Mechanical Engineer Project

JAY CHOI, Ph.D.

**** ********* *** ************@*****.***

Philadelphia, PA 19127 248-***-****

SENIOR MECHANICAL ENGINEER (CAE/FEA)

Structural Analysis, Finite Element Analysis, Product Development

Mechanical Engineer with a strong background in the automotive and defense industries. Solid academic backgrounds in composite materials, elasticity, plasticity, fatigue, dynamics, vibration and machine design. Very strong engineering problem solving skills. Held U.S. Government Security Clearance of Confidential and Secret. U.S. Citizen.

AREAS OF EXPERTISE

Structural Analysis

Crash Analysis

Fatigue Analysis

Noise, Vibration & Harshness (NVH)

Material Characterization

Linear and Non-Linear Analysis

Conceptual Designs

Testing

PROFESSIONAL EXPERIENCE

AK Steel Corp. – Research and Innovation, Dearborn, MI

Senior Engineer (2013 – 2020)

Performed structural analysis and design optimization to reduce vehicle weights and utilize AK Steel products in automobiles.

Crash Analysis.

oReduced vehicle weights by design optimization utilizing AK Steel products.

oWorked on full-vehicle and assembly level crash analysis with NHTSA and OEM FEA

models using LS-Dyna and VisualDOC.

Non-Linear Static analysis

oPerformed component and assembly level analysis such as automotive suspension control

arms, wheels, closures and other components to reduce weights and utilize AK Steel products.

oUsed Abaqus.

Linear Static and NVH analysis

oImproved various vehicle stiffness by optimizing BIW and Trim Body FEA models for Ford.

oUsed GENESIS, Nastran and Optistruct.

ZF Group North American Operations, Northville, MI

Sr. CAE Engineer (2012 - 2013)

Performed structural analysis and design optimization of automotive suspension control arm systems.

Performed linear and nonlinear static analysis using Nastran, Optistruct and Abaqus.

Performed fatigue analysis using nCode DesignLife.

US ARMY - Tank Automotive Research Development & Engineering Center, Contract, Warren, MI

FEA Engineer (2007 – 2012)

Performed structural analysis and design optimization of military vehicle components. Also responsible for writing work directives of SimBRS and SBIR projects. Major projects include:

Composite Armors Modeling & Simulation: Developed fatigue and dynamic FEA models and performed correlations of FEA results with test data for various composite armors, using LS-Dyna, Abaqus and GENOA.

Abrams Tank Track Rubber Bushing System Analysis: Developed FEA models to identify rubber bushing damage cause and to recommend solutions for Abrams tank track rubber bushing system, using Abaqus.

Jay Choi, ************@*****.***

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US ARMY - Tank Automotive Research Development & Engineering Center (cont.)

FEA Engineer (cont.)

Humvee Frontal Crash Analysis: Developed Humvee frontal crash analysis model to analyze its results with emphasis of the increase of major internal energies, using LS-Dyna.

Wrote Work Directives of SimBRS and SBIR projects

oMaterial Database and FEA Material Model Development for Polymer Materials; Rubbers, Plastics and Polymer Foams - SimBRS.

oMaterial Model Development for Impact Strength and Durability Validation of a Composite Design; SMC (Sheet Molding Compound) - SimBRS.

oCAE fatigue code developments for composite material and rubber - SBIR

L&L PRODUCTS, INC., Romeo, MI

Material Characterization and FEA Engineer (2002 - 2007)

Developed FEA material cards and new materials to improve performance and reduce costs and weight. Also performed various customer (Ford, GM, Chrysler, Toyota and suppliers) application projects.

Material Characterization

oPerformed various coupon and sub-assembly tests for materials.

oPerformed correlations of FEA results with test data.

oDeveloped LS-Dyna and RADIOSS material cards for polymer foams, nylons, Premix materials, steels, aluminums, aluminum foams and magnesiums.

Black Box Projects

oPerformed sub-assembly tests and FEA simulations for various materials.

oDeveloped new materials to replace existing CBS (composite body solution) parts.

Crash Analysis.

oImproved vehicle performance by reinforcing bodies and frames with foams, plastics and metals.

oWorked on full-vehicle and assembly level crash analysis for GM, Ford, Chrysler, Toyota and other customers using LS-Dyna and RADIOSS.

Linear Static and NVH analysis

oImproved performance and natural frequencies by reinforcing bodies and frames with foams, plastics and metals.

oUsed Nastran and Optistruct.

FAURECIA AUTOMOTIVE SEATING, Troy, MI

Project Engineer – FEA (Jan. 2001 - Nov. 2001)

Performed structural analysis of automotive seating components.

Performed nonlinear structural analysis using ABAQUS (contact and non-contact structures) and HyperMesh.

oInvestigated onset loads of plastic yield and rupture loads.

oInvestigated yield and rupture failure modes.

oOptimized geometries and materials for better strengths and stiffnesses and lower costs.

Performed pull test analysis of seating systems, using RADIOSS & HyperMesh.

oInvestigated component failures and structural stiffnesses due to FMVSS loadings.

oOptimized geometries and materials. Improved strength and stiffness. Lowered costs.

Performed fastener design research: Wrote reports on guides to fastener design.

Jay Choi, ************@*****.*** Page 3 of 4

GENERAL MOTORS CORP., Contract, Pontiac, MI

Project Engineer – Quality Engineering (Jan. 1999 - Nov. 2000)

Performed structural analysis and design optimization of automotive chassis and body. Major projects include:

Nonlinear thermal contact analysis of radiator hose and fitting: Optimized geometry of radiator fitting to prevent radiator hose separating from fitting, using ABAQUS.

Endgate hinge analysis: Optimized geometry of endgate hinges to improve endgate rigidity, using Optistruct and NASTRAN.

Endgate regulator analysis: Optimized geometry and material property of regulator glass clamp to reduce deflection of endgate glass, using Optistruct and NASTRAN.

Air cleaner clip optimal design: Designed and optimized geometry and material property of air cleaner clip to replace current bolting system, using ProMechanica.

NVH analysis of door mirror assembly: Optimized design of side door mirror assembly linkage of a medium duty truck to increase natural frequency and decrease amplitude of door mirror, using ProMechanica.

EDUCATION

Ph.D., Mechanical Engineering

University of Minnesota, Minneapolis, MN

Research: Fracture analysis of woven fabric composites, using FEA and

continuum damage mechanics

ADDITIONAL INFORMATION

Held U.S. Government Security Clearance of Confidential and Secret

Fluent in English and Korean

U.S. Citizen

Jay Choi, ************@*****.***

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TECHNICAL ADDENDUM

PRODUCTS

Bodies

Chassis components

Frames

Composite Armors

Steering components

MATERIALS

Composite Materials

Polymer Foams

Plastics & Nylons

Rubber

SMC

Ceramics

Aluminum Foam

Aluminum

Magnesium

Steel

COMPUTER AIDED ENGINEERING (CAE) tools:

LS-Dyna

ABAQUS

NASTRAN

Optistruct

RADIOSS

GENESIS

ANSYS

HyperMesh

HyperView

M-Crash

VisualDOC

nCode DesignLife

GENOA

ProMechanica

MiniTab & Design of Experiment

ProEngineer

Unix

MatLab

Mathematica

Fortran

PUBLICATIONS

Woven fabric composites - developments in engineering bounds, homogenization and applications

International Journal for Numerical Methods in Engineering

Volume 50, Issue 10, Date: 10 April 2001, Pages: 2285-2298

A computational approach for multi-scale analysis of heterogeneous elasto-plastic media subjected to short duration loads

International Journal for Numerical Methods in Engineering

Volume 50, Issue 10, Date: 10 April 2001, Pages: 2299-2315

Woven fabric composites. I - Predictions of homogenized elastic properties and micromechanical damage analysis

Jaehyon Choi and Kumar K. Tamma (Minnesota, Univ., Minneapolis)

AIAA-1999-1414

AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference and Exhibit, 40th, St. Louis, MO, Apr. 12-15, 1999, Collection of Technical Papers. Vol. 3 (A99-24601 05-39)

Woven fabric composites. II - Characterization of macro-crack initiation loads for global damage analysis

Jaehyon Choi and Kumar K. Tamma (Minnesota, Univ., Minneapolis)

AIAA-1999-1445

AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference and Exhibit, 40th, St. Louis, MO, Apr. 12-15, 1999, Collection of Technical Papers. Vol. 3 (A99-24601 05-39)

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