Engineer Design FEA
Resume:
Ghouse Mohammad
Address: Mobile #: +1-313-***-****
Detroit, MI USA-48201 Email: ********.****@*****.***
PROFILE SUMMARY:
Overall 9 years with 4 years of US work experience in leading and performing customization & manual FEA, CAD modeling, of Turbo heavy machinery turbine assemblies, Automobile, and Oil&Gas components for product development, detailing, DOE, NPI development tools.
M.S in Mechanical Eng. (Nanocomposites & advance materials) from Tuskegee University, AL, USA through NSF fully funded program with 5 international US Journal Publications.
As Project Lead, managed and lead a team of 6 members in executing Gas Turbine rotor design development projects for Pratt & Whitney, Canada UTC Client at Cyient Ltd.
Recently, for past 4 years in USA as design Engineer worked on FEA, CAD for Gas, Wind Turbine assemblies for General Electric Co. Stress & Life ETCoE, Greenville SC U.S.A.
Performed FE analyses including Static, dynamic, HCF, Fracture, Creep, Gravity Sag, Thermal HT, Transient structural, Spectrum, NVH, Substructure/Submodeling and contact behavior of Turbine assemblies, Automobile components and layered Composite structures.
Evaluated Linear, Nonlinear, Cyclic symmetric Modal, Harmonic, Fatigue, Static and Transient stresses with deflections in shafting, couplings and associated rotor components under the influence of centrifugal, thermal, torsional, bending and interface pressure loads.
Performed FEA & design of sheet metal, plastics, die cast, mold models of turbo machinery, Oil&Gas, Automobile parts in ANSYS, UG, ProE, NASTRAN, ABAQUS, HM, LSDYNA.
Experience in process development, diagnose malfunctions or production problems on the basis of Simulation, test results, and performed trouble shooting & redesign of complex parts.
Evaluated pilot fits & interference/gaps utilizing contact elements and incorporated changes to Tie-shaft Bolt Preload under Gas turbine rotor assembly and operating conditions.
Performed Modal analysis for natural frequencies, mode shapes with Campbell, Safe diagram.
Evaluated stress life-critical regions of shafting and couplings, obtained stress tensors and created fatigue load spectrum utilizing Goodman Johnson diagrams.
Expertise in design hand calculations, verification using free body diagram, drawing concepts, ASME, ANSI Y14.5M standard, Strength of materials, Structural Mechanics, failure theories.
Expertise in developing graphical user interfaces (GUI) integrated with engineering batch scripts for design, product automation using tools such as Tcl/Tk, Ansys APDL, Fortran, WB Python, Matlab and Microsoft office tools like Word, Excel, PowerPoint VBA Macros.
Knowledge of material selection, procurement, Injection mold, extrusion & Casting manufacturing processes, testing, QC and service for full scale product design lifecycles.
Published International Journals, taught engineering design subjects and used state-of-art Nano composites testing lab equipments like TEM, SEM, XRD, DSC, TGA, Zwick Tensile testing.
Self-motivated with exceptional organizational, communication & presentation skills and decision making ability to prioritize & plan work schedule and outperform with stress management.
VISA STATUS: Previously approved H1B petitions and eligible for H1B Cap exemption approval.
SKILL SET:
Modeling /GD&T: GD&T principles, Solidworks, ProE/Creo, Unigraphics.
FEA Packages: Ansys 14.5.7, Abaqus, Nastran, CAESAR II, LSDyna, Hypermesh.
Languages/Scripting: C, Visual Basic, Tcl/tk, Python, XML, Matlab, Ultra Edit.
MS development tools: MS Office Word, Excel, PowerPoint scripting.
EDUCATION:
M.S. in Mechanical Engg. from Tuskegee University, AL, USA CGPA: 3.70
B.E. in Mechanical Engg. from Osmania University, AP India CGPA: 3.80 Diploma in Mechanical Engg. from SBTET, AP India CGPA: 3.78
PROFESSIONAL EXPERIENCE:
Cyient Ltd., Feb 2014 – Mar 2015
Project Lead
Client: Pratt & Whitney, Canada UTC Ltd.
Achievements/Responsibilities:
Lead Gas Turbine Rotor design development projects for P&W Canada on product CAD design and FEA, customization using ProE/Creo 2.1, Workbench ACT Python, XML, Abaqus & Lsdyna.
Managed projects for Gas turbine Stator & Rotor components including Blades, Wheels, Spool Stress FE analysis for design by Steady Structural, Transient, thermal HT, harmonic and HCF nonlinear analyses including Fatigue Stress Lifing calculations using Goodman-Johnson diagram.
Automated data extraction in workbench models and carried Heat Transfer analysis for Nozzles, Shroud using Ansys 14.5.7 Workbench ACT using Python, APDL & XML software integration.
Worked on a project performing the 3D meshing using Hypermesh & dynamic FE analysis of Bird strike on Aircraft wing Composite laminate structure using Abaqus, Nastran applications.
Created RFI, RFQ and SOW per Client requests, defined design, FEA criteria developing concepts, executed and released drawings, FEA results working closely with the design engineer.
Acted as a liaison between Client design shop floor criteria and local engineering team to ensure accuracy, adherence to strict project timelines and exceeding quality standards.
Trained & mentored new team members and design CAE engineers on P&W processes.
Abacuss technologies, Atlanta, GA, USA Feb 2010 – Dec 2013
Tools design Engineer
Client: General Electric Co., Greenville SC, USA
Achievements/Responsibilities:
Performed modeling, detailing, FEA with post-processing results and developed customized CAD/CAE tools with GUI, for GE Frames 7E.03 60 Hz 90 MW, 9E 50 Hz 130 MW Gas turbines.
Performed Thermal Heat transfer analysis of blades, nozzles and predicted the HCF life of component, creep analysis of high temperature exposed parts during operation with HPC m/c.
Built 3D/2D parametric feature model assemblies with UniGraphics NX 7.5, ProE considering the GD&T, created BOM and carried FEA by automatic APDL meshing, material properties & BC’s.
Performed mesh sensitivity comparison of Hex & Tetragonal meshed Turbine Blades & Shrouds in Ansys Classic applying temperature & Pressure loads using BFINT interpolation.
Built Composites shell layered sandwich structures and composite laminates using Hypermesh, Abaqus for performing meshing, structural analysis of the Wind turbine blades at the GE ETCoE.
Automated post-processing tool for rabbet-flanges joints, contact gap-pressure, Speed-torque calculations at full load using MS Excel automated VBA macros & APDL with Tcl/tk integration.
Performed Modal analysis for Blades frequencies, mode shapes with Campbell diagram in Excel.
Got recognition for calculating complex tolerance stack-up of critical clearances between rotor and stator parts for both radial and axial modules, alignments required for accurate assembly.
With complete ownership designed CAE tool to build automated 2D Rotor spool axisymmetric assembly model from 3D/2D Unigraphics assembly with defeaturing, automatic Ansys Classic APDL batch scripts for Contact pairs identification between Rabbets/Flanges, automatic meshing, Iso-Ortho properties, BC’s & transient time points for turbine/compressor assemblies intended for NPI & during CDR & PDR while validating the results with manual design hand calculations.
Worked on Fatigue Lifing tool of Wind turbines to perform evaluation of bedplates, generator bedframes by performing modal superposition harmonic analysis (performed on frequencies obtained from modal analysis with clustering around Natural frequencies to obtain the unit stress harmonic transfer functions with stress transformations in global Csys using direction cosines of elements), calculating FFT of load forces, IFFT of superposed stress in both frequency and time domain & fatigue life calculations using rainflow counting, nCode tools.
Validated stress transformations by simple cantilever beam structure oriented in different CSYS.
Processed engine test data from accelerometers, strain gages, and displacement probes.
Performed die, sheet metal forming design of HP/LP outer, inner casings, bearings, diaphragm, Spacer rings and performed trouble shooting with redesign on basis of Simulation, test results.
Performed CAD, FEA of FRP plastic Air filter & air intake systems injection molding parts.
Regular interaction with GE rotor design engineers at Greenville SC for review and feedback during designing, detailing & automated FEA of mechanical design tools.
Tools: UniGraphics, ProE/Creo, Ansys, Abaqus, HM, Matlab, Tcl/Tk, MS excel, PP VBA scripts.
Tuskegee University, AL USA Jan 2007 – Sep 2009
Mechanical MS Graduate Research Asst. (NSF Funded)
Performed the prototype composite laminates & sandwich structures modeling & analysis of the Nano composite laminates shell structures using the UG, Ansys and Abaqus technologies.
Manufactured Nano composite fibers, layup & laminates using the compression molding, pre-forming and resin infusion extrusion, VARTM technique.
Experienced in carrying out experimental chemical research in laboratory, polymer hydrocarbon synthesis, characterization & testing.
Hands on experience using TEM, SEM, XRD, DSC, TGA, MTS/zwick tensile m/c for carrying out various testing including NDT of nanoparticles infused composites fibers/ laminate structures.
Presented research work in US technical conferences and published international journal papers.
QuEST Pvt. Ltd. Bangalore, India Dec 2004 – Dec 2006
Project Engineer
Clients: General Electric (Nuovo Pignone) Oil & Gas, Florence, Italy
Danaher Corporation Inc. (USA)
Responsibilities:
Performed 3D Meshing using Hypermesh & FE modeling, structural, dynamic, thermal, fatigue, Vibrational modal non-linear analysis of powertrain components using Nastran.
Performed Stamping simulation, metal forming analysis in Ansys on automotive sheet metals.
Mechanical designing, metal forming, stamping, assembly, drafting and detailing for various engine & powertrain parts like Gearbox, Transmission axle, camshaft, drive shaft, brake disc, fender with BOM for automotive using Pro/E Wildfire 2.0 solid modeling, surface modules.
Performed parametric chunking/modeling of 3D/2D components and design, Modal FEA & RCA of Centrifugal & Reciprocating Compressors components like complex Casings, impellers, Diaphragms, Turbine Blades, Cylinder manifold system, Pressure relief valves, Control valves, Connecting rods, Piston, Honeycomb seals etc using Unigraphics & Ansys.
Performed design, analysis of Oil & Gas piping structures, skids using Caesar II version 5.0
Experience in P&ID, Piping load calculations & Pipe Stress analysis of Critical lines.
Tools: Unigraphics, ProE Wildfire 2.0, HM, Ansys, Caesar II, HM, Nastran, Ultra Edit, VBA.
Farah college of Engg. & Technology, India Jun 2004 – Nov 2004
Assistant Professor
Taught Machine drawing, Mechanics subjects and instructed Fluid mechanics & Hydraulic M/c Lab.
MJCET, Osmania University, India Jun 2003 – Apr 2004
Design modifications of Automobile Connecting Rod for Horizontal engine that makes engine run on Compressed Air. (Sponsored by Government of A.P, INDIA):
Description: Worked on designing & modeling of a new connecting rod, which dwells at TOP DEAD CENTRE 65-70 degrees. An Articulated conrod mechanism serving as a blend of “simple slider crank” and “four bar mechanisms” was used to cater the requirement of extra dwell.
US JOURNAL PAPER PUBLICATIONS:
Synthesis of Ag/CNTs hybrid nanoparticles and fabrication of their nylon-6 polymer nanocomposite fibers for antimicrobial applications. Nanotechnology Journal IOP
Synthesis of hybrid ZnO/CNTs nanoparticles and their reinforcement in Nylon-6 polymer fibers. Journal of Applied Polymer Science.
Reinforcement of Si3N4 nanoparticles in Polypropylene single fibers through melt extrusion process and their properties. Journal of Applied Polymer Science.
Fabrication of Nylon nano diamond coated MWCNT composites. NanoScale Journal.
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