Engineer Design

SURESH KUMAR G.

#*, *.*.*. *** Street, Padmanaban nagar, Choolaimedu, Chennai-600 094, INDIA.

Contact: +82-10-902*****, E-mail: *******@**********.*** , Date of Birth: 7h April 1976

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LEAD ENGINEER (Core competency: Finite Element analysis)

Seeking challenging assignments in Automobile/ Aerospace/ Heavy Engineering/ Wind Turbines________________________________________

PROFILE

• Sincere & diligent Professional having 9yrs of experience across the industry; accented with the latest trends and techniques of the field, having an inborn quantitative aptitude & determined to carve a successful and satisfying career in the industry.

• Strong knowledge base and concepts clarity. Detail oriented with earnest to delve deep in the topic to evolve plausible solutions. Armed with knowledge of Design Methodologys and process capability

• Competency in detailed planning and scheduling to meet design cycle targets and conceptualizing and implementing process modifications to enhance operational efficiency and optimize resource utilization and achieve consistent increase in profitability

• Proven capabilities to propose sound design proposals in short cycle time. Proficient in working in harmony with diverse, multi-Disciplinary teams to realize desired objectives

• Excellent communication skills; participate in all technical discussion with customer, playing key role in finalizing the technical scope of work. Confident, self-motivated and an efficient problem solver, with patience to consider all options before taking a decision. Detail oriented coupled with an innate urge for knowledge.

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Areas of Expertise

• Geometry Editing using Ideas, Hyper Mesh, Ansys Design modeler.

• Generation of Tetrahedral and Hexahedral mesh of complex geometries using Ideas, Hyper Mesh, ANSYS WB as per the quality requirements.

• Generation of shell mesh of structures using Ideas, ANSYS WB and Hyper Mesh as per the quality requirements.

• Linear static and Eigen value Analysis.

• Non-linear static analysis (Geometry, material and boundary Non-linearity).

• Harmonic and Transient dynamic analysis using IDEAS and NASTRAN.

• Explicit analysis using ABAQUS Explicit

• Structural Optimization (Topology and Shape), Sensitivity analysis, Product development, CIM case RCA and DoE.

• Fatigue Evaluation, Bolted Joint Analysis and Welded joint Analysis.

• Familiarity with Steels, Ductile and Grey Cast Iron materials.

• Calculation of “hand calculation” solution of the FE model, Free Body Diagrams.

• Good Presentation and communication skills.

• Good Knowledge in using the following software’s ABAQUS, Ideas, Hyper Mesh, Nastran, Motion View, ANSYS WB.

• Correlation of Strain gauge and FEA results.

• 6 Sigma (DMAIC Green Belt and DFSS Green belt trained), Reliability Engineering.

• DFMEA trained.

• Knowledgeable in European design codes like EN 1991 -3: 2006, VDI 2230, GL Wind, EN 1993 -1-9 etc.

Software Proficiency

• Geometry editing/ Meshing-using Ideas.

• Performing Linear/ Non-linear Analysis using ABAQUS.

• Geometry editing/ Meshing-using HyperMesh.

• Linear analysis (Modal, frequency response, Static stress) using Nastran.

• Customizing, Parametric model Building and Multi body simulation using MotionView.

• MS office Products.

• Meshing & Nonlinear Analysis using ANSYS WB, APDL macros.

• Teleconference using LOTUS Sametime, Office communicator, live meeting.

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PROFESSIONAL EXPERIENCE

Samsung Wind Division, South Korea since Jul’11

Manager

• Responsible for performing Non-linear bolted joint calculation for Main bearing house to Main frame connection (for S 2.5 MW turbine) as per VDI 2230 and GL standard. Used ANSYS for FEA and GH-bladed for Fatigue calculation. Now working on optimizing the joint design.

• Responsible for performing composite analysis for the Spinner and provide suitable design improvement. Co-ordinate with the design engineers up to detail design phase. Completed the project successfully with minimum number of design iterations.

VESTAS TECHNOLOGY R&D, CHENNAI Jul’08-Jun’11

Asst. Lead Engineer

• Responsible for performing strength calculation using finite element programs of the various module components and work for certifying the modules from DNV for the V90, V80, and V112 Wind turbines. Review and present result using desk share application to interact with Reviewers in Denmark.

• Additional responsibility to lead the fresh and less experienced engineers in design and analysis using ANSYS WB and other calculation techniques.

• Performing linear, modal, Non-linear, sub model, bolted joint, welded joint and fatigue analysis using ANSYS WB, fatigue wizard and other techniques for the various Wind turbine components to capture all the possible failure modes.

• Preparing of DNV structural verification report and archive FE models for future use.

• Main bearing housing fatigue analysis, this analysis includes improving the MBH design to extend the life to 20years, maintain the weight forecast for transportation and assembly and the DNV structural verification certificate preparation.

• Skeleton module includes the nacelle structure and crane structure. Work was to verify the module components, including several bolted joints using sub models, optimize the structural components and the DNV structural verification certificate preparation. All the calculation was based on European design codes.

• Cooler Top module strength verification was to analyze the cooler top cover, the cooler structure and cooler structure interface bolted joints.

• Internal crane structural verification was to analyze the crane structure and joints as per the euro code.

• Analyzed and improved the generator foundation bolted joints.

• Performed RCA and design improvements for 2 CIM cases.

• 6 Sigma DFSS for higher slip capacity bolted joints. Design and optimization of shrink-fit coupling.

CATERPILLAR INDIA PVT LTD Sep’07-Jul’08

Sr. Design Engineer

• Main responsibilities include performing and coordinating FEA analysis, conducting strain gauge exercise, correlating FE analysis results and strain gauge results, field failure study, root cause analysis.

• Performed RCA on the Backhoe loaders failures, Swing Pin failure, Tower weld crack and slider plate weld crack.

• Worked on design improvements on the tower weld crack and slider plate weld crack.

• Worked on field repair procedure for the slider plate weld crack.

CATERPILLAR ENGINEERING DESIGN CENTER Dec’05-Sep’07

Lead Analyst

• Main responsibilities include performing finite element analysis, project estimation, mentoring young engineers.

• Review and present result using desk share application to interact with clients in USA, Japan. 345 C sticks cylinder cushion failure RCA with FEA, 385 C sticks rod failure RCA with FE, 793 Cat walk Modal and G-load (fatigue) analysis, 793 Blower frame modal and G-load (fatigue) structural, welded and bolted joint analysis.

• 2010 ATAAC frame modal and g-load analysis welded and bolted joint analysis, Monarch D Shaft Structural FEA, Engine Base frame Modal, G-load and Lifting load analysis, Whole 793 frame FE model generation.

• After cooler modal analysis to find out hot spots for strain gauge placement. Hydraulic valve bolted joint analysis.

• 320 C mufflers RCA with FEA for weld failure.

• 6 Sigma Green belt for Analysis files storage process improvement, Analysis quality check tools, Project communication improvement using project charter.

ROBERT BOSCH Aug’05-Dec’05

FEA Engineer

• Main responsibilities include performing finite element analysis, project estimation.

• Review and present result using desk share application to interact with clients in Germany.

• Structural analysis of brake disc.

• Structural analysis of common rail.

CATERPILLAR ENGINEERING DESIGN CENTER Sep’03-Aug’05

Analyst

• Main responsibilities include performing finite element analysis, project estimation.

• Review and present result using desk share application to interact with clients in France, Japan, USA.

• C32 Flywheel burst analysis.

• D6N Muffler bracket RCA and design improvement using FEA.

• Engine base frame modal and lifting load analysis for various models.

• D7 oil filters group vibration analysis.

• Pump (spline) shaft analysis for several models.

• Blower fan centrifugal analysis.

• Fan guard RCA and design improvement using FEA.

• Fuel pumps structural analysis.

• Rock breaker FE model generation.

• Lifting eye strength and bolted joint analysis.

HINODE TECHNOLOGIES LTD. Jan’03-Sep’03

Development Engineer

• Main responsibilities include performing finite element analysis and software development.

• Customized Altair motion view software to include additional 7 drive maneuver analysis.

• Structural analysis for auto rickshaw rear trailing arm and steering arm.

• Motion view parametric model for bajaj two wheel front suspension.

DESIGN INNOVATIVE PVT LTD. Jan’02-Dec’02

CAD Engineer

• Auto CAD production drawings.

• Brake disc analysis using ANSYS.

• Free lance Engineering.

LOCO WORKS, SOUTHERN RAILWAY, CHENNAI Dec’96-Dec’97

Technical Trainee

• Designed and fabricated a setup for leakage detection of dash pot and for sagging testing of the Bogie.

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EDUCATIONAL CREDENTIALS

Master’s in Mechanical Engineering (Engineering Design) 2002

Anna University, Chennai, 7.96 CGPA

Associate Member in Institution of Engineers (India) (Mech. Engg), Calcutta-20 - Dec 1999; 63.80%

Diploma in Mechanical Engineering 1994; 77.42%

Graduated 6 Sigma Greenbelt (DMAIC)

10th; 77.80%

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CAE Projects

• Structural analysis and Optimization of Main foundation and Main Bearing Housing of Vestas Wind Turbine:

The Main foundation (MF) and Main bearing housing (MBH) was analyzed using Ansys WB with main shaft, yaw bearing, tower and torque arm in a Non-linear analysis. The bolted joint between the MF and MBH were also checked for its extreme capacity and dynamic capacity. The Optimization of MF and MBH were carried out with transportation and erecting weight limits as extreme criteria. In-house fatigue software was used to identify and improve the hot spot locations such that the components shall fulfil its 20yrs life without failure. The work also includes preparation of certification documents that shall used for DNV or GL certification.

• Linear Vibration analysis of Earth moving m/c's and power genset systems:

The analysis was performed on systems like, Muffler assembly, cabin, radiator fan guards, hydraulic tanks, engine base frames, cabin hoods, Head light brackets, compressor brackets etc. A Modal analysis is performed to check if the Eigen values of the system are away from the system's exciting. Acceleration load analysis is performed in the X, Y and Z to make sure that the components would not fail due to any vibrations loads; this is a fatigue evaluation considering the vibrations as a SHM. Recommendation for few of the analysis was to increase the bracket thickness, change the load path and reduce the cost with simple designs.

Software used: Ideas & Hyper Mesh to create the FEM and NASTRAN for analysis, Goodman formula for fatigue.

Clients: Caterpillar facilities in USA, UK, Germany, Japan and France.

Team size: 2 + a client over telecon.

• Non-Linear Vibration analysis of Engine systems

The analysis is performed on engine manifold, after coolers. Material and contact non-linearity was considered in this analysis. The analysis is performed to check if the first and second order bending modes and first order twisting modes are away from the 1st and second order of Engine RPM. A fatigue analysis was performed on the assembly to make sure that the design is durable. Recommendation out of this analysis was to increase the bolt force, add more material at the failing locations. ABAQUS Bolt-Preload, Surface to surface contact, Elastic-plastic material model capability was used in the analysis.

Software used: Ideas, Hyper Mesh to create the FEM and ABAQUS for analysis, FE-safe for fatigue calculation.

Clients: Caterpillar facility in USA.

Team size: 2 + a client over telecon.

• Non-linear contact analysis of pump shaft assembly

The pump shaft is spline shaft that is used to drive the hydraulic pump. The finite element analysis is performed to do fatigue evaluation of the shaft. This is because of the torsinal vibrations that are measured in the shaft. ABAQUS contact and thread load were considered in the model. ABAQUS Global and sub model approach is employed to accurately capture the stresses.

Software used: Hyper Mesh to create the FEM and ABAQUS for analysis, FE-safe.

Clients: Caterpillar facility in Japan.

Team size: 3 + a client over telecon.

• Burst analysis of Flywheel

A cyclic symmetry model of the flywheel was analyzed to find out the max. Principal stresses. A burst factor of 2.5 was used and the elastic-plastic analysis is performed in ABAQUS.

Software used: Ideas to create the FEM and ABAQUS for analysis.

Clients: Caterpillar facility USA.

Team size: 2 + a client over telecon.

• Bolted Joint analysis of a Pump head:

The bolts that fasten the pump head to the pump body have to be analyzed for the hydraulic pressure loads. The five geometry criteria and load criteria is used to evaluate the bolts.

Software used: Ideas to create the FEM and ABAQUS for solution, Hand calculations using excel for bolted joint analysis.

Clients: Caterpillar facility USA.

Team size: 2 + a client over telecon.

• Customization of Motion view to include various drive maneuver analyses on a Four-wheeler

The Motion View software was customized to include drive maneuvers like double lane change analysis, swept sine steer analysis, constant radius circling analysis, etc. The four-wheeler model available with the software was used. The model definition language of the motion view was used for the customization.

Software used: Motion view, Text pad

Clients: Altair, USA.

Team size: 2

• Parametric modelling of the front suspension for a Two-Wheeler to perform a bump rides Analysis

The main parameters in the model are the camber and caster angle of the front suspension and the interest is to find out the forces at the forces at the handle bar.

Software used: Motion view.

Clients: Bajaj motors

Team size: 1

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Languages Known: English and Tamil

References: Available on Request

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