Engineering Mechanical

KALYANI SUNKARA

*** ****** ** *** *** • DEKALB IL 60115 • +1-630-***-**** • *******.*****@*****.***

SUMMARY:

•Over 4 years of experience in advanced design of industrial components using Creo 2.0, SolidWorks, NX and Catia V5 for modeling, assembly, detailing and creating technical drawings using ASME principles of GD&T

•2 years of expertise in FE analysis, CFD simulations using HyperMesh, COMSOL, and ANSYS

•2 years hands on experience with diesel engine performance testing and analyzing exhaust gas emissions

•Expertise in Design for Assembly (DFA) and Design for Manufacturing (DFM) of HVAC and automotive systems

•Diploma in Six sigma, Lean manufacturing, Systems Engineering and Project Management

•Experience in highly accelerated life testing (HALT) on shakers, vibrations and data analysis of automotive systems

EDUCATION:

Master of Science in Mechanical Engineering Aug'13 - Dec'15

Northern Illinois University, DeKalb, IL, USA GPA 3.7/4.0

Bachelor of Technology in Mechanical Engineering Aug'09 - Apr'13

Acharya Nagarjuna University, Andhra Pradesh, India GPA 4.0/4.0

PROFESSIONAL EXPERIENCE

CAE ENGINEER Jun’15 – Mar’16

Faurecia Emission Control Technologies

•Responsibilities include performing DV and fatigue life testing of exhaust systems and preparing DVP&R for design optimization.

•Expertise in performing CFD Simulations for the Exhaust Systems using GT Power 1D simulation tool and Star CCM+.

•Worked with CAD, Durability teams to improve the design, reliability of the exhaust systems and to ensure minimum possible complexity in design.

•Performed FEA model using HyperMesh and performed analysis through Opti-struct solver.

•Experienced in collaborating the information both from the OEMs and the technical team by providing the required data to the right teams.

•Involved in discussions with the customers and suppliers to communicate the targets and productivity of the components. Prepared Quotes for the systems by simultaneously working with the purchasing team.

•Involved in product life cycle of full exhaust system through the work done from acquisition to prototype testing. Also involved in Road Load Data Acquisition.

•Worked on Packaging study of vehicle underbody to fit the exhaust systems.

Engineering Key tools used: CATIA V5, NX, Star CCM+, HyperMesh, Team Center, Opti-struct, GT Power, NI LabVIEW, TEMPO

TEACHING ASSISTANT - Department of Mechanical Engineering

Northern Illinois University Aug'14- May'15

Courses: Design of Thermal Systems, Computational Fluid Dynamics.

•Duties comprise of helping students in conducting laboratory experiments and designing thermal systems.

•Making students work on new project ideas for the course related work.

•Assisting Professor in grading tests and assigning projects to students.

•Teaching CFD and CAD related software like StarCCM+, CREO 2.0 and SolidWorks.

RESEARCH ASSOCIATE – SAE Laboratory, IL Aug'13 – July’14

Experimental testing of Design Engines

•Experimental testing of Diesel engine done using a new additive and improved the performance of engine and executed the CFD simulations for further results.

•New additive include Triple-R mineral powder.

•Modelled CAD system to perform simulations.

•Conducted CFD simulations for thermal stress concentrations during the engine operation cycle.

•Compared the simulation results with the experimental test results to ensure calibration.

Engineering key tools used: HyperMesh, Opti-struct, CATIA V5, ANSYS Workbench, NI Lab View

Data Monitoring Engineer

KCP Sugar and Industries Corporation Ltd, India Jan'12 - July'13

•Conducted production line data monitoring to avoid the interrupted performance of the boilers and turbines through analysis.

•Sensors are connected to the boilers, conveyor belt motors, turbines, etc. and are to be monitored for condition based maintenance.

MASTER’S THESIS:

CFD SIMULATIONS FOR THERMAL AND EMISSION ANALYSIS OF DIESEL ENGINE COMBUSTION AND ITS VALIDATION

•Design and simulation of the engine cylinder with flat piston for in-cylinder motion and exhaust emissions study

•HyperMesh was used for creating a 3D elemental mesh of the cylinder head

•Produced thermal and emission analysis results based on the proposed design changes of the piston heads

•Validated the simulated flat piston results with experimental data on diesel engine from SAE lab

Applications: Automotive Engineering, Diesel Engine Optimization.

Engineering key tools used: HyperMesh, Opti-struct, Star CCM+, CATIA V5, NI Lab View, DVP&R

PROJECT EXPERIENCE:

Heat exchanger design for maximized performance

•Designed a more efficient and compact heat exchanger using heat pipes that can be used in conjunction with a positive displacement rotary natural gas compressor.

•Optimum heat transfer rate is achieved based on the number of heat pipes and a size reduction of 22% was achieved compared to the already existing heat exchanger

•Used SolidWorks to make the heat exchanger design based on given inputs and required outputs

GUI design of six bar linked robot using Visual Basic

•Obtained straight line motion for robot legs using the principles and equations of Hoeken and Pantograph mechanism

•A visual basic code was developed and the lengths of six links were obtained using the crank length as input

•Designed the six legged robot in Creo 2.0 and analyzed it for rectilinear motion

Design and fixture characterization through vibration testing

•Fixture was designed in SolidWorks and FMEA analysis was conducted

•Conducted impact tests and obtained natural frequencies using LabVIEW

•Modal and random vibration analysis were done in ANSYS to calculate transmissibility ratio

Design of MEMS based Piezoelectric shear activated beam

•Designed a composite cantilever beam with an actuator using SolidWorks

•Static and shear analysis of the beam was done by applying electric field perpendicular to the beam using COMSOL

•Obtained transverse deflection of beam for different materials and different voltages

Engineering key tools used for all Projects: NI Lab View, MATLAB, MS- Office (Excel, PowerPoint, Word), SolidWorks, CATIA V5, ANSYS, COMSOL (Multiphysics), HyperMesh, CREO, VisualBasic (.Net), DFMEA, DVP&R.

TECHNICAL SKILLS:

Engineering Design & Modelling : AUTOCAD, CREO, SOLIDWORKS, CATIA V5, NX

Engineering Analysis and Testing : ANSYS, Hyper Mesh, COMSOL, Star CCM+, NI LabVIEW, VibrationVIEW, GT Power

Computation and Compilation : MATLAB, FMEA, DVP&R, MS Office, Minitab, MATHCAD, MS Project

Programming Languages : C, JAVA, Visual Basic (.NET)

"Willing to re-locate in USA"

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