Design Engineer
Resume:
SUMMARY:
Professional Engineer with * years of experience in the Design and analysis, concept development, design calculation, welding selection, Design reviews, DFMEA, FEA calculation, Material selection, proto type verification, GD&T, Value Analysis & Value Engineering, Tolerance stacks analysis, to verify the national and International code of practice, of Automotive components (Transmission, Sheet metal part - Axle and its sub components, Platform, Bumper, Front weight frames, Engine mounting components, Bulk-heads, fender and casting & forging parts - Front engine support (FES), Axle) and steering, cylinders etc.,) and Elevator components (Sheet metal part - car body, Door & Door operator, Platform, Frame and its components, Bed plate, car sling, lower beam and upper beam., casting parts - Sill, counter Weight, diverter wheel etc
Design
CAE Analysis
CAD Application
Presentation
Design Calculation
Hypermesh
AutoCAD
Microsoft Excel
VOC
Ansys Classic and Workbench
Autodesk Inventor
Microsoft PowerPoint
QFD
NX Nastran
Pro E
Microsoft Word
Benchmark
3Ds Max
Windchill
Layout preparation
Solidworks
SAP - User
Concept Development
NX UG
Team Center
FEA validation
CATIA
PROFESSIONAL EXPERIENCE - 1
November 2014 to till date, working as an Assistant Manager (R&D),
M/s Bonfiglioli Transmissions Private Limited, Research and Development, Chennai.
Feasibility study / develop Concepts for new Products, Transmission / Gearbox for applications: construction equipment, Tractors, Electric cars.
FEA analysis, Structural, Linear, Non Linear for Axles, Gearboxes & Transmissions.
Define cost effective solutions studying alternate materials, Weight reduction.
Understanding application and duty cycle to prepare pre and post processors models.
Responsible to assess FEA results and provide appropriate solutions for design improvements.
Preparation of detailed analysis reports including results discussion and suggestion of solutions as needed based on FEA solutions.
PROFESSIONAL EXPERIENCE - 2
December 2011 to November 2014, Working as a Sr. Design Engineer (R&D),
M/s Tractors and Farm Equipment Limited (TAFE), Research and Development, Chennai.
Product - Tractors (Off-Highway Vehicle), Farm machinery, diesel engines, transmission components, hydraulic pumps and cylinders.
Design of heavy duty front axle, front engine support, Hub, Spindle, Front weight frame, Bumper and sheet metal part validated the characteristics for heavy duty applications - utilizing Pro e and Ansys, Hypermesh and benchmark, VOC, marketing study, QFD, DFMEA.
Axle design calculations (Endurance load, collision load, Bending stress calculation etc.,) for 40HP to 90 HP tractors, steering geometry and calculations agree within 0.5% of experimental data, influenced design of future axle and its components development.
Through optimization and weight reduction projects, achieved 22% weight reduction in Wheel Hub, Kingpin tube, Bumper, Front Engine Support (FES), Rear weight (Sheet metal), Axle.
Performed FEA structural Analysis (ANSYS, Hypermesh, Pro Mechanism) on various supporting configurations, Linkages, Casting, transmission case, center housing, this will impact was quicker turn around time and comparable results in the business, to reduce Lab testing time and filed testing time.
Design Failure Mode Effective Analysis (DFMEA) of Axle system, Steering and its components, Bumper.
GD&T and Tolerance stack-ups or tolerance stacks analysis for various components and systems.
Responsible for selecting materials for various components and integrating the components into complex assemblies within approved developmental budget and schedule.
Applied for patents (Sheet metal rear weight and Unitized bearing ).
Provide a front axle design of the new lunch tractor in fewer part counts, subassemblies, and weight reduction.
Provide several light weight optimized designs without sacrificing the structural strength.
Evaluated product performance and recommended design changes through official reports and presentations.
Perform Lab, Field testing on proto components and validation.
To conducting the Design reviews (various cross function team-CFT) and incorporate the recommended design changes and release the improved design for proto development.
To organizing and support the Proto build, components development and testing.
PROFESSIONAL EXPERIENCE - 2
October 2008 to 07.12.2011,
Working as a Design Engineer, M/s Kone Elevator India Pvt Ltd, Chennai.
Product - Elevator, Escalators and Auto-walks
Design of sheet metal and casting part (Various different Doors, Door Operator (Automatic, Manual & Semi automatic), Car, ceiling, Roof, car operating panel (COP), Indicator panels, Maintains access panel (MAP), Sill, wheel and counter weight etc.,) to suite the different applications and marketing requirement, benchmark, voice of customer (VOC) - utilizing Pro e and Ansys, Hypermesh.
Complex mechanical layout interface and selecting materials for various components and integrating the components into complex assemblies within approved developmental budget and schedule.
Perform structural analysis for Platform (Floor Assy), Door, Bedplate and sling (Frame), Lower beam, Upper beam, Door Operator etc., using Ansys, Hypermesh.
Perform Design Failure Mode Effective Analysis (DFMEA) of Door, Door operator, and Car body.
Utilized a combination of analytical skills, CAE tools to develop products that were lighter and easy to manufacture, yet durable enough to meet all performance targets.
Coordinate cost reduction workshops for design and manufacturing issues and achieved 10% cost saving.
To Perform the Lab and field testing on prototype components.
Create and maintain engineering documentations of prototype and existing products to meet standards.
Various standards to be followed in design EN, IS, ISO, ASME, EC, DIN and also local code.
Evaluated product performance and recommended design changes through official reports and presentations.
TECHNICAL ACCOMPLISHMENTS
Ability to apply CAD and CAE skills effectively to design and evaluate the performance of Axles, Bumper, Steering, Platform, Doors, Frame and its components, Car body, Sling, Upper beam, Lower beam, various sheet metal parts and Mechanical systems to reduce the number of prototypes required for testing.
Layout, packaging and interface analysis.
GD&T and Tolerance and stack up analysis, DFMEA, Welding.
Field complaint to be provided best possible solution trough FEA and analytical.
CAREER ACHIEVEMENT
In new and existing design achieved 15% weight reduction and 5% cost reduction in material cost through engineering action (Optimization, alternate design, alternate material) (Components like - Bumper, Axle, Front engine support (FES), Wheel Hub, Steering arm, Kingpin Assy, Rear weight, Door, Door operator, Plat form, Sling, Lower beam, Upper beam etc.,)
Introduced new concept unitized bearing and Mud block seal for front axle systems.
Introduced Hollow tube concept in axle system and achieved 3k cost saving.
Introduced weight optimized Bumper for 25HP to 60HP range.
EDUCATION, SPECIALIZED TRAINING & CONTINUING EDUCATION
Course
Specialization
College
University / Board
Percentage Class
BE
Mechanical Engineering
Thanthai Periyar Government Institute of technology
Anna University
76
First
Diploma
Production Engineering
Rajaji Institute of technology
DOTE/State
89
FWD
+2
HSC
Government higher secondary school
State
63
First
10th
SSLC
Government High school
State
70
First
PROFESSIONAL CERTIFICATION
Master Programme in Product Development using CAD/CAM/CAE in Central Institute of Plastics Engineering & Technology (CIPET), Chennai. (Pro E, Hypermesh, CATIA, Ansys) With paid internship and live projects.
TRAINING and CERTIFICATION Programmes:
Workshop on Value Engineering and Value Analysis.
Workshop on Welding Technology in Automobile, White goods and Consumer durable Industry.
Workshop on Executive Development Programme (EDP).
AWARDS & HONORS
Won best performer award.
Won cost saving award.
Won second and third position in suggestion award.
Won best leadership award.
T.THIRUMOORTHI
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