HOOMAN BAGHAEI ANARAKI

**** **** *** ***. ******. TX. 79762. TEL: 608-***-****. acs7ii@r.postjobfree.com ca.linkedin.com/in/hoomanbaghaei Page 1 of 2

SUMMARY OF QUALIFICATION

Education includes Mechanical and Materials Engineering, Metallurgical Engineering

Certifications includes Six Sigma, Blueprint interpretation, CMM and PC-DMIS

More than 5 years of experience in quality control, manufacturing and mechanical/materials lab

High knowledge of measurement system analysis, machining and casting process

Proficient in CAD/CAM, CLEMEX, OM/SEM and MATLAB

High Understanding blueprint interpretation, GD&T,FMEA,ISO/TS16949, ASTM/ASM

Excellent soft skills, problem solving skills, leadership skills, prioritization skills

Hard working, Cooperative, supportive team member and able to taking up new skills

EXPERIENCE

Research/Lab Assistant 2012-2015

UWO, Ontario

Characterized the structural and fracture properties of components using OM/SEM and image analysis-CLEMEX, performed mechanical-Instron and metallurgical experiments

Planned accurate procedures and experiments-DOE, performe failure analysis-FMEA

Analyzed the correlation between processing parameter and experimental/simulation results using ASTM/ASM standards

Delivered effective solution in response to manufacturing requirements, submitted technical reports/ECN, modified the mould design and gating systems of

Developed and validated the model to Predict the mechanical properties of the casting components of Ford-F150

Optimized the manufacturing process and productivity, suggested corrective actions to the Industrial partner-Meridian Light Weight Technologies

MEng Project: CAD/CAM, CNC Simulation 2011-2012

UWO, Ontario

Implemented accurate schedule to perform reverse engineering project, solved the production problem by upgrading of CAM processor

Converted scanned geometry(point cloud data) to the CAD model using FEA methods

Upgraded the post processor of Edgecam, generated G-Codes for 4th axes machining

Simulated milling process using CAM, performed 3Dmodelling of CNC machines utilizing GD&T, performed FEA analysis and other relevant requirements

Generated collision-free tool path, determined spindle rate and tolerances in each step

Manager & Quality Control Engineer 2007-2011

TCI, Tehran

Set cross functional meeting to determine the root causes of poor quality, addressed the problem and suggested practical solution

HOOMAN BAGHAEI ANARAKI TEL: 608-***-**** acs7ii@r.postjobfree.com Page 2 of 2

Coordinated various maintenance and manufacturing projects, directed various DMAIC projects to optimize the flow operation and productivity of organization

Reduced cost of quality, implementing 5S, 8D and SPC techniques, analyzed the pareto charts, gauge R&R diagrams, improved the quality and reliability of products,

Analyzed the technical data using statistical methods, proposed required changes in designs and fixture to ensure successful completion of manufacturing process

Created the quality vision and manufacturing policy, and ensured the implemented plans followed by all departments

RELEVANT EXPERIENCE

Furnace Operator 2014-2015

Stackpole Intl, Ontario

Examined the quality and hub diameter of spur gears, and rejected the non-conforming parts which violate the desired tolerances

Burnished bevel gears and assisted the Broach operator before performing heat treatment on root and teeth of the internal gears

Documented the specification and defects which lead to the poor quality

CNC Operator 2014-2015

Gnutti Carlo, Ontario

Partial set-up duties, minor modification of programs, tool change, trouble shooting

Performed different milling operation including reaming, honing and burnishing

Delivered efficient recommendations and corrective actions to improve the productivity and quality of products

Verified the GD&T of the machined parts using measuring instruments such as dial indicators, optical comparator, bore gauges, profilometer as well as micrometers

Quality Inspector 2013-2014

The PIC Group, Ontario

Provided third part quality services throughout different OEM(Original Equipment Manufacturer)

Applied technical quality methods and standards to perform precise quality inspection on finished products and raw materials

Identified the root causes of problems, and detected the failure initiation sites

EDUCATION & DESIGNATION

Master of Mechanical and Material Engineering 2012-2015 Western University, Ontario

REFERENCES ARE AVAILABLE UPON REQUEST

Mechanical and Microstructural

Characterization of the Bolster of Ford-F150

Research Title: Characterization of the Die-Cast Component

Goal: High fluctuation of mechanical properties across the component, and poor quality in knit line regions leads to the premature failure of the component. The main purpose was the development and validation of the failure model to predict the ductility of the components. To validate the structural based model, the microstructural-mechanical relationship is explored by performing thorough mechanical and metallographic experiments. The efficiency of proposed model is also examined when the simulation results and experimental values are considered as key input variables.

Discussion & Experimental Works:

To map the variation of mechanical properties across the component, the tensile coupons are extracted from different locations of the component. The tensile strength and fracture strain are determined by performing tensile experiments. The local variation of the mechanical properties is determined by performing hardness test on metallographic specimens.

To select appropriate locations for mechanical and microstructural studies, the simulation results of the casting process is taken into account. The flow pattern is considered to identify the knit line and last-to-fill regions. The last-to-solidify regions are identified by considering temperature profile of simulation results

The mechanical tests which are conducted in Meridian Light Weight Technology revealed that the regions close to the in-gate system are susceptible to premature failure in crash test. The apparatus which is utilized in this experiments is specialized for Ford structural components.

To identify the potential causes of failure, fractography is performed on the fracture surface of the specimens. Moreover. in-plane sections and metallographic samples are investigated using optical microscope and SEM.

To characterize the microstructural features,Image Processing software –IrfanView, and Image Analyzing software Clemex are utilized. Thorough investigations and studies are conducted to determine appropriate criteria to differentiate the microstructural features. For instance, the aspect ratio and jaggedness are considered as appropriate features to gas and shrinkage pores.

The SEM images and metallographic experiments revealed that major defects are porosities which can be classified in three different groups. They were entrapped gas pores, and pores which are formed in knit lines due to the turbulence of melt. The third group was the shrinkages.

Figure1. Mechanical & Microstructural Characterization

.

Results and Conclusions:

The study of metallographic sections from the gate system to overflow revealed that the percentage of large gas pores are doubled within the region close to the overflow position.

The inefficient performance of IP stage during the injection of melt into the mold leads to abrupt increase in the fraction of large gas pores. The average area fraction of large gas pores increased from 1.2% to 2.3%. The fracture strain of theses samples decreased from 8 to 5%.

The study of metallographic sections of the flange gates reveals that the crack like features are formed in this region. Such features are usually observed in the flange gates when the fraction of externally solidified grains are increasing in the melt before injection.

An increase in the fraction of solid materials leads to the increase in fraction of pores and cracks in the flange gates. Moreover, high fraction of pre-solidified grains leads to the sudden interruption in IP stage and an abrupt increase in fraction of large gas pores.

The accumulation of externally solidified grains within the core region of the specimens leads to decrease in hardness. Due to the non uniform distribution of intermetallic phase and local variation of grain size, higher fluctuation in hardness is obtained.

The yield strength of the samples are also correlated to the variation of grain size across the section. To determine the variation of grain size, field and objective measurement is conducted in accordance to ASTM-E112. The grain size results which are obtained from Image Analysis-Clemex is evaluated by an empirical equation which is based on the simulation of casting process by MAGMASOFT.

An increase in fraction of externally solidified grains also leads to the bimodality of microstructure. Therefore, the yielding behavior of samples varies as the percentage of these grains is increasing. To characterize the variation of yielding behavior, strain hardening of the samples are analyzed, and the correlation between the skin fraction and yield behavior is also explored.

As the percentage of externally solidified grains within the core region of the sample is increasing, the yield strength of the samples are reduced up to 95MPa. It’s also revealed that the reduction in yield strength depends on the distribution pattern of large grains. The yield strength of the sample containing dispersed pattern of large grains were higher than the accumulated one.

The higher fraction of solid material during the process and IP stage led to the formation of defect bands along the free surface of samples. These bands contains higher fraction of shrinkage pores.

The deteriorating effect of porosities on tensile strength is analyzed by considering three different impact of porosities. The first two effects were the reduction of load bearing capacity and stress concentration within the plane containing pores. Moreover the spatial location of the pores is also considered as crucial parameter. An abrupt decrease in fracture strain is obtained, while the imperfections are located close to the free surface.

Regarding the force balance between the plane containing imperfection and the perfect plane, the effect of load bearing capacity is characterized. To eliminate the effect of pores coalescence and growth, whole pores are considered as large pore within the sample. The distance of large pore from the free surface is obtained from metallography of plane below the fracture surface.

The comparison between the predicted and experimental values indicated that the maximum deviation was below 10%. A higher deviation is obtained while pores are located within the skin region of samples.

Reverse Engineering in CAD-Solidworks & Developing the Post Processor to Generate G-Codes for 4th Axes CNC Operation

Project Title: Creating a General Post Processor for 4th axes Operation of CNC Maching

Goal: The main goal of the project was to create G-codes of 4th axes operation, FADAL 4020a and TORMACH Vertical CNC machines. A scanned geometry is considered, and it’s modeled in SOLIDWORKS, then the operational machine defined and FANUC syntaxes are created using the G-code modules of EDGECAM. To create 4th axes codes, the developed post processor is validate by simulating the machining process in PCNC 1100.

Steps to Create Solid Model from Mesh/Cloud Point File: The solid model can be created using two different methods. The first one is Semi Manual Creation- Direct Mesh Referencing. The second method is the Semi-Automatic Creation, and based on the Meshprep Wizard Options.

The scan data can be modeled manually by drawing curves/sp-lines which intercept the reference points of the scanned geometry. Then the boundary surfaces are created between curves/sp-lines. It’s important to note that the reference points which intercept the sectioning planes pups up while sketching the sp-lines. The mesh data can be sectioned using Section View Feature. The last step is converting surface geometry to the solid model, and it can be performed by knitting the surfaces.

To use Meshprep Wizard the first step is to check Scan to 3D option of Ads-in of Tool Menu. By right clicking on the mesh file in Feature Manager Design Tree, the Meshprep Wizard option can be selected. The wizard is providing some tools to modify and simplify the data. The simplification and smoothness of the file can be performed locally and globally. Then we can lunch surface prep-wizard and the automated creation can be selected. The surface details can be adjusted, and the created mesh can be cleaned up using feature line options. The latter feature is usually used to fix self-intercepted surfaces. Then the surfaces can be created automatically. The surface model can be converted to the solid model using Surface-Knit option.

The other Semi-Automatic option is the Curve wizard, the feature can be selected by right clicking the scanned file in Feature Manager Tree. The sectioning tool can be used, and the generated curves can be edited and trimmed using the features of creation parameters within each section. The surface between the curves can be formed using Lofted Surface option, the solid feature of Lofted Boss/Base is can be used to generate solid model directly.

The CAD model of the CNC machine is required to simulate the machining process accurately. The modeling of components which are involving in cutting process should be accurate, otherwise the generation of collision free tool path is impossible. It’s important to define a coordinate system at the center of spindle; it defines the home position of machine.

Steps to Create and Develop the Post Processor: The translation of neutral FANUC syntaxes from CAM to an appropriate G-codes for certain CNC machines can be performed by Post Processors. The generated syntaxes are based on the limitation and requirements of CAM, CNC machine as well as type of operation. As the Edgecam’s environment is changed from Design to Manufacturing mode, the pop up window shows the existing CNC machines (Machine Tool) and the machining discipline (Mill). The new machine tool can be added, and the required steps are:

The CAD file of CNC machine can be converted to the Edgecam file by opening the CAD file in Edgecam and saving as (*epf). Then, open the Code Wizard folder form the Edgecam program, click new document, choose the mill icon among three icons (Lathe, Mill, and Wire). When the Mill window pops up choose the vertical machine. It’s important to note that this window is including different templates which are classified in Metric, Inches and both measuring systems. To simplify the creation of new post processor, the default templates can be used as the basic machines, and the related components of each machine can be replaced with new machine which are considered for the new manufacturing mode. The table shows the templates which are selected to create new post processor. . The other option is choosing one of the basic templates which only defines different axes of machining operation, and then paste the machine components which is saved as (*epf) file. The components of default machines can be identified under “Machine Set up” tab of the Code Wizard. An appropriate default template is chosen, and then in “Code Wizard Step” name the machine and click finish. The machine’s component can be exported to the Code Wizard environment, the components can be selected from the design mode and paste in Code Wizard>Machine Set up (Right click) . To generate a collision free tool path, precise constraints should be applied for the travel distance of each axes(X,Y,Z). From the Code Generator tree click the machine icon, then “Machine Parameters” window pops up, this window is including Turret, spindle and gear parameters. The coordinates of tool home is identified under the turret tab. The Format table can be selected from the tree and related window pops up. Increase the Numerical Precision up to five.

The letter address of first rotary axis should be changed to “A” for inch machines. It should be noted that code generator information is copied from template (Sample Mill Vertical BA Rotary) which is a five axes machine, and its token information has [SECOND ROT] and [FIRST ROT]. Therefore for building the five axes machines the information can be copied straight forward, but for four axes machines the token lines including [SECOND ROT] and [FIRST ROT] remains without any change and the token lines including only [SECOND ROT] should be changed to [FIRST ROT].To prevent NC lines including machine and tool information,G10, subroutines and other miscellaneous information which suppress PCNC program, all the information in these folders : Program start, Set up tooling sheet and data, comment, warning, set work datum and subroutines start should be deleted. Don’t change any information for mm machines, for the inch machines change [SECOND ROT] to [FIRST ROT]. Then click Code Constructor icon of the tree and apply appropriate changes in General Motion and other features as following:

NC Program General: Program start : Delete all information, Set Up Tooling Sheet: Delete all information, Set Up Tooling Data List: Delete all information

General Motion: Rapid Move: Don’t change any information for mm machines, for the inch machines change [SECOND ROT] to [FIRST ROT], Linear interpolation: : Don’t change any information for mm machines, for the inch machines change [SECOND ROT] to [FIRST ROT], Rapid after tool change: Don’t change any information for mm machines, for the inch machines change [SECOND ROT] to [FIRST ROT]

Miscellaneous Functions: Comment: Delete all information for all machines, Warning: Delete all the information for all machines

Tool change: Manual Tool change: change SAFEBLKNUM to BLKNUM, Datum shifting: Set work Datum: Delete all the information

Subroutines and Repeats: Subroutine Start: Delete all the information for all machines, Multi-Axis(rotary): Don’t change any information for mm machines, for the inch machines change [SECOND ROT] to [FIRST ROT], Once the characteristics of CNC machines are defined, the (*.cgd) file is ready to compile, and it will appeared in the list of existing machines in machine tool.

Steps of Design & Manufacturing Modes: The next step is to import the solid model into the design mode of Edgecam. First open the edgecam in design mode then File>Open>import, the second option is the insert option. The solid model appears, and an appropriate stock should be created before applying the manufacturing mode. To create stock, the digitize mode is used: Geometry> Stock/Fixture> Digitize. To set the datum positions, the rotation and translation features are used: Solid>Transform Solids> Rotate/Translate. To digitize the center of rotation press “X” and assign 0,0,0 for X,Y and Z. The machining material can be selected by clicking “Option” and “Select Technology”. Edgecam enable users to determine the desired features in manufacturing process, and it can be carried out automatically by clicking ‘Solid” and selecting desired features. The face feature is applied in this project. The next step is the manufacturing mode, and desired CNC machine (*.cgd) will appear in machine tool. Once the CNC machine is selected, the clamped solid model and CNC machine appear on the screen. It’s time to select tool, and machining operation. The machining instruction can be created by manual or automated methods. Once the face feature is defined as desired feature for machining operation, “Four Axis Rotary Operation” window appears. To prevent collision between the tool and stock in rapid move operation increase the safe distance. To prevent any thin wall in each step reduce the cut distance. The selection of tools can be performed by clicking tooling tab in the same window. To prevent collision between the tool and stock(or geometry) do the correction on tool length. Increase the tool length, and Z gauge. The tool path and machining sequences appears, and the machining operation can be simulated by clicking the “Rapid Result” form tool bar. The G-codes can be generated by clicking “NC” tab in tool bar, and NC codes pop up in new window.

Set Up CNC Machine: These steps are: Pre-Start>Home Position>Load Tools>Set Tool Length Offset>Set Fixture Offset XY>Set Fixture Offset Z>Load CNC Program>Run program. The first step is the Machine Zero, reposition the machine to the (0,0,0) location. Machine Turn On>Do you want to move to the last position>No> Type HO (Home Position>(X=0,Y=0,Z=0). The second step is the loading of tools: MDI/DNC key>Tool Number: T*1>ATC FWD>Position Tool in Spindle> Tool Release Button. The next step is Tool Length Offset.: Handle Jog>Jog increment 0.1>Jog Direction Z>Offset>Use Arrows to select current tool>Jog to the top of block>Jog increment 0.01(Tool slide the block)> Tool Offset Measure. The fixture offsets are also should be determined: First load Edge Finder in Spindle>MDI/DNC>Erase Program>Spindle Speed: input S1100, Push Write/Enter>Cycle Start> Handle Jog Increment 0.01>Choose Jog Direction>Jog Increment 0.001>Put Edge Finder alongside the Part>Now the distance from the center of spindle to the edge of part is 0.1(No Wobbling)>move in Z direction> Set Jog Direction in X, One clockwise rotation of Jog is equal to 0.1, because increment is readily set to 0.01>now the center of spindle is exactly placed alongside the edge of part>Offset Page>Part Zero Set> Do the same for Y axis. The last step is the Load CNC Program: Memory>List Programs>USB Device>F4>Program Name>Write/Enter>F2

Figure2. Creation of New Post Processor, and Steps of Manufacturing Mode

Contact this candidate