Design Verification Project Manager

Fariborz Forghan, Ph.D.

Expert in Thermal/CFD, Design, Aero/Gasdynamics – Licensed P.E. (MA, CA & WA)

** ****** *****

N. Chelmsford, MA 01863

*******@*******.***; 978-***-****

Accomplishment Summary

Expert in CFD and Gasdynamics, Electronic Cooling System Design, Titan Rocket Engine Propulsion Systems Turbine blade cooling, Thermal Electronic Packaging Research, Analysis, Design, and Development of new products and systems. Thermal Design of Electronic Transducers; prototype (from concept to production and Market), Reviewer for the ASME Journal of Energy Resources Technology. Very Strong analytical skills; interfacing with multidisciplinary teams.

Heat Exchangers, Condensers, Cooling Systems, and Radiation Confinement and Material Selection.

Expertise in Combustion, fluids, Thermodynamics, and cooling systems.

My expertise includes Thermal Cycling (Thermal Fatigue) analysis, Structural (Thermo/are-stress, shock, vibration/Harmonic, and Random), and DVT (design verification tests). Machine Design, Mechanism, (Synthesis/Analysis), and Material Selection. Skilled in related IEC Standards.

Thermal Analysis of ASI/Airbus Zephyr Stratospheric UAS Graphcore, Inc., Electronic enclosure. Aerodynamics load, Heating Patriot, and THAAD missiles (Raytheon and Northrop Grumman). Raytheon Command-and-Control Shelters. ASIC/PCB/Electronic thermal packaging (Avici Systems).

Enclosures Electronic cooling systems Design: Designed Enclosure for instruments to survive Sin-Sweep, Transportation, Shock, Random Vibration, Sin-Sweep, and Drop.

Thermal Analysis of THAAD missiles Thermal (Temperature) Profile of exterior and interior of Missiles and Aircraft (Raytheon, Aerojet, and NASA Ames). Boeing Aircraft Fuel System Piping design. Designed Compact Heat Exchanger for NASP and Space Shuttle; Designed Titan Rocket Engine’s Nozzle Fuel Cooling (Aerojet). 2 years; designed Fluidics/Fluid (Flex-Cell) and Boston Scientific (5 Projects).

Designed blade profile, Aerodynamics/Thermal of turbine blades, thesis sponsored by GE.

Designed for manufacturability (DFM) and Assembly (DFA) and risk mitigation; signed Assembly documentation; Analyzed and improved the design of Gas Turbine Film Cooling (GE).

Documenting Processes and Complying with military and ASME Specifications. Engineering/Project Manager and Leader of multiple projects simultaneously, while functioning as a hands-on technical contributor to Thermal/Structural Analysis and Design.

I am particularly adept at solving engineering challenges of new designs and prototypes, leading a group of Mechanical, Electrical, Software, and Industrial Engineers. Hands-on Engineer: Prepare documents for design (PDR/CDR) and procedure for components, systems testing, and communicating with vendors and suppliers. Expert designer of tests and experiments and data collection/processing. Conduct, execute & and analyze results of tests and experiments (for design verification tests, DVT).

Expert User of Analysis Tools: ANSYS Workbench FEA, Fluent/CFX (high temperature/Supersonic Turbine Blades Film Cooling (groundbreaking work), Flotherm, Thermal Desktop, IcePak and ANSYS Motion; SolidWorks FEA and Flow Simulation.

Expert user of Flotherm, Icepack, MATLAB & Mathcad, and SolidWorks Flow Simulation and Structural Linear/non-linear Simulation.

Experimental and statistical design. Wrote Design Verification and qualification Test procedures. Tested electronic packages to verify analytical predictions and accuracy.

Conducted acceptance tests for Prototype and Production. Wrote proposal. As a Systems Engineer, guided design team on matters related to DFM/DFA, Cost Reduction, and Risk Mitigation.

Performed design verification tests, HALT & HASS Tests for reliability.

Recognized as highly self-motivated, with strong leadership and training skills.

Taught master’s degree courses at Northeastern University (NU), Design of Solar and Wind Turbine Smart Micro Grid. Taught senior-level courses at NU: Thermodynamics, Heat Transfer, Gas Dynamics, and Fluid, Mechanics, Static/Dynamics, Mechanics of Material, and Machine Design. Composite Material, FEA, Vibration, Hybrid Vehicle design, and Fuel Cells.

Experience

Advance Consulting Engineering, Chelmsford, MA 1/2023 – Present

Consultant

Providing Innovative Research, Thermal Analysis, Development, and Design of new product Cooling systems for major domestic and international companies: Altran, Keurig, ASML, Boston Scientific, Olympus, and UPF.

LEIDOS, Tewksbury, MA 4/2021 5/2023

Senior Lead Principal Mechanical Engineer

Thermal Analysis/testing of Rotating X-ray Tanks.

Designed ClearScan and MSX system cooling.

Designed Electronic Enclosure Cooling Systems.

Tested ClearScan cooling system; DVT test accuracy was within 5%.

Tested/Measured Sound level vibration (NVH testing) and mapped the system temperature of ClearScan.

Wrote Spec for installation of ClearScan and MV3D machines for customer.

Documenting and presenting Test Procedure. Bearing life calculation using ANSYS Motion.

Supporting Sales (Providing installation Spec for Rotating and stationary Machines). Mentoring junior engineers.

Teradyne, Inc., North Reading, MA 2/2020 – 3/2021

Consultant

Designed Cold plate for high heat dissipating boards (liquid cooling).

Calculating liquid flow and pressure inside the Piping System.

Steady-state and Transient Heat Transfer (Conduction, Convection, and Radiation) analysis of the system (high current impulse).

Analyzed and Designed Cooling Systems for electronic enclosures using Heat Pipes.

Analyzed and Designed wafer testing (static clamping) Probe Structural/Thermal Expansion and Thermo-stresses.

Design Verification Testing of 5G and RF electronic enclosures.

Designed experiments and tested the cooling system, and design verification tests (DVT).

Doble Engineering, Watertown, MA 12/2012 -1/ 2019

Mechanical Engineering Manager

Led a Team of 8 Mechanical and Electrical Engineers, to design New Products (high voltage components), sustain and update existing products. Developed three new products.

Hands-on Engineer, Headed Research and Development as individual contributor, Thermal/Structural Analysis and Design. Performed Testing of components.

Performed Computational Fluid Dynamics (CFD) to develop new products Thermal Design.

Tested new product and provided Documentation of test result.

Outsourced manufacturing of prototype and production units and communicating with vendors.

In charge of Manufacturability, Reliability, and Cost Effectiveness, and Material selection.

High Voltage Electronic Enclosure cooling design and EMI Compliance and safety testing.

Analyzed and Designed Two different DGA (dissolved gas analyzer), monitoring industrial and network transformers of power companies.

Prepare detailed design and procedure for components, and testing, interfacing, participating, and communicating with Project Managers & Vendors. Performed Acceptance Tests.

Conduct, execute & analyze results of tests and experiments for DVT. Participated in PDR (preliminary design review) & CDR (critical design reviews). Create metrics for project schedule, performance and milestones.

Provided performance reviews for Mechanical Engineering team and set schedules and budget for research.

Raytheon Integrated Defense and Marine Systems, Sudbury, MA 3/2007 – 11/2012

Lead Principal Thermal/Structural Engineer (with Secret Clearance)

Thermal/Fluid analysis, with ANSYS CFX and Flotherm, to find technical solutions to complex designs.

Led Engineering teams in multiple projects. I am known as Raytheon product design guru.

Analyzed Structural Mechanism of the relay, avoided recall of $200 million (PowerPoint presentation is available).

Modified Parts of Patriot rocket due to aerodynamic stresses.

Researched and analyzed the design of Electronic Systems packaging, MEMS relay; analyzed, and designed, and tested enclosure to withstand spec shock and vibration, and Thermal Cycling. Designed HVAC of Command-and-Control Shelters. Analyzed, designed & tested enclosure to withstand thermal, shock & vibration. Troubleshoot, manufactured new products, and designed; and developed products for Reliability.

Designed Cascade Vapor Compression Refrigeration to cool very high heat-dissipating electronics of large stationary radars & avionics. Designed Piping (welding and mounting).

Providing PowerPoint reviews of gates and designs, while meeting deadlines.

Analyzed (FEA) and designed truck mount large reconnaissance radar antenna.

Analyzed the cause of production line defect increased to 35% by data and design investigation and thermos-stress FEA; found the root cause, reduced the defect to 3%.

Providing Project Schedules: Create metrics, detail performance, and milestones, Reporting to Value Engineering (both internal and external customers). Met all deadlines.

Interpreting Mil-Specs and providing details for DVT.

Northrop Grumman Electronic Systems, Canton, MA 3/2002 – 2/2007

Principal Mechanical Engineer

Performed Thermal Analysis with ANSYS. and Icepack; analyzed and designed Fiber Optic Gyros (FOG) and MEMS, based on Flight Profile; considered shock and vibration affecting the accuracy FOG.

Tested FOG performance; awarded certifications.

Electronic Packages & cooling scheme of new products, and DFM/DFA, Analyzed components structural integrity due to Shock (pyro-shock) and Vibration (random vibration), sin-sweep, Thermal cycling, and Risk Mitigation.

Performed Thermal analysis due to flight profile for survivability of new products.

Directed outsourced development, offsite manufacturing, offsite & customer testing. Created detailed documentation. Documented design process with customers and offsite vendors. Presented design & analysis for PDR, and CDR, and provided test results and analytical prediction of the product performance.

Analyzed Thermal, and Designed Inertial Measuring units, and avionic packages for THAAD, ATFLIR, and Exothermic Kill Vehicle (EKV); functioned as a hands-on test engineer for critical projects and supported testing of the prototype.

Avici Systems, Inc., N. Billerica, MA 1/1999 2/2002

Principal Mechanical Engineer/Project Engineer, Consultant

Analyzed Thermal systems and designed new Tera-bites Switch Router and SSR cabinet Cooling System and ASIC Packaging structural Cooling.

Analyzed Thermal and Designed 11 boards and line-cards module packages and cooling scheme; considering EMC, (Designed custom-made heat sinks).

Designed Avici’s TSR frame and modules that sustained and passed complete NEBS/IEEE thermal, structural, fire, EMI (using Flo/EMC), drop, vibration and zone 4 earthquake tests using ANSYS.

Designed electronic boards (PCB) cooling and packaging.

Verified all designs and performances by functional, thermal and structural (DVT) testing.

Education

Ph.D. in Mechanical & Manufacturing Eng’g. (GPA: 4.0) Northeastern University

Thesis: High-Temperature Gas Turbine Blade Film Cooling With Shaped Holes

Founded theory of gas behavior in the shaped cooling holes

Sub-major in Dynamics, FEA, Control Systems & Combustion

Professional Engineering Degree in Mechanical Engineering Columbia University

Designed Innovative Nuclear Power Plant Core Thermal System

Sub-major in Mechanism Synthesis, Analysis and Design

M.S. Aeronautical & Astronautical Engineering U. of Washington, Seattle

High Power Gas Lasers Cooling - Designed and Built High Power Gas Laser

BS & MS in Mechanical Engineering (emphasis on Heat Transfer) University of Tehran

Affiliations: Kappa Phi Kappa honor society. ASME, AIAA & SAE.

Publications

Forghan, F., Askari, O., Narusawa, U., and Metghalchi, H., “Cooling of Turbine Blades with Expanded Exit Holes: Computational Analyses of Leading Edge and Pressure Side,” Journal of Energy Resources Technology, Vol. 139 / 052001-1, September 2017.

Forghan, F., Askari, O., Narusawa, U., and Metghalchi, H.,

“Cooling of Turbine Blade Surface with Expanded Exit Holes: Computational Suction-side Analysis,” Journal of Energy Resources Technology, Vol. 138/051602-1, September 2016.

Forghan, F., Askari, O., Narusawa, U., and Metghalchi, H., “Cooling of Turbine Blade Surface with Extended Exit Holes: Parametric Study”, ASME 2014 International Mechanical Engineering Congress & Exposition, November 14-20, 2014, Montreal, Canada.

Forghan, F., Askari, O., Narusawa, U., and Metghalchi, H., “Film Cooling of Turbine Blade Surface with Extended Exit Holes”, Proceedings of the ASME 2014 8th International Conference on Energy Sustainability & 12th Fuel Cell Science, Engineering and Technology Conference ESFuelCell2014, June 29-July2, 2014, Boston, Massachusetts”.

Forghan, F., Narusawa, U., Metghalchi, M., “Discharge Coefficient of Expanded Exit Holes for Film Cooling of Turbine Blades,” AIAA Journal of Propulsion and Power, Vol. 26, No. 6, PP. 1322-1325, November-December 2010.

Forghan, F., “Design of High Conductive Printed Circuit Boards,” Mechanical Systems Technology Network (MSTN) conference, Tucson, AZ, October 20-23, 2009.

Forghan, F., “Eliminating Electro-Mechanical Relay Operational Anomaly”, Mechanical and Material Technology Network (MMTN) conference, Dallas, TX, September 16-18, 2008.

Forghan, F.; Kowalski, G., Metghalchi, M., “Thermal Simulation Benchmark of Graphic Module under Installed Operating Conditions,” ASME InterPack 2005, SF, CA, July 17-22.

Forghan, F.; Metghalchi M., “Experimental and Theoretical Investigation of Special Heat Sinks Performance,” ISME Conference, June 2, 2001.

Forghan, F., "Aerodynamic Measurements in a Turbine Blade Cascade with Continuous Transonic Flow," Conference on Energy, Electrical Power systems, City University, NY, NY, Sept. 8, 1996.

Forghan, F., 1995, "Discharge Coefficient of Diffusion Holes", AIAA Paper No.95-3622.

Contact this candidate