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Engineer Design

Dearborn, MI
April 23, 2016

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352-***-**** 5450 Wessex Ct, Apt 202, Dearborn, Mi-48126

Over 7 years of experience as a Thermal CFD CAE Analyst in OEM and academic environment. Highly motivated engineer with excellent technical expertise coupled with leadership capability. Also a good team player with strong communication and collaboration skills.


Master of Science in Mechanical/Aerospace Engineering 2009 - 2011

University of Florida, Gainesville, Florida, USA. GPA: 4.00/4.00

M.S. Thesis in Thermal Sciences and Computational Fluid Dynamics

Bachelor of Technology in Mechanical Engineering 2005-2009

National Institute of Technology (NIT), Warangal, India. GPA: 8.70/10.00

Work Experience

CFD CAE Lead Engineer at Ford Motor Company Research 2400 Village Road Advanced Engineering Feb 01 2016 - Current

Supported design of catalyst turbocharger interface - close coupling through relevant 3D CFD analysis on 2.0/2.3/2.7/3.0L turbocharged engines. This analysis helped the design of exhaust system to meet stringent ULEV70/SULEV30 emission requirements.

Provided Thermal/CFD analysis support to global exhaust system community, to reduce product development time and cost of exhaust components/ turbo chargers and to give design directions during CAD packaging.

Developed and implemented best practice CAE work processes that can be replicated within Exhaust PTI CAE team. Deployed the methodology to other global CAE teams and helped them to implement the process.

Reached beyond immediate teams like after treatment, crash/safety to build relationships for better product quality and functional excellence.

Worked closely with Design and Release engineers (D&R) and built 3D-CFD analytical models to predict catalyst brick inlet temperatures, thermal/flow fields around the oxygen sensors and catalyst bricks .Help the design and release engineers in critical go/no-go decisions.

Thermal CFD Engineer at Altair Product Design Inc. Ford Motor Company - Client

Dec 09 2013 - Jan 30 2016

Profound knowledge in Fluid Dynamics, Heat Transfer and Thermal Management. Applied concepts of heat transfer, thermal management to optimize the thermal losses in the exhaust system.

Built 3D CFD fuel slosh analysis models to identify slosh noise issue on several start/stop car programs and recommended baffle designs to mitigate slosh noise issues.

Demonstrated custom data visualization for various commercial solver results using Ensight. Very effective in visual presentation of technical data to foster the needs of customers. Provided 3D CFD analytical data to support upper management and design engineers to evaluate what-if scenarios and understand the design space in the analytical world and make good engineering decisions.

Performed hands on calculations on reduced or simplified math models to make designing and testing more efficient.

Interpreted test/simulation results and explain their consequence on part functionality and performance to product engineer to assist design and problem solving process.

Significant Accomplishments:

Instrumental in developing a first of its kind CAE process “Process to Optimize Exhaust Enthalpy” to potentially support multiple engine programs/platforms and help in delivering stringent SULEV30 emission targets. Worked in collaboration with engine research aftertreatment and design teams to correlate the methodology with analytical data.

Received “VCSE DI CAE Chief award at Ford Motor Company” for developing the above process. This analysis will improve preservation of environmental and economic capital and is in the best interest of Ford’s sustainability motives. “Fuel economy benefits” up to 1.0% based on measured test data. Emission compliance.

Worked on 2.0/2.3L engine platform to close couple the turbo catalyst interface using CFD analysis-Making the system ULEV 70 capable and “enable GPF delete” which would reduce $100 per engine.

Provided CFD analysis support on 2.7/3.0L Nano to improve the catalyst inlet temperature by 70 degC in the first 20s after engine key-on. This will help the catalyst to light-off quickly and regulate emissions.

Developed a 1-D tool to automate the post processing results of slosh noise CFD analysis. Reduce the turnaround time by 6 hours for each analysis.

Awarded certificate of recognition twice for supporting critical launch issues and program related work in PTI Fuel Systems.

Cooling Performance Analyst at Amerit Consulting Inc. Caterpillar Inc. - Client July 11 2011 – Dec 06 2013

Utilized analytical techniques to develop and validate 3D cooling system designs considering performance and underhood temperatures.

Performed Exhaust Thermal Management using Fluent, Star CCM, and ANSA.

Generated multiple cooling system concepts and maintain analytical master models with accountability to ensure cooling systems meet performance specifications.

Sized/selected heat exchangers and fans using 1D analysis program similar to KULI.

Determined water circuit configuration including pump sizing, flow split balancing, and pressure drop assessment using 1D analysis programs.

Collaborated with design partners to meet ambient temperature capability, fan power and noise requirements.

Developed under hood thermal 3D CFD models to predict component temperatures and effects on cooling package air flow. Participate in cooling/airflow tests and correlate analysis models to test data.

Significant Accomplishments:

Functioned as “Lead CFD analyst for Forest Products” cooling package design F568 and F324.Optimized the design of cooling package. Collaborated with other product teams to understand their core components like Radiator, TOC, HOC, and CAC. Used components for which tooling existed, to build a cooling package for Forest Products and provide cost effective solutions to the product team.

Used 3D-CFD analysis and Performed “Exhaust Thermal Management” on several Medium Wheel Loader applications to regulate pressure drop through the after treatment and exhaust systems. This reduced back pressure helped to improve engine performance output. Predicted the skin temperatures of critical components like Bosch injectors, oxygen sensors in and around the exhaust system. Resolved the component temperature concerns by providing shield designs analytically. Performed A to B comparison studies in CAE to evaluate the shield / flow diverter effectiveness.

“Pump CFD analysis 6 Sigma project”- Developed a standard 3D-CFD method to predict the pump performance, cavitation using PumpLinx. Worked with the tool vendor to improve the correlation of the analytical data to test data. This project resulted in late tool changes – robust impeller / housing design in the earlier phase of the Pump program.

Research Experience

Master’s Thesis - CFD analysis on the performance of an Ejector a jet pump in application to a pulse refrigeration system. Advisor Dr. S.A.Sherif Aug 18 2009- Aug 05 2011

Graduate Research Assistant – University of Florida, Department of Mechanical Engineering

An Ejector-based pulse refrigeration system (PRS) is a system that may be powered by solar or waste heat, and which is suitable for terrestrial and micro-gravity environments. The Ejector eliminates the need for a circulation pump, thus reducing system mass and increasing reliability.

Designed Ejector using geometric scaling ratios from existing ejector based cooling systems and literature, with computational analysis.

Simulated Ejector using 3D-CFD, Fluent a flow modeling software to predict the effect of performance parameters on the Coefficient of Performance of the system.

Analyzed the flow field, geometrical recommendations were given to improve the design in terms of pressure ratio and entrainment ratio. Optimized design point is predicted by using the pressure contours.

Worked in collaboration with a team of 2 members from South African University of kwa Zulu Natal. They provided experimental data.

Significant Achievements / Publications

Thesis work published as a conference paper in American Institute of Aeronautics and Astronautics (AIAA) at Nashville Tennessee July 2010. - 3 Citations.

Awarded student of outstanding achievement twice in consecutive years for academic excellence and cumulative GPA of 4.0 over the MS degree.

Skills Summary

Modeling/Analysis: FLUENT, Star CCM+, PumpLinx, Ensight, CFD post, Paraview, ANSA, TGRID, RADTHERM, Space claim, MATLAB, PROE, Gambit, Auto CAD, CATIA.

Theoretical: Fluid Mechanics, Thermodynamics, Computational Fluid Dynamics (CFD), Internal Combustion Engines, Turbo Machinery, Convective Heat Transfer, Compressible flow

Inter personnel: Working in a cross functional team, excellent communication skills, and project scheduling.

Programming Languages: C, C++, JAVA, SQL Certified, Sun Certification SCJP 5.

Microsoft Office: Word, Excel, PowerPoint, Visual Studio.

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