Analysis Manager

KAUSTUBH PATEL

C-*/***, Mahadkar Residency, Right Bhusari Colony, Kothrud, Pune-38

Contact: +91-982******* Email: *****************@*****.*** HEADLINE

CAE-MANAGER, NVH & DURABILITY ANALYSIS

SUMMARY

I am an industrious professional with core strengths in Powertrain NVH, Full vehicle NVH, Static and Dynamic Analysis, Durability and Fatigue Analysis using CAE tools like Preprocessor Hypermesh, Solvers Nastran, Optistruct, LMS-Virtual Lab, Adams. I have been instrumental in identifying the CAE need from diverse product lines & develop the CAE methodologies and capabilities for diverse products of the company. I am highly skilled in completing the system/project status updates, preparing reports while participating in the construction of required simulation models & assisting with the body simulation development schedule for noise performance. I have been shouldering the responsibility of performing the required analysis to ensure smooth operations & achievement of performance targets. This includes co-ordination of conducting basic NVH tests to confirm the performance on the actual vehicle. I am also contributing technical inputs in planning & executing finite element modeling & analysis projects related to automotive domain using CAE tools. I have been working on the development of methods for optimization of components for common and concurrent improvement of designs. Driven by the key values of leadership, innovation and responsiveness, I always ensure to implement measures for cost rationalization and increased productivity.

My Expertise lies in integrating the requirements of different computational disciplines (NVH and durability) together with geometrical specifications into a numerical optimization approach while coordinating with the cross functional departments of the company.

EXPERIENCE

Company Name – The Automotive Research Association of India Title – Manager, NVH-CAE Lab

Description –NVH Analysis (Hypermesh, Optistruct, Hyperstudy, Nastran, LMS Virtual lab): BIW, Trimmed BIW, Full vehicle NVH analysis (vehicle boom noise prediction and reduction):

Normal modal analysis, Frequency response analysis, VTF, Panel stiffness analysis, Modal/Panel Contribution Analysis, NTF analysis, In-cab noise predication

Bending/Torsion modal improvement

Finding counter measures and suggesting structural modifications for in-cab NVH performance improvement

Dynamic stiffness and mobility, NTF targets achievement by structural modifications

Weight optimization for mass reduction

FE model refinement for subassembly and full vehicle level for FE-Test correlation:

Comparison of vibration characteristics of front door for baseline FE model with test

Finding out counter measures and FE model improvement of front door for acceptable level FE-Test correlation

Comparison of FE-Test NTF at drivers’ ear level with improved FE model of door to verify acceptable level of test to FE correlation

FE model refinement for vehicle booming noise accuracy improvement:

Study of modal parameters of baseline FE model up to 50Hz

Compare vibration characteristics of baseline FE model with experimental testing (mode shapes and natural frequencies)

Comparison parameters are inertances at LHS and RHS steering knuckle

Identify FE model improvement parameters and achieve the specified modal and inertance correlation targets FE model building and NVH performance improvement of vehicle aggregates:

FE model building of vehicle aggregates viz. steering subsystem, front and rear suspension subsystem, exhaust system, front and rear seating, HVAC. NVH performance improvement and optimization for mass reduction without hampering NVH performance

Rear axle FE modal performance improvement by structural modifications with no weight cost (getting implemented in production)

Exhaust system hanger location prediction without hampering NVH performance. NVH shell radiation noise prediction of engine intake manifold:

Constrained modal analysis to extract natural frequencies

Frequency response analysis for sinusoidal load input to calculate contact stiffness at various locations over the surface and overall mobility

Vibration analysis under engine input in three direction for WOT/NL sweep conditions

Structural modifications to meet the noise targets NVH performance prediction and performance improvement of power train using CAE and Experimental correlation Technique

MBD model building of crank train sub-system to predict piston slap, bearing forces

Power train NVH analysis for baseline concept

Experimental correlation of subassemblies and full PT level

Meeting modal targets for power train global modes (vertical and lateral bending modes)

Structural modifications to achieve the NVH targets for different subsystems/ancillaries and mounting brackets considering design and manufacturing, packaging and weight constraints

Topology optimization for mass reduction without hampering NVH performance of PT Engine Mount Design and Optimization for reduced SPL inside cabin

Set up a methodology to optimize the engine mount system for reduced vibration transfer from engine to frame

Estimation of mount stiffness, no of mounts and their locations/orientations

DOE and Optimization of mount compression/shear stiffness and orientation angle

Finalization of mount specifications

Company Name – The Automotive Research Association of India Title – Manager, NVH and Durability

Description – Static-Dynamic, Durability and Fatigue Analysis (Using ADAMS, Hypermesh, Nastran, FE-Fatigue) Durability analysis of bus structure to predict structural strength as per DTC requirements

FE modeling of full bus model - chassis and body assembly

Static analysis of bus structure to get the structural strength for GVW, braking and cornering loads, loads from front and rear articulation

MBD model building of full vehicle with suspension and bushing characteristics

Multibody dynamic analysis of full vehicle to predict the force history at chassis to suspension attachment locations for given road inputs

Dynamic transient response analysis to predict structural strength of bus body and chassis structure also to predict stress history of bus structure

Fatigue analysis of full vehicle structure from predicted stress history using fatigue material Properties

Structural analysis of 3 wheeler

Detailed FE model building with spot weld, seam weld and bolting connections

Finalization of durability load cases for replication of field failure

Suggesting structural modification considering design, manufacturing and assembly constraints

Finalization of design proposals by continual interaction with customer Structural analysis of truck chassis

FE modeling of full truck model - chassis and body and cab assembly

FE modeling of axle, front and rear suspension including tires

Static analysis of full vehicle to get the structural strength for GVW, braking and cornering loads, loads from front and rear articulation

Dynamic transient response analysis to get the structural strength of chassis structure also to predict stress history

Fatigue analysis of chassis structure from predicted stress history Durability analysis of SUV Cabin structure and seating assembly

FE modeling of cabin assembly with connections as spot welds

Dynamic transient response analysis to evaluate the structural strength of cabin structure from given measured accelerations for various loading conditions

Fatigue life calculation and structural modifications for strength improvement Durability analysis of two wheeler frame structure - 2-poster simulation and experimental validation

MBD model building of the motorcycle in ADAMS/View. It includes the modeling of front and rear suspension, bushings, connectors and approximate tire. Model to be updated to match the aggregate mass of full vehicle

MBD analysis for static equilibrium and validate the model in terms of front and rear axle weight and to check the stability of the model

MBD analysis for sinusoidal input with known frequency and amplitude to validate the model with 2-poster test.

MBD analysis for random road input and validation with 2-poster test in terms of front and rear suspension displacement and accelerations at various locations with respect to time.

MBD analysis of the motorcycle model for frame attachment forces prediction.

Finite element transient response analysis of the frame structure to get the stress history and maximum stress locations.

Company Name – TATA Auto Comp Systems Limited (1 Year), Asahi Engineering Solutions Limited, 1 Year Title – CAE Analyst

Description –Static and dynamic analysis of various automotive components, Component and assembly level FE model building and static/dynamic analysis of various automotive components (Hypermesh, Nastran) Managerial Skill

Leading team of 7 people (3 Analyst and 4 meshers)

Handling cross functional activities as NVH testing for FE to test correlation

Responsible for understanding customer requirement, preparation of technical proposal, project costing and project planning

Responsible for project report review and customer interaction

Responsible for review and finalization of Standard Operation Procedures EDUCATION

Master in Mechanical Engineering, 2004

(Specialization in Automobile Engineering)

VJTI, Mumbai University

Bachelor in Mechanical Engineering, 2001

D. Y. Patil College of engineering, Pune, Pune University RESEARCH PAPER

SAE Paper No. 201*-**-**** “The Application of the Simulation Techniques to Predict and Reduce the Interior Noise in Bus Development”, SAE International 2012

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