Electromechanical Engineer - Precision Vacuum & Multiphysics Modeling

Nihal Saji

Mechanical Engineer – R&D Product Development Simulation & Validation

219-***-**** # *****@***.*** ï linkedin.com/in/nihalsaji/ * Hammond, IN PROFESSIONAL SUMMARY

Mechanical engineer with 4+ years of experience in structural analysis, vibration, fatigue, and 3D CAD modeling, along with advanced multiphase CFD and data-driven modeling from graduate research. Experienced in CAE model development and validation for stress, modal, and flow sys- tems. Demonstrated impact through process optimization and predictive modeling, with hands-on experience in test–CAE correlation across R&D and validation teams. PROFESSIONAL EXPERIENCE & PROJECTS

Graduate Research Assistant (Purdue University Northwest CIVS) (Aug 2024–Present)

• Developed multiphase CFD simulations in ANSYS Fluent to analyze thermal-fluid flow behavior in RH degasser systems, improving mixing efficiency by 15%.

• Applied two-phase flow modeling and transport phenomena concepts to study gas–liquid interac- tions relevant to heat and mass transfer processes.

• Developed UDF-basedmodelstosimulateargonbubbleinjectionandcompressibleflowinvacuum tank degasser systems.

• Developed parametric 3D mechanical models from 2D drawings for simulation workflows, en- abling design space exploration and supporting geometry-driven performance improvements.

• Developed empirical regression models based on experimental data to predict inclusion content in steel, integrating the model into CFD simulations to capture phenomena difficult to resolve directly.

• Published results in peer-reviewed journals and presented at technical conferences. Engineer – FEA (Trane Technologies, ETC Bangalore) (Sep 2020–Aug 2024)

• Performed structural, multibody dynamics, vibration, acoustics, and fatigue analyses using AN- SYS Workbench, MSC Adams, HyperWorks, and nCode DesignLife for HVAC assemblies (150+ components), supporting structural validation programs.

• Developed explicit nonlinear impact simulations using LS-DYNA to evaluate flat-drop and corner- drop load cases.

• Developed test plans, supported fixture design, and processed strain and vibration data for test– CAE correlation using Simcenter TestLab.

• Supported mechanical product design and testing through simulation, documentation, and cross- functional engineering collaboration.

• Developed ML-enhanced reduced-order models for a physics-based digital twin of a condenser fan, enabling rapid evaluation of system behavior and supporting predictive monitoring.

• Collaborated with testing teams to acquire sensor data using NI-DAQ systems and developed Python- based data processing workflows.

• Evaluated actuation force requirements for mechanical systems usingMSCAdamsincollaboration with manufacturing teams.

• Automated simulation and test-data post-processing using Python and ANSYS ACT, improving repeatability and reducing manual effort by 25 % and saving $20k annually. Mechanical Coordinator (Robotics Interest Group, NITC) (June 2018–July 2020)

• Developed a pneumatic-controlledmultifunctionalcrutchsystemwithanergonomic,patent-pending concept and a 5-DOF robotic manipulator with an augmented-reality interface. EDUCATION

Purdue University Northwest Hammond, IN

Master of Science in Mechanical Engineering [GPA: 4.0/4.0] (2024–May 2026) Coursework: Advanced FEA, Fatigue & Fracture, Advanced Mechanics of Materials, Combustion, CFD, Computational Mathematics

Awards: Graduate Research Grant Award (2025–2026)

National Institute of Technology Calicut India

Bachelor of Technology in Mechanical Engineering (2016–2020) TECHNICAL SKILL SET

3D CAD Modeling: SOLIDWORKS, PTC Creo, SpaceClaim, DesignModeler, Siemens NX Structural Simulation: ANSYS Mechanical, MSC Adams, Altair HyperWorks, LS-DYNA, Abaqus Vibration Testing/Model Correlation: Simcenter TestLab, Modal Assurance Criterion Fatigue Analysis: nCode DesignLife, FASTRAN, Strain-Life Fatigue, Weld Fatigue, Vibration Fatigue CFD & Thermal Simulation: ANSYS Fluent, COMSOL Multiphysics, thermal-structural coupling Mathematical Modelling: MATLAB, OpenModelica, Reduced Order Model building, Simulink Scripting & Automation: Python, ANSYS ACT, MS Power Automate, C++ Mechatronics: Arduino programming, pneumatics, sensor integration, prototyping Engineering Tools: GD&T (ASME Y14.5), Design Thinking, DVP&R, DFMEA, Root Cause Analy- sis, Project Management

SELECTED PUBLICATIONS

• Numerical Investigation of Gas Flow Rate Optimization for Mixing in RH Degassing (2025)

• Numerical Study of Flow Behavior in an Industrial RH Degasser Using a VOF-DPM Method (2025)

• Optimization of Accelerometer Locations for Experimental Modal Analysis (2023)

• Finite Element Analysis of Strength of Non-Permanent Joints Under Eccentric Loading (2020) LEADERSHIP & AFFILIATIONS

• MaterialAdvantageClubPresident (PNW): Organized seminars, industryvisitsandnetworkingevents.

• Memberships: AIST, TMS, ASM International, American Ceramic Society. CERTIFICATIONS & PROFESSIONAL DEVELOPMENT

• Project Management (Google Qwiklabs) (2025)

• Introduction to ANSYS ACT Mechanical (ANSYS) (2023)

• Design Thinking and Innovation (IISc Bangalore) (2022)

• Noise & Vibration – Advanced Basics & Data Processing (NV Dynamics) (2022)

• Recipient of Spot Awards & Path Breaker Awards (Trane Technologies) (2020–2024)

• Winner of Samsung Star Scholarship (Samsung & NIT Calicut) (2016–2020)

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