Mechanical Power

BALAJI M.S.

A-Block, G*, Vandalur Park Residency, Urapakkam,

Chennai – 603210, Tamilnadu, INDIA.

Mobile: +91-989******* - ****************@*****.*** EXPERIENCE SUMMARY

A competent CAE professional with 8 years of experience in durability analysis, Structural strength – static, dynamic and thermal analysis in automotive electric vehicle battery, power electronics components, exhaust systems and clutch assembly components. EXPERTISED CAE TOOLS

SOFTWARE PROCESS AREA OF EXPERTISATION

Hypermesh, Ansa Preprocessing

FE model creation, property and material

assignment, application of boundary condition

and load

Nastran, Abaqus,

Ansys Workbench, n’code

Solver

Preparation of simulation setup and error

debugging

Hyperview, Metapost Post processing Reporting simulation results PROFESSIONAL EXPERIENCE

April 2019 to till date

Company Name : Renault Nissan Technology and Business Center (I) Pvt Ltd. Designation : Assistant Manager

Jan 2012 to March2019

Company Name : Ambigai Consultancy Services (I) Pvt Ltd, Chennai. Designation : CAE Specialist

Onsite Experience : Eberspaecher Exhaust Systems, Gmbh, Germany. 20months of work experience in fatigue life calculation of exhaust assembly and Coordination of technical projects with offshore. Responsibility

Performing vibration fatigue calculation and static assembly tolerance calculation for electric vehicle battery assembly and power electronics components.

Performing FE modeling, modal analysis, frequency response analysis, thermo mechanical analysis and evaluating fatigue life cycle for exhaust system components.

Result evaluation, discussion with designer, project team and Handling Resources. Key Projects Handled in CAE

1. Vibration fatigue calculation for electric vehicle battery assembly

To determine fatigue life repeats of battery assembly using random PSD data.

1G Base excitation frequency response calculation is performed in Nastran solver.

Random PSD data mapped to the structural frequency response and fatigue life repeats calculated using vibration fatigue n’code.

Counter measure calculation performed for the failure location and proposed for further design changes.

Tools used: Ansa, Nastran, n’code, metapost

2. Static Sealing strength calculation for electric vehicle power electronic components

To perform bolt pretension for power electronic housing and cover components and determine sealing strength by applying pressure and thermal load inside the assembly.

The height of the compressed seal, contact opening/pressure between the housing and cover, plastic strain in the assembly are evaluated.

Then the critical locations/parameters are identified and counter measure calculations are performed.

Tools used: Ansa, Abaqus, metapost

3. Frequency response analysis for exhaust system assembly under engine excitation load and safety factor calculation for high cycle fatigue.

The critical resonance modes are found out from engine excitation test data, then correlate the test results with simulation results using MAC matrix and matching the displacement amplitude values by changing the damping parameters.

The correlation is carried out for different engine motor order with full load and engine ideal condition.

Wöhler line is generated to predict the fatigue life of 5million cycle and safety factor is calculated for each assembly components by comparing results from bending moment, frequency response analysis and prepare the complete investigation report. Tools used: Nastran, Hyperworks, Wöhler line (S-N curve) 4. Temperature distribution, Thermo Mechanical Analysis for exhaust system.

Heat transfer steady state or transient for the complete exhaust system is carried out and then the temperature distribution is correlated the with test thermograph.

Pretension load is applied to bolts at mounting location and sequentially temperature from heat transfer analysis is applied for one thermal cycle (Heating, Cooling, Heating).

Low cycle fatigue is calculated using coffin-manson theory by considering equivalent plastic strain as damage parameter.

Tools used: Abaqus, Hyperworks

5. Fatigue life calculation for pressure plate in clutch assembly

To determine the static strength and fatigue strength of pressure plate in clutch assembly under spring force and clutch slave cylinder force.

Understanding the physical constraints, boundary condition in the clutch assembly and reproduce in FE model.

To evaluate the fatigue strength using maximum utilization factor by considering stress gradient and surface roughness in FKM.

Tools used: Ansys Workbench, FKM

ACADEMIC PROFILE

Course Institution Year Of Passing Percentage

B.E.Mechanical

Engineering

K.L.N. College of engineering,

Madurai.

2011 84%

HSC

Sourashtra boy’s higher

secondary school, Madurai.

2007 73.9%

SSLC

Sourashtra boy’s higher

secondary school, Madurai.

2005 79.6%

ACADEMIC ACHIEVEMENTS

University rank holder, Secured 31stRank in Anna University of technology in B.E

(Mechanical) degree program.

PERSONAL INFORMATION

Gender & Marital Status: Male & Married

Age & DOB: 29 years, 25.03.1990

Nationality: Indian

Languages known: Sourashtra, Tamil, English

I hereby declare that the particulars given above are correct and true to the best of my knowledge. Date:

Place: Chennai Balaji M.S.

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