FEA Engineer
Resume:
Sudharsan Srinivasan
*.*********@*****.***
http://www.linkedin.com/in/sudharsansrinivasan
SUMMARY:
5+ years of experience in automotive industry with specialization in design optimization, development and vehicle testing.
3+ years of experience in Finite Element Analysis (FEA), including static/dynamic, linear/non-linear analysis.
Thrives in a constantly changing and high pressure work environment, excellent communication and problem-solving skills and works well in crisis situations.
EDUCATION:
Master of Science (M.S) Mechanical Engineering, Wayne State University, Detroit MI, Apr 2008.
Master of Science (M.Sc) Automotive Systems Engineering, Loughborough University, UK 2002 – 2005.
Bachelor of Engineering (B.E) Mechanical Engineering, University of Madras, 1998 – 2002.
PROFESSIONAL EXPERIENCE:
Volt Technical Resources LLC, Onsite at Caterpillar Inc., Peoria, IL 2008 – 2009
Powertrain Test Engineer
Responsible for providing performance analysis of various Tier 4 powertrain components for electric drive.
Worked with system engineers & customers to perform timely analysis in support on product development schedules & strategy projects.
Worked on bearing current damage problem, which seems to be a big threat for any electric drive system.
Development of drive-train components & system for new products.
Data Collection from test vehicles in proving grounds & analyzing them to interpret the results.
Performance & durability testing of components.
Troubleshooting & technical analysis on drive train components.
Cold room testing for the spring coupler problems.
Optimal CAE Inc., Onsite at Toyota Technical Center, Ann Arbor, MI 2007 –2008
Powertrain CAE NVH Engineer
Establish problem and define conditions.
Worked on FE models for durability and NVH projects.
Document analysis results via comprehensive formal project report.
Co-ordinate with testing to validate analysis results.
Powertrain skinning for Noise, Vibration issue using Simlab & Hypermesh.
Analysis of Powertrain model displacement with Nastran & Abaqus.
Analysis of critical parameters using iSIGHT.
Wayne State University, Detroit, MI. The Department of Mechanical Engineering 2006 – 2007
Graduate Research Assistant
This work was focused to reduce friction wear and the piston slap noise.
The intent of this work is to simulate the piston secondary motion under no load condition with ADAMS/Engine with the pressure data as the input from experimental data.
Further, the single cylinder diesel engine with telemetric system is coupled with the dyno and the motion of the piston is determined under various load conditions.
Finally, the simulation results for the loaded condition and the experimental data is compared to get an in depth knowledge about the piston slap and the motion behavior of the piston under various conditions.
Mando Brake Systems India Ltd. 2003 – 2005
Senior Engineer New Product Development
Identification of new projects to develop the current braking system.
Worked with NVH problems on hydraulic braking system.
Vehicle testing.
FEA and Failure Mode Effective Analysis on hydraulic braking system.
Design and optimization of critical components in braking system.
Development of braking system components with new material (cost reduction).
Assisting to conduct warranty and FEA tests.
PROJECT ACCOMPLISHMENTS:
Crank Shaft Design – The crankshaft for a V8 engine is designed using the fundamentals of engine dynamics & vibration. This project was accomplished as part of a coursework requirement, which involved in depth designing from the fundamentals. After designing the base model it is refined with counterweights and balanced. Finally, the torsional vibration and the critical speed of the crankshaft are determined.
Caliper Weight Reduction – The frontal caliper housing was designed using CATIA V5 and analyzed for their deformation and stress distribution under different loading conditions. Some amount of material removal was done on less stress concentrated area and the modified model was analyzed using FEA to ensure that the component meet the manufacture requirement. Finally the component was prototyped and verified to pass in vehicle testing.
Alternate material for caliper piston – The caliper brake pistons are made of cast iron material and this component was verified for its performance with PEEK material which is a polymer. The PEEK material can withstand higher temperature than the cast iron and it had a better performance. Also the weight of the PEEK component was 1/25 of cast iron. The model and the basic analysis were done in CATIA V5.
Finite Element Analysis on piston skirt deformation – The piston of a single cylindered diesel engine was modeled and analyzed for the skirt deformation under different pressure level. The model was developed and analyzed using CATIA V5.
Residual Drag Analysis – The residual drag value for the frontal disc brakes were investigated to be much higher than the manufacture specification and this problem lead to faster wear of the disc pads. After keenly analyzing the problem and vehicle testing the major and the minor dimensions of the seal groove were modified to solve this problem.
Chassis Torsional Stiffness Measurement Using Nastran – The primary purpose of this project was to investigate the torsional stiffness of the chassis of a Formula SAE car. The FEA tool used in this project was Nastran and the results were compared with the real test data and found satisfactory.
Coastdown Analysis for Extreme Wind Condition – The track data with vehicle speed and yaw angle versus the time were recorded under extreme windy noisy condition. Using the recorded track data a model was developed in Simulink and the major parametric coefficients in the coastdown equation were analyzed for their sensitivity.
Engine Mount Noise Path Analysis – The noise path analysis technique is used to calculate the noise contribution of the individual components. Powertrain assembly is the main noise source with a critical boom frequency up to 500 Hz. This noise is transmitted as vibration into the body of the vehicle by various connecting elements, e.g. engine mounts, frontal suspension, shock absorbers, and gearshift lever & exhaust hangers. The sound pressure levels were measured in the left and right side of the mount and the noise transfer functions were obtained for those positions. To conclude, the gear mount was replaced with softer element with constant stiffness and scrutinized for the performance.
Drivetrain Vibration Modeling – A drivetrain model was simulated using Simulink and this model was used to investigate the drivetrain analysis. This analysis was performed for the shuffle and rattle. The shuffle produced an uneven acceleration and this was noticeable particularly after the tip-in. This model was simulated for both linear and non-linear modes. The simulated data was compared with the measured data and an optifit curve was determined
COMPUTER SKILLS:
Finite Element packages: HyperMesh, Nastran, Abaqus, Hyperview, Ansys, Catia V5, Pro-E.
Simulation packages: ADAMS-Engine, AVL-Excite, iSIGHT, SimLab, Matlab/Simulink.
Data Acquisition: AVL Indicom, SOMAT.
Operating system: Windows – 95+, Unix.
Other software tools: MS – Office, Vector-Canape, MINITAB, DAT-K.
ADDITIONAL INFORMATION:
Completed the applied mechanics course certified by Caterpillar Inc.
Completed the OSHA training at Caterpillar Inc.
Representative for Mando Brake Systems India Ltd. at AUTOEXPO – 2004 held at Pragathi Maidan, New Delhi, India.
Active member of the Formula SAE team at Loughborough University.
National level papers presented on: Mechatronics & Automation, Recent trends in Automobiles, Alternate Fuels.
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