Product Development Cae Engineer

RAJKUMAR MANI (he/him)

Stress Engineer / Mechanical FEA Engineer / CAE Engineer

+44-790******* https://www.linkedin.com/in/rajkumar-manie/ ********.*****@*****.*** London, England, United Kingdom PERSONAL STATEMENT

• A specialist in mechanical structural engineering and having 12 years of experience in mechanical FEA engineer in automotive product design (engine powertrain) components and systems from concept through to production.

• Performing FEA simulations to assess the durability of the engine components and investigate NVH behavior of engine systems and having very good knowledge in product development of engine components in automotive industry.

• Evaluating structural strength by performing FEM calculations in the fields of thermo-mechanical fatigue analysis and making detailed FEA reports, technical proposals and presenting it to stakeholders. Experience in correlating physical test results with simulated predictions.

• Expertise in the complete product development (such as design, prototyping, testing, manufacturing, and deployment) within the context of a corporate development process.

EDUCATION

ME, St. Peter's University, Chennai, India May 2013 - April 2015 CAD-CAM Engineering, CGPA – 7.9

BE, Anna University, Chennai, India May 2008 - April 2011 Aeronautical Engineering, CGPA – 6.9

DipEng, Gov’t Polytechnic College, Chennai, India May 2005 - April 2008 Mechatronics Engineering, CGPA – 8.5

CAREER HISTORY

MAHLE Engine Components, Chennai, India Sept 2014 – Feb 2025 Automotive manufacturer

Mechanical FEA Simulation

• Leading a design and simulation activities from concept through testing to finished product, considering 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.

• Performing FEA calculations for engine components to assess its structural integrity of the strength in the field of temperature analysis, nonlinear static analysis, and (thermo-mechanical fatigue) durability 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 performing design optimization.

• Expert in dealing with design, CAE and technical presentations reviews, interpret the results and present the same to customer and responsible for ensuring 100% quality and on-time delivery and performing correlation FE analysis for test requirements, test validation, and investigation cases.

• I actively participate in test lab experiments, performing correlation finite element (FE) analysis by utilizing engine tested results, validating tests, and investigating tested parts. Additionally, I address NVH related issues and strive to identify analysis solutions, recommend improvements, and suggest alternative methods.

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

• Involving in full lifecycle product development such as design, develop, test prototypes, manufacture and implement of engine components and having material exposure in aluminum alloy, cast iron, and steel alloy materials.

• 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.

• 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.

NOVA-GLOBAL Technosoft, Bangalore, India May 2011 - May 2013 Engineering Service

Project Engineer CAE

• Experienced in automotive structures plastic and BIW components in FE modelling and pre-processing activity, and perform the FEA simulation activities including geometry clean-up, meshing, applying boundary conditions, material model and analysis type in Abaqus and HyperWorks software.

• Checked for CAD penetration and all basic checks, creating shell and tetrahedral elements for the BIW and plastics structured components using HYPERMEH for Linear static analysis and finally checking the quality of mesh for error-free FEA calculations. SKILLS, INTERESTS & EXTRACURRICULAR ACTIVITIES

Software Knowledge: CATIA Abaqus, Ansys, Permas, and HyperWorks Microsoft office (Excel, Word, PowerPoint etc.). Technical Skills: Product design, Structural analysis (Temperature, Non-Linear static) and Durability analysis (thermo-mechanical fatigue calculation), and NVH analysis (modal, frequency response and acoustic evaluation). Leading and Mentoring: Provided technical expertise, direction, and guidance to drive innovation and excellence of design and CAE team.

Cross-Functional Collaboration: Work closely with design, testing, and validation teams to integrate durability considerations seamlessly into the product development process.

ONSITE EXPERIENCE

Structural Dynamic and NVH / Acoustic FEA Simulation of Engine Systems and Components Mar – Apr 2018 MAHLE International GmbH - Stuttgart, Germany

Structural Static and Fatigue / Durability FEA Simulation of Engine Components May – Aug 2015 MAHLE Automotive Technology - Shanghai, China

RESEARCH & CONFERENCE EXPERIENCE

ICoRD 2017 Conference 9-11 Jan 2017

Advanced piston technologies for gasoline and diesel engine applications to meet EU6 emission norms

(Published in Springer Journal)

FMFP 46th National Conference 9-11 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 2020

Advanced methods to handle LSPI in TGDI engines

(Published in SAE International)

VIT (Vellore Institute of Technology) 21 Mar 2019

Influence of alternate fuels on power cell unit (PCU) engine components

(Guest Lecture)

HONORS & AWARDS

Spot Appreciation, MAHLE Engine Components - Chennai, India 21 Mar 2022 Mahindra HCE 3&4 cylinder 6 variants worked continuously including weekends to meet deadline (Heavy duty engine). Spot Appreciation, MAHLE Engine Components - Chennai, India 26 Aug 2020 Excellent output of FEA simulation for TopCast elevated salt core and low-weight piston capability development. Spot Appreciation, MAHLE Engine Components - Chennai, India 24 Sep 2018 Optimum light weight design of piston and pin for TGDI BS6 gasoline engine application (high speed/passenger car engine). REFERENCES

Available based upon request.

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