Mechanical Design Engineer

Saurabh Khadke

Milwaukee, WI **********@*****.*** 317-***-**** https://www.linkedin.com/in/khadke-saurabh Professional Experience

Research and Product Development Consultant, CAE-net Inc, Carmel, IN 07/2019 – 02/2020

• Conducted FEA, CFD on ANSYS to verify performance predictions, structural integrity, and failure criteria.

• Identified the problems with existing design and devise methods and approaches to solve problems by applying knowledge of engineering structures and finite element analysis.

• Constructed and verified 3D CAD models on Solidworks as well as detailed manufacturing drawings.

• Support strategic planning and deployment of additional CAE modeling processes to accelerate product development. Research Assistant, Purdue University School of Engineering and Technology, IUPUI 10/2017 – 06/2019

• Performed research and development work of Vertical Axis Wind Turbine (VAWT), 1008V battery pack, 3.2V lithium-ion battery, 210W Solar panels for mobile power grid and wind farm project.

• Constructed 3D CAD models and conducted Computational Fluid Dynamics, Modal analysis, Structural analysis, Random Vibration, Explicit Dynamics to determine the results for Airflow, Stresses and strain, Factor of safety.

• Analyzed performance metrics, assessed quality issues and applied corrective action to improve the performance. Product Design Engineer, RAJA Tools Pvt. Ltd., India 06/2016 – 04/2017

• Designed and developed various specialized combination tools.

• Utilized Solidworks to identified mechanical design requirements and developed solutions combination tools.

• Worked on Sheet metal parts, Laser cutting equipments and CNC machines.

• Lead Design reviews to capture and improve product features, feasibility, analysis results and quality as per tools specifications to meet customer and business needs.

• Coordinated across departments to prepare Standard Operating Procedure (SOPs), Bill of Material (BOMs), production and datasheets for the machine shop. Involved in the preparation of FMEA, DFMEA.

• Significant Participant in root cause investigations to identify and implement improvements and resolutions. Mechanical Engineering Intern, HUSCO Hydraulics Pvt. Ltd., Pune, India 06/2015 – 07/2015

• Completed product design and development tasks to include writing and verifying specifications, maintaining product & process documentation, testing processes, operations, raw materials and validating equipment and processes.

• Performed Quality Analysis on the product ensuring it meets lean manufacturing principles.

• Assembled a variety of hydraulic valves and tested them for proper function, and structural integrity. Lead Powertrain Engineer, BAJA SAEINDIA 03/2013 – 06/2015

• Lead the team in designing and manufacturing of the transmission and powertrain systems.

• Designed a highly efficient CVT-FNR gearbox and achieved a 10% weight reduction from the previous year.

• Contemplated the issues which came during the testing phase and resolved it.

• Gained knowledge about engine tuning and understood the basics of ECU software. Technical Skills

CAD/CAM/CAE SOLIDWORKS SolidEdge PTC CREO ANSYS AutoCAD Unigraphics NX 3D Printing MS EXCEL MS Office Suite GD&T Process Planning and management DFMEA Knowledgeable in Six Sigma, SCM, ERP. Certifications

Certified SolidWorks Professional (CSWP) SolidEdge ST9 Certified Associate I Certified Solidworks Professional Advanced – Sheet Metal (CSWPA-SM) and Weldments (CSWPA-WD) AutoCAD and GD&T Certified DriveWorksXpress Associate & Solo Projects

• Designed a vertical axis wind turbine (VAWT) performing CFD, Random vibration and Explicit Dynamics on Solidworks and ANSYS capable of generating 8KW power with wind speed as low as 6 m/s.

• Designed, analyzed and Optimized SCCA P2 Race car Rear Wing Mechanism. The process requirements were drafted in CAMEO and further validated in Process Simulate. Pioneered and simulated the rear wing mechanism in NX CAD and Amesim. Achieved 9% increase in performance of the car by further optimizing the model in HEEDS.

• Designed a BMW M3 wheel in Solidworks further performed Optimization, determining the effective plastic strain by varying thickness ensuring adequate safety factor by improving the design with required mechanical performance. Education

Indiana University - Purdue University Indianapolis, IN 05/2019 Master of Science in Mechanical Engineering, GPA 3.97/4 University of Mumbai, India 05/2016

Bachelor of Engineering in Mechanical Engineering, GPA 3.2/4

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