RAJKUMAR MANI (He/Him)

Chennai, Tamil Nadu, India https://www.linkedin.com/in/rajkumar-manie/

+91-868******* ad4cza@r.postjobfree.com

PROFESSIONAL SUMMARY

• A structural FEA engineer having 12 years of experience in stress and fatigue analysis in automotive product designs (engine components).

• Perform multibody simulation for NVH and durability analysis, and very good knowledge in FEA theory, solid mechanics, and fatigue theory.

• Expertise in handling various structural analysis tools like Ansys, Abaqus, Permas, and HyperWorks (HyperMesh, Optistruct, Radioss, HyperView).

• Having strong knowledge in 2D & 3D finite element modeling of simple, moderate and complex components (Hexahedral & tetrahedral elements).

• Strong knowledge in thermal and non-linear static stress analysis (geometric, and contact linearity).

• Good knowledge in vibration and transient dynamic stress analysis (wear and friction).

• Expertise in fatigue, and durability (Thermo Mechanical Fatigue) calculations.

• Performing correlation FE analysis with test data/validation results and for test requirements.

• Good knowledge on damage tolerance analysis to estimate fracture life.

• Basic knowledge of CAD tools and design for manufacturing (DFM) techniques.

• Design from first concept, through validation and productization of engine components (ICE powertrain components and systems). EDUCATIONAL QUALIFICATION

Master of Engineering CAD CAM Engineering May 2015 St. Peter’s University - Chennai, India

GPA: 8.0

Bachelor of Engineering Aeronautical Engineering May 2011 Anna University - Chennai, India

GPA: 7.0

Diploma of Engineering Mechatronics Engineering May 2008 Gov’t Polytechnic College - Chennai, India

GPA: 8.5

LANGUAGE

English – Advanced (C1)

Tamil – Advanced (C1)

SKILLS

Design & simulation software’s and tools: CATIA Abaqus, Ansys, Permas, and HyperWorks Microsoft office (Excel, Word, PowerPoint etc.) Technical skills: Product design, Strutural analysis ( Temperature, Non-linear static) and Durability analysis (Thermo-mechanical fatigue calculation ), and NVH analysis (modal, frequency response and acoustic evaluation). Technical leadership: Leading and mentoring the design and CAE team (structural, fatigue, durability and NVH engineering), providing technical expertise, direction, and guidance to drive innovation and excellence. Cross-functional collaboration: Working closely with design, testing, and validation teams to integrate durability considerations seamlessly into the product development process.

Continuous improvement: Staying abreast of industry trends, emerging technologies, and best practices, leading R&D efforts to enhance CAE structural and durability capabilities continually. WORK EXPERIENCE

FEA Simulation Engineer Product Design & Development – Manager Sept 2014 – still MAHLE Engine Components - Chennai, India

• Leading a structural FEA analysis activity from concept through testing to finished product, considering function, cost, compliance to the relevant standards and end of life requirements and liaise with internal and external customers to define requirements and specifications for new products of engine components and systems.

• Playing a lead role in product design & simulation of engine components to meet customer requirements as mentioned in the RFQ document and performing FEM calculations in the fields of thermal, structural statics (nonlinear, contact, and quasi-static), dynamics (modal, vibration, and acoustic) and durability analyses (thermo mechanical fatigue and lifetime calculations).

• Performing FEA calculations for structural integrity of the strength in the field of temperature analysis, nonlinear static analysis, and durability

(thermo mechanical fatigue) analysis and making detailed FEA reports and presenting it to stakeholders.

• Evaluating the FEA results and discussing the conclusions with the designers and make suggestions for the stress and deformation-oriented design and having experience in design optimization and perform multibody simulation for NVH and durability (thermo-mechanical fatigue) analysis.

• Extensive experience in structural optimization, cost and weight reduction, and value analysis & value engineering (VAVE) studies using FEA simulation to save costs in product development and manufacturing.

• Performing correlation FE analysis for test requirements, test validation, and investigation cases for fatigue and NVH related issues and actively participating in test lab experiments and identify analysis solutions, recommend improvements, or suggest alternative methods.

• Expert in dealing with CAE and technical report reviews (design proposal reports, FEA reports, and investigation reports), interpret the results and present the same to customer and responsible for ensuring 100% quality and on-time delivery.

• Managing the projects, monitoring the progress, supervising a team of engineers and participating in team evaluation, and responsible for the execution, deliverable of projects, quality, costs, and project deadline, contributing to the productivity and profitability improvement of an ongoing projects and interacting with internal and external stakeholder to prepare and present the technical proposals and reports. Engineer – CAE Engineering Service May 2011 – May 2013 NOVA-GLOBAL Technosoft - Bangalore, India

• Experienced in automobile structures like plastic and BIW components in FE modeling and pre-processing activity.

• Perform the FEA simulation including geometry cleanup, meshing, applying boundary conditions, assign material and analysis setup in hypermesh.

• Checking for the CAD penetration and all basic checks.

• Creating shell and tetrahedral elements for the BIW and plastics structured components using hypermesh for linear static analysis.

• Checking the quality of mesh for error-free FEA calculations. ONSITE EXPERIENCE

S tructural Dynamic and NVH FEA Simulation Mar – Apr 2018 MAHLE International GmbH - Stuttgart, Germany

• Structural Dynamic and NVH / Acoustic FEA Simulation of Engine Systems and Components S tructural Static and Durability FEA Simulation May – Aug 2015 MAHLE Automotive Technology - Shanghai, China

• Structural Static and Fatigue / Durability FEA Simulation of Engine Components RESEARCH & CONFERENCE EXPERIENCE

ICoRD 2017 Conference 9 Jan – 11 Jan 2017

• Advanced piston technologies for gasoline and diesel engine applications to meet EU6 emission norms (Published in Springer Journal) FMFP 46th National Conference 9 Jan – 11 Jan 2019

• Methodologies to achieve high performance in cast aluminum diesel pistons to meet BS6 and CAFÉ (Published in Springer Journal) SAE INDIA National Web Conference 18 Aug – 18 Aug 2020

• Advanced methods to handle LSPI in TGDI engines (Published in SAE International) VIT (Vellore Institute of Technology) 21 Mar – 21 Mar 2019

• Influence of alternate fuels on power cell unit (PCU) engine components (Guest Lecture) HONORS & AWARDS

MAHLE Spot Appreciation 21 Mar 2022

MAHLE Engine Components - Chennai, India

• Mahindra HCE 3&4 cylinder of 6 variants worked continuously including weekends to meet deadline MAHLE Spot Appreciation 26 Aug 2020

MAHLE Engine Components - Chennai, India

• Excellent output of FEA simulation for TopCast elevated salt core and EVOTEC-RSC piston capability development MAHLE Spot Appreciation 24 Sep 2018

MAHLE Engine Components - Chennai, India

• Optimum light weight design of piston and pin for TGDI BS6 gasoline engine application REFERENCES

• Available based upon request.

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