ZHICHAO ZHANG

315-***-**** acuayb@r.postjobfree.com **717 Farmington Rd, Livonia, MI 48152

SUMMARY

Mechanical component CAD experience using AutoCAD, SolidWorks, UG NX and CATIA V5, managing dimensioning, and applying GD&T standards in Product Design and Development;

Analytical skills and knowledge of Solid Mechanics, Fluid Dynamics and Thermodynamics in CAE projects, including FEA and CFD simulations with HyperMesh, ANSYS and Star-CCM+;

Double major in Business Management with knowledge of Project Management, Logistics Management, Quality Management and Information System.

EDUCATIONS

Syracuse University, Syracuse, NY 08/2013-05/2015 M.S. in Mechanical and Aerospace Engineering, GPA: 3.97/4.0

Wuhan University of Technology, Wuhan, China 09/2008-06/2012 B.S. in Energy Power System and Automation, GPA: 3.5/4.0

Wuhan University, Wuhan, China 09/2008-06/2012

Bachelor of Administration in Business Management, GPA: 3.7/4.0 EXPERIENCES

Product Design Internship, Smoothies Technology Inc., Elmhurst, NY 09/2015-03/2016

Communicated with DRE to understand concepts of products, developed detailed design drawings and 3-D models for various mechanical components (shaft, filter tube, pillow block bearing, flange) using CATIA V5 and UG NX;

Coordinated with and consulted other engineers, vendors and customers to modify dimensioning and tolerancing of design based on tolerance stack-up analysis for simplifying manufacturing and assembling processes. Design Engineer Internship, Longxue Shipbuilding Co., Ltd, Guangzhou, China 07/2012-08/2012

Designed the main shaft in transmission system for 85m Drag-Suction Dredger and selected corresponding components

(bearings, couplings, joints, seals) according to the design specification;

Developed 3-D models using UG NX, generated part drawings and applied GD&T;

Conducted pre-processing to generate meshes for the shaft using HyperMesh, applied specific material properties, loads and restrictions for the FEA model and prepared for further analysis. Manufacturing Internship, Wenchong Shipyard Co., Ltd, Guangzhou, China 06/2011-08/2011

Received training and rotationally practiced in processes of casting, machining, welding, painting and assembling;

Created and released BOM database, assessed manufacturing cost and reduced 7% cost by selecting appropriate suppliers;

Verified quality for products by collecting and analyzing dimension test data from random samples using Minitab, conducted quality control for databases applying 6-Sigma Principle and 8Ds method, and assisted FMEA and DOE. PROJECTS

Design Optimization for Hamilton Beach 49611 Coffeemaker

Created 3-D model for each coffeemaker component and assembly drawing using SolidWorks;

Analyzed and reduced the number of components by combining small parts and redesigning the injection mold, compared various materials and selected PP as thermoplastic material, and achieved 10% cost saving using Lucas cost assessment. Mechanical Design for 2-Stage Gear Reducer

Based on the design specification, calculated necessary parameters of shafts and gears (transmission ratio, rotation rate, torque, module, tooth number, helix angle, etc.), designed geometry and checked bending strength and fatigue strength of each component to validate its reliability;

Selected appropriate rolling bearings, flat keys, flexible couplings, washers, lubrication and other accessories of gearbox;

Developed 2-D part drawings and assembly drawing using AutoCAD and applied GD&T to them. Process Design and Manufacturing for Metal Hammer

Applied GD&T principles and designed the cold working manufacturing process according to part drawings;

Conducted turning, milling, drilling and tapping process to manufacture and assemble a sample hammer from raw material, and examined the dimensions to verify its quality;

Programmed in CNC lathe (G-Codes, M-Codes) for further mass production. Solid Stress Analysis for Pillow Block

Created 3-D model for pillow block in SolidWorks based on engineering specification;

Generated grids and applied material properties, restrictions and loads for the model using ANSYS;

Conducted CAE durability analysis for the model to get the parameter results (deflection, von Mises stresses, etc.), and compared the simulation result with experimental results under given loads and boundary conditions. FEA Simulation for Heat Dissipation of Water Pipes

Developed models for hot-water pipes and their housing, applied boundary conditions and initial conditions for the models, and simulated heat dissipation around pipes with ANSYS;

Plotted temperature distribution and found key points with the highest temperature on housing surface;

Ran the simulation again under different water temperature, analyzed long-term temperature tendency at key points, and calculated the minimum water temperature to prevent the housing from freezing in winter. CFD Simulation for Audi RS8 Race Prepped Model

Analyzed and simplified external geometry of car model using SolidWorks;

Generated meshes around the model and simulated surrounding airflow under different speeds using Star-CCM+;

Based on the simulation result, calculated mass flux to evaluate the availability of cooling air for intercooler duct and engine cooling duct, modified the angle of intercooler duct to decrease the flow pressure at stagnation points, and adjusted rear wing to reduce aerodynamic lift and drag.

TECHNICAL SKILLS

SolidWorks, UG NX, CATIA V5, AutoCAD, ANSYS, HyperMesh, Star-CCM+, Minitab, MATLAB, Programming

(C++/C), LabVIEW, Microsoft Office.

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