Project Design Engineer

ARJUN ARUGONDA

Apt ***, *** nutmeg lane, East Hartford, CT- 06118

Cell: 859-***-****,********.*****@*****.***

STRUCTURAL ENGINEER / FEA ANALYST

Technical Skills

Proprietary Tools of IEL : Auto-modeler, APDL Macros.

Operating System : Windows2000, XP

CAD/CAE Tools : Unigraphics (UG)

FEA Tools : ANSYS, NX-CAE, Abaqus, HyperMesh and AutoCAD

Programming languages : ANSYS APDL, VBA

Areas of Expertise : Gas Turbine Components

Professional Expertise

•Strong professional experience in Finite Element Analysis, and Process planning and Quality control for Aerospace Engines.

•Proficient in ANSYS Classic, PW Auto Modular and fair knowledge on Unigraphics. Abaqus,HyperMesh and AutoCAD

•Modeling and structural static analyses of Rotors and cases

•Having experience in LCF analysis, sub model analysis

•Proficient in Structural Linear and Non-Linear (Material, Geometric and contact) Analysis, Fatigue Analysis, Plasticity Analysis, Product optimization and basic Knowledge in analytical calculations.

•Expert in writing Macros in APDL to perform efficiently in order to increase the Productivity as well as Time & Cost Savings.

WORK EXPERIENCE:

Name of company: CYIENT Ltd.

Period: May 2011 – April 2016

Title/Designation: Design Engineer

Name of company: CYIENT Inc.

Period: April 2016 – Till date

Title/Designation: Design Engineer

As a Design Engineer, besides working on Finite Element structural analysis of gas turbine components for Pratt & Whitney, the following responsibilities have also to be executed.

oUnderstanding the scope for statement of work and customer requirements.

oCo-ordination with the clients and offshore team on schedules and deliverables.

oFE Modeling and analysis of the structures.

oQuality checking of the FE models and results interpretation.

oResponsible for technical deliverables from offshore Mechanical structure team.

oFinal review and documentation of the project.

Aerospace Components:

HPC: Front hub, Bladed Disks, Integrated Bladed Rotors IBRs5-8, Rear Hub, Tie Shaft, Mid Nut

Case: H flange and split flange.

Engines: MRJ, BA, 30K, SWORDFISH

PROJECT PROFILE:

1. Project title : Structural Analysis on BA and 30k Global Model

Client : Pratt&Whitney, USA

Project Details:

The main objectives of this task are

To define attributes in PW auto modeler, which is a modeling tool for generating finite element models for analysis using UG and ANSYS.

To simulate the assembly of the Global model for different kinds of Missions/flight cycles.

Role: Defining attributes for the global model using PWAUM tool which will give us an optimized FE model with thermal & Pressure components required for the analysis. Global model is consisting of HPC, HPT,#3 bearing and #4 bearing assemblies. The analysis is performed for all the time points of different missions and with different thermals. Three preloads are considered for analysis and it is simulated at HPC, HPT and # 4 bearing locations of the tie shaft and through fit at #bearing location. After applying the required preload, steady stress analysis is carried out for the flight cycle. To check the stress and displacement behavior of the global model. Percentage error at critical locations of Rotor5 to 8, Front, Aft hubs and on tie-shaft is checked, to meet the 30% error criteria. In turn, this global is used to take loads/BCs for sub models. PW life input files are generated with the help of a tool called Surf life. FM input files

2. Project title : Structural Analysis on BA, 30k engines IBR 5 to 8 components

Client : Pratt&Whitney, USA

Project Details:

Objective of this project is to perform the structural analysis on integrated bladed rotors stage 5 to 8 to assess the life at leading edge, trailing edge, trench and balance cut location as per ESW Criteria,

Role:

Preparation of FE model of integrated bladed rotor sub model in such a way that mesh error has to be less than 30% error criteria at critical locations such as leading edge of the airfoil, trailing edge of airfoil, trenches on the rotor rim surface and balance cut region. Single sector or 180 degree model is considered for the preparation of sub model as per the requirement. Application of Boundary conditions and loads for all the time points of a concerned mission. Sub modeling concept is used to take thermals and cut boundary conditions from the global model. Prepared a detailed result pitch and Stress summary of all critical locations. Depending of the size of the model the two or three sub model are considered

3. Project title : Structural Analysis of 2D-3D AVT

Client : Pratt & Whitney, CT, USA

Project Details :

The Main objective of this project is to optimize the design of AVT assembly which is not meeting lifing criteria and burst margin.

Role:

Preparing the FE model of 3D AVT (Anti Vortex tube) assembly with in 2D HPC assembly. Modeling and Boundary conditions for 2D and 3D combination gives us to explore the model. Application of Boundary conditions and loads for the critical time points of MTGW and AD27 missions for life and for burst margin calculations. Structural analysis has been carried out for the critical time points of different design iterations/different material combinations of AVT assembly to fix the design. Sub modeling concept is used to take thermals for 3D components from the HPC alone model. Preparation of a detailed result pitch and Stress summary on AVT assembly.

4. Project Title : Instrumentation hole Structural analysis for Rotors

Client : Pratt & Whitney, CT, US

Project Description:

Integrated Bladed Rotors (IBR) is a component in the 30K Engine. This is the new Engine program, whose objective is to develop a 30K thrust engine which is superior to other engines in terms of noise, fuel efficiency, weight savings and overall performance. Pratt & Whitney is incorporating IBR for the first time in its engines program. IBR Instrumentation hole is required to guide the wires from Front hub of HPC to Rear Hub (High Pressure Compressor), Thermal load and pressure loading is the critical loads for the gas turbine components. Static stress analysis is carried out at all the critical points of the working cycle. Stress data is then analyzed and the fatigue capability of the component is assessed. Strength of the component is assessed at the blade out loading conditions. Various design modifications are carried out to meet the life and strength requirements.

Role:

I have been involved in creating the high fidelity finite element model. Carrying out durability analysis of Instrumentation holes to determine life of component at operating condition, strength analysis at Limit and Ultimate load cases and burst analysis as per Engineering Standard work. Based on the results, design suggestions are provided and guidelines for material removal and addition at critical locations.

5. Project title : Structural Analysis of Front hub with Balance mass and rivets

Client : Pratt and Whitney, USA

Project Details:

Objective of this project is to perform the structural analysis on Front hub with balance mass and rivets to assess the life at front hub oil drain slots, flow hole, rivet hole and balance cut location as per ESW Criteria, deflection of front hub arm to check the clearance between the front hub and the stator knife edge

Role:

Preparation of FE model of Front hub with balance mass and rivets sub model in such a way that mesh error has to be less than 30% error criteria at critical locations such as rivet holes of balance mass, oil drain slot, balance cut and flow hole of front hub. Application of Boundary conditions and loads for all the time points of a concerned mission. Sub modeling concept is used to take thermals and cut boundary conditions from the global model. Prepared a detailed result pitch and Stress summary of all critical locations. Depending of the size of the model the two or three sub model are considered

6 Project title : Structural analysis of BA HPC case components.

Client : Pratt & Whitney, USA

Project Details:

First a 2D FE model is built to analyze the assembly behavior at different hot and cold Conditions.

Since the thermal gradients are high in the aft stages of the compressor the life of the Components are vital. So the life of the component is determined. If the 2D results are not realistic a 3D sub model is built for the location depending on the area of interest. So the 3D Sub model will be analyzed all the boundary conditions for the respective critical conditions. The summary of the analysis is documented and presented to the client.

Role:

I have been involved in creating the 3D UG models, Global and Sub model FE models as per the standard work. I performed Quality checks for the FE models and the loads applied. Also interacting with the clients to discuss on the progress of the project and the schedules. Preparation of the final SAM report.

Macros Written in APDL:

Macro used to mesh the Model with Solid 95 tet elements and to form Pyramids with adjacent 4 nodal Solid 45 Elements

Macro used to extract real constant for one ansys 2D model to another

Macro to move nodes in a 2D geometry to match with the updated geometry

Macro to move nodes in a 3D geometry to match with the updated geometry

Macro to create 3D axi-symmetric model for given 2D cross section and also create pressure zones for pressure mapping, thermal components for thermal mapping, mass elements at centre of gravity and centre of pressure, connect them to the solid model with rb3 and combine 14, creating 3D contacts and components and combine 14 creation for convergence and constraining the model

Editing and using of Flight cycle macros for 2D and 3D models, which run and create load conditions for multiple number of time points

And lot of minor macros for Time Savings.

Macros Written in VBA:

The purpose of validating radial deflection taken circumferentially at various location of HPC component contact location was solved by a macro which would create multiple sheets copy data created through APDL in to a these sheets, change data according to the iteration carried out and also create and summary sheet

Career Progression

CYIENT Ltd, Hyderabad, India 2011 Mar – 2016 April

CYIENT Inc, CT, USA 2016 April - Present

Working in structures discipline of engineering solutions division as a Design Engineer. The nature work encompasses working on finite element analysis of various gas turbine components for Pratt & Whitney engines.

Education and Credentials

B.S: Aeronautical Engineering, Jawaharlal Nehru Technological University, India GPA: 3.50

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