Sunil Mate

***** ***** **** **, **********, MI **335 acvvuz@r.postjobfree.com 480-***-****

Professional Mechanical Engineer having 3 years of experience in Product Development, Design and Analysis domain. Specialize in 3D CAD modeling, Component design, Design Failure Mode & Effect analysis (DFMEA), CAE and FEA. Seeking a Full-time position in the area of Product Design & Development.

CAD Tools: Creo Elements, Pro/ENGINEER Wildfire, Siemens PLM NX (Unigraphics NX), PDMS, SolidWorks, CATIA V5, AutoCAD

Solid & Parametric Modeling, Detail and Assembly Design, GD&T Y 14.5-2009, DFM, DFA, Rapid Prototyping, C, C++, C#, Matlab

CAE Tools: Structural Analysis, ABAQUS, ANSYS 16.0, HYPERMESH 8, MoldFlow, Forge 3, MSC Adams Multibody Dynamics Software EDUCATION

Master of Science- Mechanical Engineering, Arizona State University, Tempe, AZ, USA (GPA 3.52/4) May 2016 Bachelor of Science - Mechanical Engineering, College of Engineering, Pune (COEP), MH, India (GPA 3.81/4) May 2011 WORK EXPERIENCE

Research and Development Engineer – Polymer & Metal Division July 2013 – Aug 2014 Varroc Engineering Pvt. Ltd, Aurangabad, MH, India

Designed automotive stamping dies for pressed structural sheet metal/ body-in-white (BIW) parts for OEMs & tier 1 auto suppliers.

Designed dies for stamping metal chassis parts, inner and outer body parts such as cross members, bracket assemblies, doors, roofs, side-panels, hoods, floor panels, seat reinforcements and wheel houses.

Designed automotive forged components from Powertrain and transmission assembly such as Gears, Pinions, Connecting rods, Crankshaft, Camshaft, Spool, Engine valves, Power input and output shafts of OEMs such as GM, Harley-Davidson, Ducati, Honda etc.

Designed forged component Dies required for component manufacturing in PTC Creo, NX Unigraphics, CATIA V5, SolidWorks

Used professional courses of GD & T along with Tolerance Stack-up analysis for optimal design of the components.

Analyzed forging process in Forge 3, a metal flow simulation software, and optimized the design, forging machine capacity, resting position in die for product quality improvement, weight and cost reduction. Redesigned the mass production cycle of plastic components for maximizing production.

Designed and developed plastic injection molded parts for automotive Interior Systems, Exterior Systems, Closures, Cockpit components, Door panel, Seating assemblies, Instrument panel, Mirror assemblies, Air-filter assemblies, HVAC & under hood parts.

Designed molds of injection and compression molded automotive and allied rubber components in UG NX, CATIA V5 & PTC Pro-E.

Designed and developed Foam in place (FIP) mold for seat assembly. Tested & validated for endurance test under various load cases.

Used MoldFlow, a plastic injection simulation software, to improve manufacturability by optimizing wall thickness, gate location, tool geometry parameters such as draft angles, alignment, interferences. Validated & optimized design & layout of tools for plastic parts.

Identified and resolved tooling feasibility issues in pre-production environment by analyzing results of Moldflow simulation.

Tested and validated the final injection molded plastic component by 3D scanning the component comparing against CAD model.

Initiated efficiency improvement activities for Sawing machine by determining sawing capacity of machine to utilize to full extend and for Heat treatment process by adding two extra burners to minimize the material loss (Scale) during normalization process. Mechanical Design Engineer – Plant Design, July 2011 – July 2013 ThyssenKrupp Industrial Solution, Mumbai, MH, India

Worked as material specification engineer and 3D CAD design Administrator of piping, mechanical equipments in SolidWorks, Unigraphics NX, PTC Creo, ‘PDMS’ (Plant Design and Management System), AutoCAD software and solved design related issues.

Performed Structural and Mechanical Analysis for mechanical equipment piping system using CAE tools ANSYS and CAESER 2.0

Designed and modeled industrial valves, piping components by using dimensional standards such as ASME B31.3, API, ANSI, PIP, NACE in Pro-Engineering, SolidWorks and PDMS modeling software.

Extensively worked with procurement department for generation of bill of material (BOM) and vendor development. ACADEMIC PROJECTS

Design Team Lead – Vehicle Body (Chassis & Suspension) Aug 2010 – May 2011 BAJA SAE, India

Developed, analyzed and fabricated chassis/roll cage and optimized for compact and ergonomically comfortable design.

Modeled chassis design, suspension system in Pro-E CAD software & analyzed roll cage model in ANSYS for front, rear & side impact

Analyzed rear Wishbone suspension design using ANSYS and optimized the component to produce high roll center.

Analyzed the camber angle, roll center height variation against wheel travel in MSC ADAMS, a multi-body dynamics software.

Fabricated the components within the set tolerances, tested and tuned system for better performance.

Supervised and coordinated the work and goals of chassis & suspension to engineer optimized system. Design and FEA analysis of a multilayer laminated bicycle front fork Aug 2014 – Dec 2014 Arizona State University, Tempe, AZ, USA

Designed composite bicycle front fork considering static loading, braking load, impact loading and critical buckling load, and Optimized stacking sequence of laminate using MATLAB code. Modeled 3D CAD part geometry in ANSA.

Determined critical buckling load by running buckling analysis simulation in Abaqus FEA software.

Ran hygrothermoelastic FEA analysis in ABAQUS for fork to check effect of external environmental condition.

Optimized the overall weight of front fork by selecting minimum safe thickness. Design and weight optimization of a critical section of Aircraft Fuselage Jan 2015 – May 2015 Arizona State University, Tempe, AZ, USA

Designed a critical section of an aircraft fuselage using metallic & composite materials with minimum weight ‘Z’ skin-stiffener configuration. Design approach included shear stresses for skin, compression buckling stresses calculation for stiffener.

Optimized skin-stiffener weight in design trade study by writing program code in MATLAB software.