Product Design and Analysis

Nagarajan Thiyagarajan

**** ***** **. *** *, Champaign, IL 61822

Tel: (cell) 937-***-**** Email: *.******@*****.***

Objective:

I am interested in the area of product/component design and analysis. I have experience in both advanced FEA/Optimization techniques and also in product/process design in a fast paced manufacturing environment.

Technical Competence:

• FEA Packages: Hypermesh, Optistruct, Nastran, Abaqus, Deform, Ansys

• Modeling Packages: Unigraphics, I-DEAS, PRO-E(Beginner)

• Programming: Tools Matlab, Python

• Others: FE-Safe, I-Sight, Statistical Analysis, FMEA, GD&T skills

Relevant Experience:

Sept 2007~Present Project Engineer

(On Contract) Caterpillar, Champaign Simulation Center, Champaign, IL

• Structural Analysis and Optimization of various structures including frames, brackets, support structures, valve covers, axle housings, etc

• Have performed extensive analysis and design optimization in the initial conceptual phase of the project

• Good understanding of manufacturing constraints such as forge-ability, cast-ability, and other manufacturing capabilities

• Successfully improved product performance while reducing material and manufacturing cost.

• Performed Statistical Analysis, DOE techniques, fatigue analysis, Topology and Size and Shape Optimization

• Good knowledge of fastener and bolted joint design criteria

• Experience and Knowledge of advanced analysis techniques such as Bolted Joint Analysis, Welded Structures, Contact Analysis, Iso-Mounts and Dynamic Impact Analysis

• Experience in working on multiple projects to meet demanding deadlines. Have worked with overseas business units. Actively participate in weekly meetings and project updates

Nov 2005 ~ Sept 2007 Product/Tooling Engineer

Colfor Manufacturing Inc. (AAM Company), Malvern, OH

• Design warm and cold forging process and toolings

• Managed projects from creating proposal drawings to parts delivery (PPAP and Prototypes)

• Good knowledge of tool design calculations and press fits

• Responsible for conducting (FEA) simulation studies or performance predictions for forgings

• Good knowledge and experience in forward and backward extrusion and upset forging process

• Focus on automation improvements, process improvements, labor reduction and better equipment utilization

• Experience in designing jigs and fixtures

• Prepare estimates, reports, stress analysis and technical calculations as required

• Hands on experience as a process engineer to make the various designs and process work in the real shop floor environment

• Good shop floor experience, press operation, internal audition and communication with shop floor supervisors and workers to get work done in a timely manner

• Good understanding of temperature and wear resistance materials and coatings

• Responsible for creating PFMEAS, developing gages, incorporating corrective actions for various products/process

• Improved existing tooling designs to improve die life and to make the process more robust

• Successfully implemented data collecting techniques for various process in a fast paced manufacturing environment

• Successfully improved die life and saw blade life

• Develop and participate in technical presentations for customer and management

March 2005 ~ Nov 2005 FE Analyst

(On Contract) Alcoa Technical Center, Alcoa, Pittsburgh, PA

• Execute linear, non-linear and multi-physics finite element problems and perform sensitivity analysis

• Written codes for complex electro-thermal analysis including joule heating for aluminum production

• Performed stress analysis on the Anode block to eliminate storage/stacking problems

• Extensive work on sensitivity analysis on all results and also in building approximation models to guide senior engineers at the plant

• Performed complete automation of various stages beginning from writing script files, to executing FE solver and reading required results for post processing using MatLab

January 2002 ~ Dec 2004 Graduate Research Assistant

Computational Design and Optimization Center (CDOC), Wright State University, Dayton, OH

• Designed die shapes for several geometrically complex parts such as the steering link and Toyota wheel hub

• Developed simulation-based optimization methodologies for complex, large-scale problems that require commercial finite element codes

• Modeled dies for V8 crankshaft (for forging analysis) and also many complicated components, such as a Toyota front wheel hub, steering link, etc, using I-DEAS

• Studied different kind of Domains – Structures with finite deformations, large deformation, heat transformation

• Developed high quality function approximations (two-point adaptive nonlinear approximations-TANA) for reducing FEM simulations during design optimization to minimize computational cost

• Used reliability-based design techniques for complex metal forming processes that would enable an integrated design of non-linear systems with uncertainties

• Used I-DEAS surfacing capabilities to repair many IGS files (exported from Autocad) to enable FE analysis and also have good knowledge of assembly and detail drawing

• Conducted workshop for graduate students in CDOC on Modeling, Analysis and Programming capabilities of I-DEAS

March 2000~July 2001 Research Engineer, Defense Bio Engineering and Electro Medical Laboratory (DEBEL), Bangalore, India

• Responsible for developing assembly techniques for various mechanical systems (G-Value and Oxygen regulators)

• Involved in calibration of artificial breathing machine and gravity simulators

• Used I-DEAS 3D and 2D CAD software to design and document complex mechanical, and pneumatic components, products, and systems

• Developed specific design solutions which satisfy engineering principles and manufacturing practices

• Interface with design and analysis teams to ensure targets are established, met and verified via analysis and testing

• Involved in extensive experimental work on life support systems of light combat aircraft in developmental stages

Other Projects:

Metaldyne, Michigan Billet shape design (preform design) of metal wheel hub to reduce material waste, power consumption, and eliminate underfill in its forging process

DURA Automotive Systems Inc., MichiganInvestigated various failure modes of SUV door hinge pin under static and dynamic loading conditions that limit its load-carrying capacity leading to premature failure

TE-CO Workholding Technology, Ohio3-D modeling and finite element analysis of RELOCK VISE SYSTEM to determine the stress concentration leading to failure of the attachment jaw (holder) under fatigue

Education:

Wright State University, Dayton, OH  December 2004

M.S. in Mechanical Engineering

Malnad College of Engineering, Karnataka, India  1999

B.E. in Automobile Engineering

Publications and Papers:

• Thiyagarajan, N., and Grandhi, R. V., “3-D Preform Shape Optimization Using Reduced Basis Techniques,” Journal of Engineering Optimization, Vol. 37, # 8, Dec. ‘05, pp. 797-811(15)

• Thiyagarajan, N., and Grandhi, R. V., “Multi-Level Design Process for 3-D Preform Shape Optimization in Metal Forming,” Journal of Materials Processing Technology, Vol. 170, Issues 1-2, Dec ‘05, pp. 421-429

• Thiyagarajan, N., Repalle J., Belur B., and Grandhi, R. V., “Forged Part Distortion Prediction and Minimization,” AIAA/ICAS, International Air and Space Symposium and Exposition, July 14-17, 2003, 18 pages.

• Thiyagarajan, N., and Grandhi, R. V., “3-D Preform Shape Optimization In Metal Forming,” Material Processing and Design: Modeling, Simulation and Applications, Numiform 2004, Paper no.173, June 13-17, 2004, pp. 2038-2043.

Available to Travel  Willing to Relocate

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