Sagar Bocheer K J

*** ******* **, # *** *******, MI 48202 Cell #: +1-313-***-****

aczlac@r.postjobfree.com LinkedIn: www.linkedin.com/in/sagarbocheer

Objective

A performance driven Mechanical Engineer who expertise in Product development and improving the existing design and believes in engineering solutions. Working towards a strong foundation for a long-term career path in automotive industry. Looking for full time position in Product design, FEA and Reliability.

SUMMARY

Mechanical engineer with 4 years of work experience in the field of Product design, CAE, durability and strength simulation along with and Reliability analysis.

Masters in Mechanical Engineering from Wayne State University specializing in Solid mechanics.

Hands on experience in full Vehicle simulation using ANSA, LS-Dyna and LS-Prepost.

Experience in Product design and Reliability Engineering under design and development for various Automotive and Industrial products.

SOFTWARE SKILLS

Modeling: CATIA V5, SolidWorks

CAE Preprocessing & post processing: ANSA, HyperMesh, LS-Prepost, Inspire

CAE Solvers: Abacus, LS-Dyna

Reliability package: Reliasoft’s Weibull++, ALTA, CAFTA

Other: PLM - Enovia, MS Excel and MS Office suite

PROFESSIONAL SKILLS

In CAD, Creation of drawings for Plastic, Casted, Machined and Sheet Metal Parts as per ASME Y14.5M-1994 & delivery of files as per client specification using CATIA, SolidWorks.

Incorporation of Engineering Changes and creation of BOM along with Performing complete ECO analysis and ECO release using Enovia- Release / Configuration Management.

Expert in creating detailed mechanical drawings for assemblies from Catia V5. And sound knowledge on GD&T

CAE SKILLS: Professional in structural static/dynamic simulation for both implicit and explicit with CAE software’s and with an experience in mesh generation and quality checks using ANSA, Hypermesh and projects handled on car crash like head on, side, rear and roof impact using LS-Dyna and LS-Prepost as per FMVSS standards.

Reliability analysis: FMEA, PFMEA, DFMEA, FTA, FHA, MTBF Estimation, NPRD and NSWC Approach to analyze and report for aerospace, automotive and industrial products.

PROFESSIONAL EXPERIENCE

HCL Technologies LTD- an Engineering R&D service sector Sept 2011 – July 2015

Designation: Design Engineer

Involved in Reverse Engineering and Benchmarking Project for seatbelt and Airbags – Takata

Tools: Solidworks, MS-excel, Geo- magic

Involved in the tear down of the seat belts and airbags, preparing a functionality list of all the individual parts.

3D scanning of the individual parts using the faro arm, extracting the 3D scanned Cad model using geo-magic and creation of new 3D models in solid works.

Involved in Conceptualization/design of Bioreactors for GE Healthcare

Tools: CATIA, windchill, Geo- magic, MS-Excel

Conceptualized & designed Sheet metal parts related to various unit assemblies in CATIA V5.

Designed the structure and sheet metal brackets in the device and creation of fabrication drawings for the newly created parts.

Frequent interaction with the vendor and getting the proof of concept done.

Coordinated with cross functional team like sourcing, manufacturing and supplier to make many prototypes for verification.

Carried out verification activity for developed prototypes and created documentation for same.

In CAE, BIW and Plastic automotive components and their connections using ANSA, Guidelines, Quality Checks, material, Removal of Penetrations etc. Some of the components in BIW and plastic components like Cross-car Beam assembly, Pillar assembly, Instrument Panel, Hood, Door Trims, Pillar trims (A-pillar, B-pillar)- Ford

To follow FMVSS standard to setup the car model for different test setup like frontal, rollover and to run LS-dyna for these setups.

To use LS-Prepost to capture the results that are required to validate the FMVSS set standards.

Structural analysis of the Xerox-Brilliance B12 machine (printer) for Drop test and abuse load using Hypermesh, Abacus – Xerox

Structural analysis of LH work shelf and its bracket which is designed to withstand 12.5kgs - Xerox

Safety bracket structural analysis for a load of 65kgs using Hypermesh and Abaqus – Xerox

BTR back plate strength analysis using Hypermesh and Abaqus.

In Reliability, worked on several reliability programs and involved in tasks like PFMEA, DFMEA, FTA, FHA, Different Safety analysis, MTBF Estimation, Life Data Analysis, Test Protocols Preparation, Test Report preparation – Parker, Bergstorm, Diebold

Executed DFMEA and FFMEA for complete ATM machines, coin vending machines and identified the potential failure cause along with possible prevention techniques for those failures.

Trainings Undergone

Trained and certified on Fundamentals of GD&T and its application, a GEHC Internal training course on ASME Y14.5M Standard.

Trained on Reverse engineering of automobile components like seat belts and airbags.

Project Handled at Wayne State University, Graduate Studies Winter Jan 2016- May 2016

Analysis of Automotive Body Structure (Pillar trims)- Project involves in adding reasonable amount of spot weld to the B-Pillar to increase stiffness. FEA of B-Pillar using Hypermesh and Optistruct and finding the lateral deflection due to pressure load of 5Mpa on elements. Then validate the results with hand calculations considering deflection at midspan with load of 3KN.

Vehicle crash simulation in LS-Dyna and LS-Prepost,

Frontal Crash: To determine overall vehicle deformations, crash pulse, barrier force, structural deformation force and analyzed the available crush space and intrusion into occupant space.

Similarly, have setup the model for roof crash, car to car impact, car to pole, van to a deformable barrier, sled tests, effects of using composite materials during frontal crashes etc. carried out acc. to FMVSS standards like FMVSS 208, 213, 214, 201, 216.

The results like Sil drop deformation, Crash Pulse, Dash board intrusion, dummy severity is examined.

To Topology Optimization of the vehicle brake pedal to reduce mass/volume by performing topology optimization in Hypermesh and Inspire.

Apply Abaqus/Standard to simulate full range motion of the six-slot Geneva gear. Assess the implication due to geometry misalignment (due to manufacturing/assembling error, wear, etc.) and to summarize the assessment of simulation quality. Make recommendation on how to further improve the quality.

Technical Paper Presented:

Seminar titled “Advance materials and Self-healing polymers” presented as a part of final year Undergrad curriculum. April 2011

First price in Technical paper “Fly by Wire” presented in as technical paper discussions. Feb 2011

EDUCATION

Master of Science: Mechanical Engineering GPA: 3.5

Solid mechanics, Product Design & Optimization May 2017

Wayne State University. Detroit, MI, USA.

Bachelor of Engineering in Mechanical Engineering GPA: 3.7

PESCE, Mandya, KA, India. Graduated May 2011

KEY ACCOMPLISHMENTS

LiveWire and Spot awards- For quick and effective learning in Reliability tasks along with CAE analysis in HCL Technologies. 2013 and 2014

PROFESSIONAL BODY MEMBERSHIP

Active Volunteer for the TiEcon Detroit Chapter, Entrepreneurship and technology conference.

Formula one SAE student’s chapter at Wayne State University, Active member.

ASME student’s chapter, Wayne State University, Active member.

Contact this candidate