloping Study.

Correlation for Dynamic Acceleration for Loader on Dozing, Drop and Catch and K Loading.

Correlation for Dynamic Acceleration for Backhoe on Backhoe Trench Digging, Rock Chipping, Backhoe Swing, Tree Uproot,

Side Rock Hitting.

Predicting the Static and Dynamic Stability for Backhoe and Excavator.

Static and Dynamic Load generation for Full Construction and Supporting the CAE Durability group for the same.

ACHIVEMENTS

Distinction of receiving “Expectation Surpassed” Award consecutively from last five years from M&M Ltd.

Awarded with Best Paper of the Day:

At MSC VPD conference, Bangalore – 2012.

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At MSC VPD conference, Bangalore – 2011.

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At MSC VPD conference, Bangalore – 2009.

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At MSC VPD conference, Bangalore – 2008.

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At HTC 08 Conference, Bangalore – 2008.

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At MSC VPD conference, Bangalore – 2007.

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At MSC VPD conference, Pune – 2006.

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Spot awarded in Mahindra for Reducing the Process time, by creating the K&C Macro, Plot Macro, Ride Macro sheet

and so on for Auto Sector in 2012.

Accelerated award for introducing First time right Independent Rear Suspension on XUV500 in 2010.

Appreciated with Category of Improvement – Quality / Process Award 2008 from M&M ltd for setting a process of Static

Stability process.

Published SAE Paper (SAE Number 200*-**-****) Modeling and Analysis of Rotational Steering Vibration

for SUV using Multibody Dynamics Tool at SAE Mobility Conference, New Delhi in Jan’08.

OTHER ENGAGEMENTS

Proactive Member of:

SAE India since 2007.

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Lead member of Bureau of Indian Standards for deciding Test Procedure for Vehicle Dynamics Standard in

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India 2013.

Lead Member for Innovation Club at Mahindra (2010 till date).

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Indian Society of Technical Education (I.S.T.E) (2001 2003).

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TRAININGS UNDERGONE

Effective Mass Communication “Story Telling” at Mumbai by Michael Burns (2014).

The Relationship Management Program (RMP), at Lonavala by Homi Mulla (2014) .

Advanced Adams Expert Consulting Training at Mahindra from Takashi, Japan (2013).

Front and Rear Independent suspension K&C measurement and its effect at SYMC, South Korea (2012).

Front Independent and Rear Dependent suspension K&C measurement and its effect at Magneti Marelli, Italy (2012).

Adams/Tire from MSC.Software at Munich, Germany (2011).

Adams/F Tire Training from Gerald Hofmann, cosin scientific software at Munich, Germany (2011).

Five Day Certificate Course on “Vehicle Dynamics and Motor Sport engineering” organized by ARAI, SAEINDIA Western

Section and OptimumG (USA). conducted by Mr. Claude Rouelle, at Pune from 15th till 19th March, 2010.

Advanced Vehicle Dynamics conducted by M S Ramaiah School of Advanced Studies at Bangalore in Nov’09.

Theoretical and Experimental Vibration Analysis Applied to Machine Elements Health Diagnostics organized by Quantum

Age Tech Solutions Pvt. Ltd., conducted by Mr. Rajeev Dubey, at Vadodara in Apr’08.

Objective to Subjective Vehicle Dynamics one week training at Lotus Norwich, U.K in 2007.

“Mechanical Vibration Concepts, Understanding & Practices" conducted by M S Ramaiah School of Advanced Studies at

Bangalore in May’06.

“Basic Advanced Concepts for Assessment of Structural Integrity of Automotive Structures" jointly organized by ARAI &

SAEINDIA Western Section in association with Esslingen University of Germany at Pune conducted by Dr. Lother Issler in

Aug’05.

One month Training on “Turbine Blade Manufacturing” at B.H.E.L Hardwar in 2002.

CAE TOOL’s EXPOSURE

MSC Products: ADAMS

CAR/VIEW/ACHASSIS/INSIGHT/CONTROL/FLEX/DRIVELINE/VIBRATION/RIDE/DURABILITY

Altair Products: MotionView, Motion Solve, OptiStruct, Hyper Study, Hyper Graph, Hyper Mesh

Fatigue Solvers: FEMFAT, LMS FALANCS & MSC Fatigue

Carsim, MATLAB/ Simulink, MSC Easy5, AMESim, TK Solver, Galaxy

0D & 1D :

DOE / Optimization : HEEDS, Isight, ADAMS/Insight, Hyper Study

Others: SIMPACK, LS Dyna, Ansys, Isight, MS Office etc

ACADEMIA

Masters in Business Administration from ICFAI in 2013. Secured first class.

M.E. (Automobile Engineering) from V.J.T.I, Mumbai in 2005. Secured first class with distinction.

B.E. (Mechanical Engineering) from K.D.K.C.E., Nagpur in 2003. Secured first class with distinction.

OTHER CREDENTIALS

Certificate in Professional Communication from International Outreach Programs, University of Washington, USA in 2003.

ACADEMIC PROJECTS

M.E. Project:

Title: CAE Correlation of Durability Analysis with Accelerated Durability Test (ADT) for SUV

Description:

Automotive manufacturers are increasingly using computer models to simulate automotive testing in the conceptualization and

design stages. Computer Simulation of automotive testing has the potential to save time and money for automobile

manufacturers and suppliers. Computer Aided Engineering (CAE) provides a means of verifying design for durability of

automotive structures by reducing the number of testing prototypes. CAE durability can thus reduce time and cost for product

development.

A practical three step procedure for automotive CAE durability analysis using the time domain approach is illustrated, for several

level structures under multiple road loading inputs. The procedure incorporates:

1) The proving ground (PG) road load data process (RLD).

2) The finite element (FE) transient response simulation.

3) The fatigue Life Evaluation.

B.E. Project:

Title: Design and Fabrication of Semi Automatic Clamping and Bar Feed Mechanism Power Hacksaw Machine

PERSONAL VITAE

Current Address: Flat No. F 102, Sylvan County, Mahindra World City, Chengalpattu, Tamilnadu 603204

India.

Date of Birth: 31 December 1981

st

Language Known: English, Hindi, Punjabi and Sanskrit.

Visa Status: Approved HSMP Visa for U.K (25 11 08 till 25 11 11).

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