Engineer Design

HADI RABBANI

**** ********* ****** 248-***-****

West Bloomfield, Michigan 48323 ***********@*****.***

CAREER SUMMARY

Experienced structural dynamics engineer and innovative technical leader with extensive experience in automotive in the areas of NVH (Noise, Vibration and Harshness) testing and analytical (CAE), Durability, Safety CAE and Aerodynamics. Demonstrated skill in applying new analytical methodologies and advanced techniques in vehicle development.

Expertise (Core Competency)

• Vehicle Road, wind and Powertrain-induced Noise, Vibration, and Harshness (NVH) benchmarking, target setting, and target compatibility assessment; root cause determination, issue resolution and design enhancement recommendations.

• Working extensively with the Powertrain engineers and suppliers on the powertrain-induced (engine radiated, air intake, and exhaust) airborne and structure-borne noise measurements, identified the root causes and recommended resolution of the interior noise issues.

• Leading NVH, durability, and aerodynamics, vehicle development teams from concept to design.

• Demonstrating technical expertise in the related field of Computer Aided Engineering (CAE) analysis and providing guidance to external engineering activities and suppliers on analysis matters.

• Customer satisfaction, stemming from vehicle Interior Quietness, Smoothness of Ride, and other NVH metrics.

• Vehicle Modal Alignment Strategy.

• Vehicle Design Specification (VDS) for Powertrain, Road, and Wind-induced NVH Target Compatibility Assessment.

• Extensive use of Experimental Design (DOE) and DFSS (Design for Six Sigma) for vehicle subsystems, components, and full vehicle optimization.

• Aluminum Intensive (concept) Vehicle development for NVH, including development and application of weld-bonding methodology.

PROFESSIONAL EXPERIENCE

Next Autoworks Company (formerly, V-Vehicle Company), San Diego, CA/Detroit technical Center,Detroit, MI 03/2009-12/2011

Technical Expert, Vehicle NVH CAE and Testing (NVH, Durability, and Aerodynamics)

Responsible for leading all NVH, Aerodynamics, Durability CAE and Durability test Schedule, and Vehicle Benchmarking . This included:

• Through optimization of the exhaust attachment locations, eliminated the structure-borne noise stemming from the exhaust underbody attachments.

• Working extensively with the P/T mount supplier to optimize and decouple (~90%) the P/T rigid body modes.

• Subjective and Objective assessment and tuning of vehicle NVH on the Nissan Arizona test track.

• Leading NVH and durability, modal and stiffness target setting, conducting full-vehicle NVH subjective/objective assessment, modal alignment strategy, point mobility (CAE and testing), and designing durability test track schedule.

• Overseeing NVH and durability analysis and leading other full vehicle CAE activities; such as: Static Bending and Torsional Stiffnesses, Multi-Body Dynamics, and Aerodynamics.

• Closely working with the design staff (studio) and directing the CFD Aero supplier to tune the body exterior to meet the target Coefficient of Drag of 0.29.

• Providing full analytical support for the full vehicle test track Coastdown testing.

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FORD MOTOR COMPANY, Dearborn, MI 12/1978 - 01/1981

(Contract) 04/1984 - 08/1987

09/1987 - 08/2008

NVH Leader/ Section Supervisor

Supervised and led groups of product development engineers, as many as 25 engineers, responsible for analytical assessment and evaluation of vehicle NVH (Noise, Vibration and Harshness), root cause, issue resolution for road and powertrain induced tactile and sound for all Unitized and Body-on-Frame vehicles (SUV).

• Pioneered the development of a robustness analysis technique for the NVH / VVWD

(Vehicle Vibrates While Driving) Vehicle Design Specification, using ISIGHT FD Monte Carlo capability, in order to capture the inherent variability in all chassis and powertrain tunables

• Led and supported the development of the Tuning Tool in the form of Excel Regression model for different NVH Vehicle Design Specifications (VDS) metrics and supported the special application of the Tuning Tool to DFSS (Design for Six Sigma) steering wheel Nibble, Brake Roughness, and Shake.

• Guided the NVH CAE team to produce the quietest SUV in its segment by delivering the analytical model of a 4-mount rear differential unit ( RDU ), optimized for driveline imbalance and axle whine, leading to annual cost savings of $15M (through preservation of Rear Trailing Arm suspension and reduction in Axle whine warranty cost).

Pre-program NVH CAE Leader/Supervisor 01/1990-12/2000

In charge of full vehicle and body NVH CAE for all pre-program work including Ford of Europe’s B and C platforms. A major effort with success was expended on the modal separation of the front end bending mode and the east-west oriented engine firing order.

• Led the development of a comprehensive analytical tool, utilizing Fuzzy Logic, for vehicle NVH CAE performance trade-off and target compatibility assessment during early stages of vehicle program development.

• Established a CAE modeling methodology for the structural adhesive and validated the methodology by designing several weld-bonded test specimens and developing test techniques and comparing test / CAE modes and dynamic responses, yielding excellent correlation.

Provided full support and NVH CAE technical expertise to the concept Aluminum Intensive Vehicle ( AIV ) development community, ensuring no degradation in aluminum body structural integrity (compared to steel ) including tactile and sound responses. The project resulted in substantial weight savings at the full vehicle level. Coordinated the department’s ISO9000 for several years, ensuring that department personnel were trained and ready for internal / external audits.

Group / Project Leader 04/1984-01/1990

12/1978-01/1981

• Performed an in-depth investigation of the automobile FEM ( finite element model ) methodology and developed guidelines to improve the quality of the automobile body models.

• Implemented a building block approach on modeling and test / CAE correlation of an automobile trimmed body.

• Published Modeling Guidelines for an Automobile Body and Presented a Paper at the NASTRAN World User’s Conference.

TRW ELECTRONIC AND DEFENSE 01/1981-04/1984

One Space Park, Redondo Beach, CA

Staff Engineer (Secret Clearance)

Responsible for structural dynamic analysis of spacecraft solar arrays (TDRSS).

• Developed a two-stage dynamic analysis method, utilizing NASTRAN’s non-linear transient force capability for analysis of a vehicle subjected to transient loads.

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CHRYSLER CORP ( Presently: GENERAL DYNAMICS LAND SYSTEMS) 05/1976-12/1978

Warren Defense Division, Centerline, MI

Product Engineer (Secret Clearance )

Modeling, design and structural dynamic analysis of vehicle component subjected to static and dynamic transient loadings.

EDUCATION

PhD, Engineering Science-Applied Mechanics, University of California, Berkeley, CA

MS, Mechanical Engineering Sciences, Wayne State University, Detroit, MI

BS, Mechanical Engineering, Wayne State University, Detroit, MI

AWARDS RECEIVED

• Recipient of “2005 VE ( Vehicle Engineering ) Achievement Award for the Explorer Four Mount Rear Axle Optimizer for Driveline Imbalance and rear Axle Whine,” August 2005.

• Recipient of Excellence Award at the “2007 1St CAE Technology Innovation Award.”

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