***** ***** **** **, *** **, Farmington Hills, MI-48335.

Cell: 906-***-**** Email: acu0li@r.postjobfree.com

BHALCHANDRA MAHAJAN

Summary

I am a quick-learning and industrious person with interest to work in the area of Product Design & Development.

Proficient in CATIA V5 modeling as well as FEA tools ANSA, Hypermesh, Abaqus, ANSYS.

Deep understanding of Product Development & Design Release process.

Excellent Leadership, Customer Interaction, Presentation Skills, Data Logging & Problem Solving Skills.

3+ years of Industry experience, 1.5 years of Graduate Research Assistant experience & SAE BAJA experience.

Objective

Obtain full-time position in Product Design & Development area as Mechanical Engineer.

Education

Courses

Michigan Tech University, Houghton, MI, USA. OPT Start 23 May 2016

Master of Science in Mechanical Engineering. 3.82/4.0 GPA

Intro-to-FEA, Finite Element Methods in Eng., Design with Plastics, Vehicle Dynamics.

Walchand College of Engineering, India. Graduated May 2011

B.Tech in Mechanical Engineering. 7.32/10 CGPA

Industry

Experience

Role

Project I

Project II

Project III

Trainings

Cummins India Ltd., Pune, India. (29 Aug 2011-02 Jul 2014)

Product Engineer, Application Engineering.

• Conceptualize Engine Mounting Brackets, Radiator Mounts, Air Intake & Exhaust System

• Design & Release of Engine Mounting, Cooling, Air intake, Exhaust system components by using DFSS Tools.

• Liaise with FEA Analysis, R&D, Sourcing, and Manufacturing teams for New Product Development.

• Understand OEM design requirements, Participate in technical discussions with OEM.

• Be the OEM technical point of contact for resolution of New Product Development issues.

Repowering of BRDM (An Armored Reconnaissance Vehicle) for Ministry of Defense, India.

• An 8X8 wheel driven tank was repowered with Cummins Engine and Allison Transmission.

• Replaced petrol engine, manual transmission with automatic transmission, diesel engine powertrain.

• Performed powertrain packaging study, Power calculation to accommodate new powertrain.

• Designed Engine and Transmission mountings, Driveshaft, Cooling system and mounts.

• Validated and Released components by completing standard DVP&R tasks.

• Used DFSS tools such as Boundary and P-Diagram, RACI & Pugh Matrix, DFMEA for designing.

Result: Successfully repowered tank with very stringent timelines.

Part Level Shop Order (SO)/ (BOM) to Option Level SO Conversion (Product Configuration Management).

• Studied, Identified, and grouped various engine parts together as per part family.

• Wrote and compiled Engineering Job Release (EJR) for identified parts.

Result: Reduced part mismatch to zero & thereby increase Customer satisfaction.

Hands-on building of Engine, Alternator, Gen-set at manufacturing plant. (Self-initiative)

• Understand parts, components, assemblies and processes involved in manufacturing of Cummins products.

• Built Engine, Alternator, Gen-set assembly by own hands and built final product of defined quality.

Result: Good understanding of products, their working and role of departments involved in manufacturing.

Design for Six Sigma, Sales Training & Recognition for Gen-sets, Ethics at Workplace.

Industry

Experience

Project I

Project II

Cummins Inc. Columbus, IN, USA. (07 May 2015-30 Jul2015) Engineering Summer Intern.

Fuel Cooler Tool Development.

• Max Engine Fuel Temp is crucial parameter while designing and no existing method was available to predict Max Temp except experimental measurement after prototype is built.

• Developed MATLAB based tool which can predict Engine Fuel inlet temperature based on factors like Fuel Return Temp, Ambient Temp, Tank Volume, and Cooling Rates etc. before prototype is built.

• Implemented code in Excel Macro/VBA to save MATLAB licensing cost (Approximate 180$ per license).

Result: Developed Tool which will reduce Customer design modifications during development process.

Measure Oil Delay to Turbocharger in Cold Chamber.

• Measuring turbo oil delay was time consuming, costly procedure & had to be performed by every customer.

• Experimentally measured effect of ‘Oil Filter Height’ on ‘Turbocharger Oil Inlet Pressure’ on QSB 6.7 Tier4F Engine. Correlation between variables was established.

Result: Reduced OEM testing time by experimentally mapping relationship between variables.

Industry

Training

ANSA Training organized by BETA CAE Systems USA. (10 May 2016-12 May 2016)

• Attended a 3-Day training organized by BETA CAE Systems USA (Owner of ANSA products).

• Learned to handle basic GUI, Geometry Import, Geometry Clean-up, Geometry Modification on ANSA.

• Performed 2D, Tetra and Hex mesh operations on standard components (Provided in tutorial).

Result: Learned to handle ANSA software (as Preprocessor)

Educational Experience

Project I

Project II

Project III

Project IV

Project V

Graduate Research Assistant, Structural & FEA. (02 Mar 2015-29 Apr 2016)

Dept. of Mechanical Engineering, Michigan Tech University, MI.

Hertzian Contact Analysis of Tapered Roller Bearing, Amsted Inc. (Thesis Project).

• Modeled Hertzian contact by using Surface-to-Surface Hard type contact in Abaqus Standard.

• Compared improvement in stresses caused by Steel vs Multi layered carbide roller bearing.

• Mesh improvement was studied by use of mixed Tetra-Hex and mixed first & second order elements.

Result: 6% Max Von Mises Stress reduction achieved by using Carbide Roller Bearing.

Modelling of Differential Case to Optimize Weight, Eaton Transmissions.

• The stress concentration areas in casing were already identified by using Hypermesh Optistruct.

• Decreased wall thickness of casing and removed material from low stress regions by using CATIA V5.

• Modeled casings with different thickness for further analysis and optimization.

Result: Offered various casings with variable wall thickness for further analysis and optimization.

Finite Element Analysis of Aluminum chassis, Magliner Inc.

• By using 2D shell elements chassis was meshed and Mesh Optimization study was completed.

• Analyzed models for two different Aluminum materials by using Hyeprmesh Optistruct.

• Modifications in geometry suggested to decrease excessive strains at front end of chassis.

Result: Improved chassis strength & Decreased excessive strain at the front end.

Crash Analysis of football helmet (Coursework Project).

• Modeled football helmet with four layers in CATIA. Analysis setup was completed by using Abaqus Explicit.

• Used Impulse Momentum Principle to determine velocity of crash from available force vs time plot.

• Analyzed effectiveness of helmet by measuring energy absorbed by helmet with different layer thickness.

Result: Learned to work with Abaqus Explicit for nonlinear dynamic analysis.

Vehicle Ride & Handling of the bicycle model. (Vehicle Dynamics Coursework Project)

• Investigated the influence of tire stiffness and the CG location on vehicle stability for Pick-up Truck

• Created MATLAB script to calculate the CG, steer gradient, characteristic/critical velocity, steer angle, lateral acceleration gain, sideslip angle for velocities in the range of 0-100 Mph.

Results: Observed the variation of above parameters & analyzed steering response with respect to velocity.

Undergrad Project

Design of Powertrain Mounting & Driveline in ATV for BAJA SAE, INDIA. (01 Mar 2010-30 Apr 2011)

• Designed mounting arrangement for Powertrain in to an ATV by considering parameters like Propeller Shaft Angles of universal joints, Vehicle balance, Max Engine inclinations by using CATIA.

• Designed driveline shafts by taking in to account suspension travel and torque transmission capacity.

Result: Successfully designed, analyzed and fabricated sturdy engine and transmission (Driveline) system.

Skills Used

• CATIA V5

• GD&T

• MATLAB

• DVP&R

• DFMEA

• DFSS

• Design Release(DR)

• Hypermesh

• ANSA

• Abaqus

• ANSYS(Novice)

• Microsoft Office

• VBA/Macros Coding

• Data logging

• Minitab

Awards

• ‘Spot Award’ by ‘Cummins India Ltd’ for actively participating in ‘Asbestos Material Cleanup Activity’ under Hazardous Material Clean-up Initiative.

Interests & Hobbies

Photography, Traveling, Trekking, Exercise, Learning New Things.

Contact this candidate