Mechanical Engineer

Dr. Stepan V. Lunin

** **********, ******, ** ***** 949-***-**** *******@*****.***

* Spiral Bevel Corporation. CA.

Current.

Design, development and sales support of of mechanical simulation software for dynamic components.

* Calnetix. CA

11/10-2/12.

Sr. Mechanical Engineer. High speed electric machines.

Design, development and customer support of dynamic high speed machines resulted $2mil extra earning from GE. Two award for invention disclosures.

* The Boeing Company. CA

12/06-11/10.

Senior Design Engineer. A160, HALE..

Designed and developed electromechanical flight control, landing gears, and propulsion actuators. Developing and improving main rotor and tail rotor gearboxes. Won Boeing design competition for HALE main gearbox resulted $5mil earning. 2 patents.

* Curtiss-Wright. NC.

1/06-8/06.

Lead Design Engineer. Aerospace actuators .

Lead design and development flight controls and accessory electromechanical actuators. Proposed 20% cost reduction for electro-mechanical actuators.

* Moog. CA.

2/05-12/05.

Senior Design Engineer. Aerospace mechanical actuators.

Research and development in new flight controls and accessory electromechanical actuators. Proposed mechanical actuator design with 40% weight reduction. Patent.

* Volvo Penta. VA

4/99-8/04.

Principal Specialist. Spiral bevel gear transmissions.

Lead effort in developing of marine gearboxes. Acted as primary expert in gears and principal specialist in hydrodynamics. Promoted to Principal Specialist for 10% fuel economy improvement.

* General Motors. MI.

1/97-3/99.

Mechanical Engineer. Product development and manufacturing.

Manufacturing development of electromechanical actuators for electric power steering system. 2 awards and promotion in first 9 months for contribution to product improvement.

* AKS, Glas-Tec. and Glas-Tec Inc. Tucson, AZ.

4/95-1/97. Chief Engineer. Fiber reinforced composites.

Supervised 16 shop workers. Interacted with customers. Offered company ownership.

* Mil-Helicopter. Moscow, Russia.

4/86-12/94. Manufacturing engineer. Mi-8,-24,-26 helicopter production and deployment.

Supervised manufacturing of helicopter gearboxes. 4 patents. Promoted during first year.

Ph.D.2002. Izhevsk Institute of Mechanics Computer science.

M.Sc.1989. Moscow State University. Applied Mathematics.

M.Eng. 1986. Moscow Aviation Institute. Aerospace engineering

20+ years of experience in mechanical design and manufacturing, digital modeling and software development. 15+ years of true hands-on fabrication of fiber reinforced composite plastics.

Well-known in power transmission gear manufacturing industry:

6 gear related design patents, 16 gear related technical articles, 3 gear related presentations on international scientific conferences, 1 book about gears.

Unique combination of hands-on skills in manufacturing, design, computer modeling, and education.

Initiated and sold engineering projects for a number of companies in USA, Japan, Germany, Italy, South Africa, India, China, Belgium, Finland, Nederland, UK, Canada, Turkey. Customers: Boeing, Moog, Curtiss-Wright, Terex, Rolls-Royce, GM, GE, DMG, MAZAK, Breton, Remacontrols, Boeing, Delphi Automotive, Chrysler, Formula One teams, New Venture Gear, Metso Minerals, National Oil Varco, Brad Foote Gear Works, Overton Gear, Volvo.

14 years in aerospace gears design and manufacturing. Went through all the stages from gear cutting machine setup, shop supervision, design, R&D, and consulting on critical design concepts. Won design competition for main gearbox for Boeing (HALE) Phantom Eye by proposing the least expensive and high efficiency rotor gearbox. Have 2 gear related patents with Boeing. Top Boeing expert in spiral bevel gears. Can design, develop, prototype, inspect manufacturing, fix contact pattern and other problems. Can suggest on Gleason or Klingelnberg gear cutting machine summary adjustments just by looking at the tooth pattern. Have developed a number of different software tools for tooth contact pattern simulation. First in the world started to design power transmission gears with fiber reinforced composite plastic elements. Patent with Moog.

5+ years of direct employment and 2 years on part time consulting on marine gears.

Research and development in marine power transmissions. Small (4” dia) and large (95”Dia) spiral bevel gears. Developed software for digital simulation of rolling/sliding and driving efficiency on the gear tooth for spiral bevel and hypoid gears. Suggested ideas for to increase load and driving efficiency of spiral bevel and hypoid gear drives. Improvements: efficiency +5%, noise -6 Db, transmission error -50%. Develop algorithms and write codes for in-house CAD, FEA software. Research and development of new marine gear systems. Investigated gear failure for large hard cut spiral bevel gears from Klingelnberg for Rolls-Royce by computer reverse simulation of the tooth contact pattern from clouds of CMM points on the tooth surface. Developed manufacturing methods for machining 90”+ Dia case hardened spiral bevel gears in the US.

2 years in industrial gears. Designed and manufactured large case hardened spiral bevel, hypoid, spur gears and splines. Acted as a lead gear expert for proposals, customer relations, design and manufacturing. Developed and put into production a new method of making gears.

Continues involvement in automotive gears since 1986. Well known around the world as an expert in gear design and tooth contact pattern simulation for different gears. Worked with GM and Chrysler on new design and manufacturing methods of improved gears. Developed design tools and sold variable ratio steering rack and pinion design for a number of companies including GM, TRW and several Formula One teams. Know within Formula One Ferrari team as a top gear expert. Proposed alternative drive axle gears. Invented a new method of drive axle differential housing manufacturing with use of fiber reinforced composite plastic materials. Personally built a few prototypes with use of carbon fiber and Aramid fibers. Resulted in cost reduction and reduction of the moment of inertia for racing application and high performance cars like AUDI or BMW.

Pro/E, UG, AutoCAD, Solid Works, CATIA, FEA, UTS, KissSoft, Fortran, Visual Basic, C, Java Scripts, HTML, MS Office, CFD, CNC, spiral bevel, hypoid, spiroid, helical, worm gear, variable ratio rack, Formula One, aerodynamics, hydrodynamics.

FEA experience: COSMOS, own FEA software developed for GM:

http://www.zakgear.com/FEA.html

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