Design Engineer Power Plant

RAJKUMAR, B.Tech (Mech),

Design Engineer

Phone: +91-948*******, +91-994******* Email ID: ***********@*****.***

Experience Summary:

Overall 4.5+ years of experience in the Mechanical Design, Manufacturing and Testing of Various Electromechanical and Aero-structure components in Aerospace and Defence systems.

Experienced in Build to Specification products, which includes, conceptual design and detailed design of the aircraft equipment.

Extensive Knowledge in CAD tools like CATIA V5, Solid works, AutoCAD and drafting per ASME Y14.5 practices.

Generating Design, Assembly and Manufacturing documentation and processes (BOM management, assembly procedures and drawings)

Gained extensive knowledge in the field of Product Definition as per ASME Y14.5M and GD&T Geometrical Dimensioning and Tolerances.

Hands-on experience in the Design and Development of Power Distribution LRUs for various aircraft programs like Airbus A320/321 Passenger-to-Freighter (P2F), Boeing 737 Max and Boeing 777.

Hands on experience in production line to resolve manufacturing and quality problems related methods, processes, tooling, equipment and product design.

Authoring various Testing documents (Qualification Plan, Procedures, Reports)

Real-time work experience in all DO-160 Environmental Testing for Developmental as well as Qualification testing.

Experienced in material selection, Hardware selection, DFM, DFA. Adept knowledge in manufacturing processes.

Experienced in the Wire harness development from the circuit schematic.

Gained substantial knowledge in thermal management for the LRUs, worked in thermal analysis for Circuit boards.

Good understanding of CNC Machine manufacturing and assembly methodologies.

Strong communication, interpersonal & presentation skills, working with international customers have given me diverse culture awareness. Ability to work effectively in team environment and as an individual contributor.

SKILLS:

CAD Tools CATIA V5, Solid works, AutoCAD and Pro-E

CAE Tools ANSYS Workbench

Other Tools MS Office (Word, Excel and PowerPoint)

Hardware CNC Machine operation and programming, NDT (Level 2), Manufacturing.

Employment Details:

Company 1 : CYIENT Limited, Bangalore, Karnataka (Present Employer)

oDesignation : Design Engineer (DE)

oWorking Period : 1st December 2017 to Present (2.5+ Years)

Company 2 : AVTEC Limited, Hosur, Tamil Nadu

oDesignation : Design Engineer Trainee (DET)

oWorking Period : 17th August 2015 to 20th August 2017 (2 Years)

ACADEMIC PROFILE:

2012 – 15 SASTRA University, Thanjavur, Tamil Nadu, India

B.Tech. Mechanical Engineering

2010 – 12 Bharath Polytechnic College, Nammakal, Tamil Nadu, India

D.M.E. Mechanical Engineering

2008 – 10 R.N.G.H.S.School, Ayyakaranpulam, Tamil Nadu, India

12th Standard, State Board

PEOFESSIONAL EXPERIENCE:

1.Project Title: Boeing 737 - Development of Smart Power Distribution Panel (Smart PDP)

Client: Boeing Aerospace, USA

Role: Design Engineer

Tool Used: CATIA V5 and MS Office

Duration: 1st Oct 2019 to Present (7+ Months)

Responsibilities:

Design of mechanical parts and system-level assemblies for DAL A LRU (SPDP) using CATIA V5.

Provided GD & T stack up analysis for ease of assembly and manufacturing through drawings.

Derived the manufacturing process plan through Design for Manufacturing (DFM) / Design for Assembly (DFA) for reliable product and verified its integration in the LRU.

Inspected/ validated all the design features through FAI process specification requirements.

Performed analysis for an entire LRU to check the structural integrity while it is rack mounted.

Hardware selection, BOM creation, Developing Assembly procedures, performing Weight analysis and quality checks.

2.Project Title: Design and Development Dual USB TYPE A & C for Commercial Aircrafts

Client: NBA Cyient (New Business Accelerator)

Role: Design Engineer

Tool Used: CATIA V5 and MS Office

Duration: 1st Oct 2018 to 30th September 2019 (12 Months)

Responsibilities:

Design and development of USB Type A and Type C under IPDP process.

USB Type C and A devices capable of charging the Laptop and new generation Mobile devices

USB Type C -Output Voltage supports 5V,9V, 15V and 20V DC, 3Amp and Input Voltage is 28V DC, USB Type A –Output Voltage is 5V DC, 2.1 Amp and Input Volt age is 28V DC

Feasibility study for installation of CMD USB to the passenger seats and operated within the cabin of the aircraft.

Case study on product details and specifications.

Preliminary design for USB involving with manufacturer for making prototype model.

Selecting the suitable material for USB enclosure for prototype model.

Part design and drafting of USB components and module building by using assembly.

Competencies in GD&T application in composite tooling and modelling.

3.Project Title: Design and Development HVDC to DC Converter for Commercial Aircrafts.

Client: NBA Cyient. (New Business Accelerator)

Role: Design Engineer

Tool Used: CATIA V5 and MS Office

Duration: 1st Oct 2018 to 30th September 2019 (12 Months)

Responsibilities:

Design and development of HVDC Converter under IPDP process.

Design and manufacture highly reliable, efficient and configurable solid state 540V HVDC to 28V DC or 270V HVDC to 28V DC power supply for commercial aircrafts.

Feasibility study for installation of HVDC Converter to the LRU.

Case study on product details and specifications.

Preliminary design for HVDC Converter involving with manufacturer for making prototype model.

Selecting the suitable material for HVDC Converter enclosure for prototype model.

Part design and drafting of HVDC Converter components and module building by using assembly.

Competencies in GD&T application in composite tooling and modelling.

4.Project Title: Design and Drawing Creation of Boeing 747-8 (2D to 3D conversion)

Client: Boeing Aerospace, USA

Role: Design Engineer

Tool Used: CATIA V5, AutoCAD and MS Office

Duration: 1st October 2017 to 30th April 2018 (7 Months)

Responsibilities:

Study and validation of inputs from the customer required to build the parts and assemblies at the respective aircraft location as per BOEING Standards

Assembling the Structures and performing clash analysis.

Implementation of applicable ADCN's.

Modeling the parts as per the given inputs like PCM & dimensioned drawings.

Creating assemblies and product structure in CATIA V5.

Conversion of V4 model to V5 model by using Catia v5R26.

PCM tracing of aircraft hand drawings with the help of AutoCAD Raster design.

5. Project Title: DQDRFC for BA-7000/8000 (Bombardier Business Jet)

Client: Triumph Vought Aerospace, USA

Role: Design Engineer

Tool Used: CATIA V5, ENOVIA and MS Office

Duration: 1st May 2017 to 31st September 2017 (5 Months)

Responsibilities:

Working for Triumph Aero structures, who is a supplier of wing structures to Bombardier Aerospace. Currently working on Wing Structure for BA Global 7000/8000 Business aircraft.

DQDRFC team will get input which are found to be deficiencies of the released data. Deficiencies can be drawing errors, assembly parts update, BOM errors, methodology errors, 2D-3D mismatch, Hardware mismatch, etc.

Working alongside with ENOVIA PLM to revise or roll Data based on fit, form functionality changes. Creating PLM actions for affected objects and sending it for re-release. All the affected objects are updated to Global Wing node in CATIA.

Part design and drafting of aircraft components and module building by using assembly.

Competencies in GD&T application in composite tooling and modelling

6.Project Title: Design and Manufacturing of Gearbox Assembly (AVTEC, Hosur, Tamil Nadu)

Tool Used: CATIA V5, AutoCAD, CNC Machines (coding) and MS Office

Client: Allison Transmission & Ford Motor Company

Role: Design Engineer Trainee

Duration: August 2015 to August 2017 (2 Years)

Responsibilities:

Car gearbox and Engine components are manufactured and assembled in the Horizontal Machine Center at Hosur plant (Tamil Nadu) and Pithampur plant (Madhya Pradesh).

Creation of 3D components in CATIA V5 w.r.t hand drawings from client.

Created Sheet metal layout drawings.

Checking of models for surface integrity, including no gaps and Assembly Models.

Responsible for Horizontal Machine Center CNC machine programming, supervising and Quality controlling.

Creating assemblies and product structure in CATIA V5.

Conversion of V4 model to V5 model by using Catia v5R26.

TRAINING AND INDUSTRIAL VISITS:

Undergone CATIA V5 training

Undergone NDT, Level 2 training

Attended AutoCAD training on CADD Centre, Nammakal in 2012.

Industrial visit to Integral Coach Factory (ICF), Chennai to study about industrial requirement of railway coach manufacturing sector in 2014.

Industrial visit to Lakshmi Machine Works Limited (LMW), Coimbatore which is India's largest CNC machine tool manufacturers and textile machinery in 2011.

Industrial visit to Mettur Thermal Power Station to understand operation about thermal power plant in 2012.

PERSONAL DETAILS:

Date of Birth : 10th, April, 1993

Father’s Name : Mr. M.S.Senthilkumar

Mother’s Name : Mrs. S.Santhi

Marital Status : Married

Spouse Name : Mrs. Ramya

Address : C,F1 RC Blossoms

Perumbakkam,

Chennai.

Tamil Nadu – 600100.

Languages Known : Tamil and English (speak, write, and read)

Passport No. : N2429143 (Valid upto 27-08-2025)

Place: Bangalore

Date: 25-oct-2020 Rajkumar. S.

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