Resume of Mr. Damien K.W. Leung, B. Eng., M.Eng.

Residence: 3043 Burlington Ct. Tel.: 248-***-**** (Home) Rochester Hills, MI 248-***-**** (cell)

***** *****: acxg1f@r.postjobfree.com

Structural/dynamics FEA engineer with many years of hands-on and in-depth experience and expertise in durability (strength, fatigue) and dynamic (crashworthiness, NVH) analysis, and direct & DOE-based Design Optimization; multi-body vehicle dynamics software development (FORTRAN), testing of structures & vehicles; strong background in solid mechanics and vehicle dynamics; well versed in theory of multi-body dynamics; sharp structural sense; thorough, highly motivated and dedicated; versatile with great aptitude for new environments; self-starter; quick learner; work well with little supervision and/or independently; focused, organized, methodic, & efficient; work smart, hard, & fast; walk the extra mile; excellent verbal and written communications skills; software experience includes Abaqus/Standard and Explicit, LS-Dyna, Nastran, Optistruct, ANSA, Hypermesh, DesignLife, iSight, Hyperstudy, iDEAS, ADAMS, ANSYS; proficient in shell scripting and TCL for automation tools development;

Citizenship: U.S. Citizen and Canadian Citizen

PROFESSIONAL EXPERIENCE

Sept. 2013 – July 2016

Virtual Tool Engineer/Science Engineer, Fiat Chrysler, Auburn Hills, MI

Created efficient DOE-based multi-discipline design optimization (MDO) processes for various closure and frame products, thereby allowing such studies to be completed efficiently;

Wrote training manual for DOE-based multi-discipline design optimization and hosted multiple training sessions for the CAE Department;

Led and supported a major DOE-based multi-discipline design optimization (MDO) initiative across 5 vehicle programs for Closures group using the above-mentioned processes;

Performed DOE-based MDO of hood and frame systems for cross-functional product teams (durability, safety, NVH), including model parameterization (such as sizing, shape via morphing) and creation of DOEs using ANSA/Hyperstudy, optimization using iSight and Hyperstudy, and scripting for automated pre- and post-processing of models and responses;

Performed direct design optimization (sizing, shape, topology, topography) using Optistruct for components (suspension, ducts)

Performed durability evaluation (using Abaqus, LS-Dyna, Nastran, DesignLife) for product teams (truck frames, chassis, suspension, hoods, doors, lift-gates);

Undertook multiple initiatives for automation of various processes and efficiency enhancements, using shell and TCL scripts, thus allowing many hours or even days of manual work to be completed in seconds or minutes for enormous time savings;

Provided training, technical assistance and guidance to junior engineers;

June 2012 – Sept. 2013

Senior Structural Engineer, Martinrea International, Troy, MI

Performed modeling, linear and non-linear FEA (static, modal, and crash), fatigue evaluation of vehicle suspension and chassis components using Abaqus, LS-Dyna, Nastran, and FE-Fatigue/DesignLife, and design optimization using Optistruct;

Provided technical assistance and guidance to junior engineers;

January 2011 – June 2012

Senior Structural Engineer, Cosma Engineering, Troy, MI

Perform modeling, linear and non-linear FEA (static, modal, and crash), fatigue evaluation of vehicle suspension and chassis components, BIW, bumpers, and solar energy equipment and structures using Abaqus, LS-Dyna, Nastran, and FE-Fatigue/DesignLife, and design optimization using Optistruct;

Provide technical assistance and guidance to junior engineers;

October 2010 – January 2011

Structural Engineer, Gibbs Technology Inc., Auburn Hills, MI

Performed modeling and FEA of amphibian vehicles;

Performed FEA to resolve design issues and propose design fixes;

Promoted reliable and accurate FE modeling and meshing methodologies and techniques to improve efficiency and accuracy;

August 2010 – October 2010

Stress/FEA Engineer, AAR Cargo Systems, Livonia, MI

Completed fully non-linear modeling and FEA, using Abaqus, of complex cargo loading/unloading, restraint and securement systems for civilian/military aircraft applications;

Performed optimization studies;

Based on FEA findings, provided design guidance to designers, and provided loading inputs to other stress engineers for FAA certification analysis;

Promoted efficient, reliable, and accurate FE modeling and meshing methodologies and techniques, improving efficiency and accuracy;

November 2009 – August 2010

Research Engineer (Contract), GM Research & Development, Warren, MI

Performed research and development in the characterization of the anisotropic behavior of fiber-filled plastics, composites and visco-elastic materials, and the finite element analysis of such materials in vehicle component applications;

Performed testing for material property characterization, and develop material models for numerical simulation;

Simulated injection molding using MoldFlow, and generate the respective anisotropic material models using Digimat for use in the structural FEA of vehicle components using Abaqus;

Completed metal forming studies to establish suitable physical forming procedures;

Promoted efficient, reliable, and accurate FE modeling and meshing methodologies, and techniques, improving efficiency and accuracy by 20% on average;

April 2000 – September 2009

CAE Supervisor, Dura Automotive Systems, Inc., Rochester Hills, MI

Worked as “hands-on working” supervisor in the FEA department at Dura’s headquarters to provide design guidance via FEA to all U.S. product groups of Dura; single-handedly turned the previous 6-member FEA department into a much smaller high-productivity, high-quality unit with a maximum staff complement of 3 members including myself;

Supervised and mentored at various times up to 3 mid- to senior level FEA analysts (most of whom held PH.D. degrees and had 5 years min. prior FEA experience), providing technical direction, assistance and guidance as needed;

2 direct reports who left for greener pastures specifically acknowledged my mentoring as having been instrumental in bringing their FEA capabilities and efficiency to a much higher level than before they came on board;

Developed non-linear 3D FEA models of complex mechanical/structural assemblies including hand and foot parking brakes, tire carriers, window regulators, lift-gates, door systems, window systems, window seals, adjustable and fixed brake pedals, shifters, cable systems, hood hinges, jacks, jack stowage systems, hood latches, seat recliners, seat tracks, etc. using Hypermesh, and performed the appropriate FEA using Abaqus/Standard as per customers’ test and durability (fatigue) requirements;

Developed an accurate 3D cable modeling methodology that is simple and yet functionally and structurally correct;

Developed great insights into proper 3D modeling of gear systems, which are essential elements in many of the above-listed products;

Performed crashworthiness simulations of seat track systems (with dummy occupant), for FMVSS 207/210 compliance, and of hood latches, and lift-gates; full vehicle crashworthiness simulations of tire carrier assemblies; and dynamic impact analysis of park brakes and pedals, using LS-Dyna and Abaqus/Explicit;

Performed crashworthiness study of pedestrian-safe hood hinges (Ford) using LS-Dyna;

Performed vibration analysis (frequency response, modal) to prevent/resolve NVH issues;

Performed forming, & snap-through FEA (using Abaqus/Explicit), and thermal analysis of a number of products;

Performed a comparative study of Abaqus/Explicit vs. LS-Dyna;

Collaborated closely with Dura’s product engineers, providing design inputs and eliminating numerous unwarranted or deficient design iterations even before start of FEA work;

Eliminated prototyping in virtually all product groups until the final FEA-certified design iteration as of 2003;

No part failure during design verification or in the field was reported during my tenure;

Assisted product engineers in writing test procedures, in design verification & prototype release (DVPR), and in root cause failure analysis;

Wrote detailed step-by-step FEA work instructions/standards for several products;

Developed Strength of Materials and Structural Principles workshop for Dura engineers;

Communicated closely with customers at all times to ensure their needs are met, and provide concise and easy-to-read written reports on all FEA findings, including design improvement suggestions as appropriate;

Consistently exceeded my normal call of duty to meet the company’s heavy workload, performing the lion share of the prevalent work while also providing supervision to my direct reports, and handling various administrative and systems functions;

Consistently received commendations from internal and external customers, and from my supervisors for my superb ability to identify problem areas, for the excellent correlation of my FEA work to test results, and for my performance excellence and dedication;

Sept. 1999 – March 2000

CAE Analyst, Dura Automotive Systems, Inc., Rochester Hills, MI

Developed non-linear 3-D FEA models of parking brakes, shifters, window regulators, window systems, recliners, etc. using Hypermesh, and performed the appropriate FEA using Abaqus/Standard;

Performed crashworthiness simulations of seat tracks (with dummy occupant) for FMVSS 207/210 compliance using LS-Dyna;

Communicated closely with, and provided concise written reports to customers on all FEA findings, including design improvement suggestions as appropriate;

Aug. 1997 – Aug. 1999

CAE Analyst, Excel Industries, Elkart, Indiana

Completed an FEA-test correlation study using Abaqus/Standard on a strain-gauged GMX800 seat track system; also performed a comparative study of Abaqus vs. ANSYS using the same seat track;

Developed detailed non-linear 3-D FEA models of window regulators, window systems, and recliners, using I-DEAS, and performed the FEA using Abaqus/Standard;

Developed detailed non-linear 3-D FEA models of seat track systems for FMVSS 207 and 210 compliance using I-DEAS, and performed the FEA using Abaqus/Standard;

Communicated closely with, and provided concise written reports to customers on all FEA findings, including design improvement suggestions;

Nov. 1983 – July 1997

Project Research Engineer, Ministry of Transportation of Ontario, Ontario, Canada

- Developed non-linear transient multi-body dynamics computer models for several rail vehicle designs and generalized models for a rail vehicle of an arbitrary configuration, using FORTRAN, and conducted the structural and dynamic assessment of several large-scale rail and bus transit projects using these models and commercial FEA codes (ANSYS, NASTRAN);

- Conducted dynamic and structural analysis (ANSYS, NASTRAN) and testing of rail vehicles, and of track substructures for major transit properties and for the private sector;

- Conducted structural analysis (ANSYS, NASTRAN) and testing of heavy truck equipment, in support of a North America-wide initiative to devise a cargo securement standard;

- Acted as consultant to a top U.S. consulting firm (Booz Allen Hamilton) in two light rail transit projects (Los Angeles, CA, and Pittsburgh, PA), successfully resolving critical vehicle performance problems using custom-developed computer models;

- Completed development and testing of a prototype HP Unix-based automated wheel defect detection system for the Toronto Transit Commission (software written in C);

- Developed and tested a prototype machine vision system for the measurement of rail wear;

- Organized and chaired a global machine vision conference attended by managers and professionals from over 20 major rail companies and organizations;

- Published a number of papers at major world-renowned rail dynamics conferences;

Nov. 1981 - Sept. 1983

Support Engineer, University Computing Company, Don Mills, Ontario, Canada

- Performed piping analysis, pressure vessel analysis, and finite element analysis (specifically of the Pickering nuclear reactor structures in Ontario, Canada) using ANSYS, NASTRAN;

June 1980 - Aug. 1981

Earthquake Engineer, McMaster University, Hamilton, Ontario, Canada

- Performed seismic testing and analysis (static and dynamic – modal, response spectrum, PSD) using SAP IV and proprietary codes, of nuclear reactor sub-systems;

- Developed signal processing applications for floor motion characterization

EDUCATION

B. Eng., M.Eng Civil Engineering/Structural Engineering, McMaster University, Ontario, Canada (1978, 1980)

M. Eng Thesis: “Lateral Load Analysis of High Rise Buildings”

Contact this candidate