Engineering Engineer

HADI RABBANI

**** ********* ****** 248-***-****

West Bloomfield, Michigan 48323 ***********@*****.***

CAREER SUMMARY

Experienced structural dynamics engineer and innovative technical leader with extensive experience in automotive in the areas of NVH (Noise, Vibration and Harshness) CAE and Testing (Vehicle and component). Demonstrated skill in applying new analytical methodologies and advanced techniques in vehicle development.

Expertise (Core Competency: CAE and Testing)

Proficient in utilizing LMS Test. Lab Processing, Post-Processing, and Reporting Agents for vehicle and component tests.

Demonstrating technical expertise in the related field of Computer Aided Engineering (CAE) analysis and providing guidance to external engineering activities and suppliers on analysis matters.

Vehicle Road, wind and Powertrain-induced Noise, Vibration, and Harshness (NVH) benchmarking, target setting, and target compatibility assessment; root cause determination, issue resolution and design enhancement recommendations.

Customer satisfaction, stemming from vehicle Interior Quietness, Smoothness of Ride, and other NVH metrics.

Vehicle Modal Alignment Strategy.

Vehicle Design Specification (VDS) for Powertrain, Road, and Wind-induced NVH Target Compatibility Assessment.

Extensive use of Experimental Design (DOE) and DFSS (Design for Six Sigma) for vehicle subsystems, components, and full vehicle optimization.

Leading NVH, durability, aerodynamics, and safety vehicle development teams from concept to design.

Aluminum Intensive (concept) Vehicle development for NVH, including development and application of weld-bonding methodology.

PROFESSIONAL EXPERIENCE

Advantage Resourcing; Assigned to Ford Motor Company 08/19/2014--06/15/2015

Engineering Test Lead ---Coordinating DV Efficiency Tests; working with subsystem leaders to facilitate DV Efficiency test templates (List of channels and runs necessary for first pass DV tests).

Leading and facilitating DV Efficiency weekly meetings to review the status of the DV Efficiency projects

Chrysler Corporation; CTC; Auburn Hills, MI (Contract NVH Engineer) 12/2012 04/2014

Stop-Start starter-ring gear engagement noise tests

Designed test fixtures and conducted multiple bench tests on different starters (Denso, Bosch) to record the starter-ring gear engagement-induced noise and identify the source of the starter noise in order to minimize the stop-start noise.

Conducted a number of bench tests to measure and record the following parameters:

Starters-ring gear engagement noise for a 3.6L engine; Ring Gear RPM; Engine RPM; Battery Voltage; and Starter voltage. These tests were repeated for different starter covers to determine the effect of the covers with and without acoustic treatment on the starter-ring gear engagement noise.

Benchmarked different vehicles for VDV (Vibration Dose Values) associated with Stop-Start feature.

Prop-Shaft Dynamic Stiffness Test

Designed a test fixture to measure the dynamic stiffness of the Jeep Wrangler propshaft.

Different methods of excitation technique; such as: Sine Sweep and Impact were utilized to determine the optimum excitation technique for the torsional mode of the propshaft.

Driveline Bending and Torsion and Point Mobility tests

Jeep Wrangler driveline bending and torsion test.

Underbody suspension attachment points point mobility tests and engine mounts passive and active side FRFs.

All test results were analyzed and processed using LMS test. Lab.

Next Autoworks Company (formerly, V-Vehicle Company), San Diego, CA 03/2009-12/2011

Technical Expert, Vehicle CAE and Testing (NVH, Durability, Safety and Aerodynamics)

Responsible for leading all NVH, Aerodynamics, Durability CAE and Durability test Schedule, Safety CAE, and Vehicle Benchmarking . This included:

Working extensively with the Powertrain engineers and suppliers on the powertrain-induced (engine radiated, air intake, and exhaust) airborne and structure-borne noise measurements, identified the root causes and recommended resolution of the interior noise issues.

Through optimization of the exhaust attachment locations, eliminated the structure-borne noise stemming from the exhaust underbody attachments.

Working extensively with the P/T mount supplier to optimize and decouple (~90%) the P/T rigid body modes.

Subjective and Objective assessment and tuning of vehicle NVH on the Nissan Arizona test track.

Leading NVH and durability, modal and stiffness target setting, conducting full-vehicle NVH subjective/objective assessment, modal alignment strategy, point mobility (CAE and testing), and designing durability test track schedule.

Overseeing NVH and durability analysis and leading other full vehicle CAE activities; such as: Static Bending and Torsional Stiffnesses, Multi-Body Dynamics, and Aerodynamics.

Closely working with the design staff (studio) and directing the CFD Aero supplier to tune the body exterior to meet the target Coefficient of Drag of 0.29.

Providing full analytical support for the full vehicle test track Coastdown testing.

FORD MOTOR COMPANY, Dearborn, MI

09/1984 - 08/2008

NVH Leader/ Section Supervisor

Supervised and led groups of product development engineers, as many as 25 engineers, responsible for analytical assessment and evaluation of vehicle NVH (Noise, Vibration and Harshness), root cause, issue resolution for road and powertrain induced tactile and sound for all Unitized and Body-on-Frame vehicles (SUV).

Pioneered the development of a robustness analysis technique for the NVH / VVWD

(Vehicle Vibrates While Driving) Vehicle Design Specification, using ISIGHT FD Monte Carlo capability, in order to capture the inherent variability in all chassis and powertrain tunables

Led and supported the development of the Tuning Tool in the form of Excel Regression model for different NVH Vehicle Design Specifications (VDS) metrics and supported the special application of the Tuning Tool to DFSS (Design for Six Sigma) steering wheel Nibble, Brake Roughness, and Shake.

Guided the NVH CAE team to produce the quietest SUV in its segment by delivering the analytical model of a 4-mount rear differential unit ( RDU ), optimized for driveline imbalance and axle whine, leading to annual cost savings of $15M (through preservation of Rear Trailing Arm suspension and reduction in Axle whine warranty cost).

Pre-program NVH CAE Leader/Supervisor 01/1990-12/2000

In charge of full vehicle and body NVH CAE for all pre-program work including Ford of Europe’s B and C platforms. A major effort with success was expended on the modal separation of the front end bending mode and the east-west oriented engine firing order.

Led the development of a comprehensive analytical tool, utilizing Fuzzy Logic, for vehicle NVH CAE performance trade-off and target compatibility assessment during early stages of vehicle program development.

Established a CAE modeling methodology for the structural adhesive and validated the methodology by designing several weld-bonded test specimens and developing test techniques and comparing test / CAE modes and dynamic responses, yielding excellent correlation.

Group / Project Leader 04/1984-01/1990

Performed an in-depth investigation of the automobile FEM ( finite element model ) methodology

EDUCATION

PhD, Engineering Science-Applied Mechanics, University of California, Berkeley, CA

MS, Mechanical Engineering Sciences, Wayne State University, Detroit, MI

BS, Mechanical Engineering, Wayne State University, Detroit, MI

AWARDS RECEIVED

Recipient of “2005 VE ( Vehicle Engineering ) Achievement Award for the Explorer Four Mount Rear

Axle Optimizer for Driveline Imbalance and rear Axle Whine,” August 2005.

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