Design Engineer

VISHWA KALYANASUNDARAM

*** ***** ****, *** # ***, Amherst, NY 14226

Ph #: 716-***-****; Email: ****@*******.***

SUMMARY:

• Comprehensive knowledge in Product Design Theories, TRIZ, Multidisciplinary Optimization, Mass Customization, Product Platforms and Families, Reconfigurable and Adaptive Products, QFD and DFMEA.

• Manufacturing Engineer in Delphi-TVS Diesel Systems Ltd., with hands-on experience in production line establishment, product development for manufacturability and assembly(DFMA), machine capability analysis, Statistical Process Control(SPC), TPM, DFSS, FMEA processes and lean manufacturing principles.

EDUCATION:

Master of Science in Mechanical Engineering (Thesis) GPA: 3.92/4.00 Aug ’08–Feb ‘11

University at Buffalo, The State University of New York

Bachelor of Engineering in Mechanical Engineering GPA: 78 % Jun ‘03–May ‘07

Anna University, Coimbatore, India

PROFESSIONAL EXPERIENCE:

The General Engineering Company, Ashok Leyland Limited May’05–Jun’05

Design, Manufacturing Intern

• Supported the design team in designing components for submersible pumps using DFMA principles.

• Performed process capability analysis for cylinder head production line and proposed a more efficient layout that increased throughput by 5%.

Delphi-TVS Diesel Systems Limited, CRDi division June ‘07–May ‘08

Manufacturing Engineer (GET), Engineering and Design Centre

• Refined component and fixture design for three different common rails by assimilation of product function requisites with machine and production line capacity using DFMA tools.

• Optimized the production line flow and increased the efficiency of rail manufacturing line from 150K/Annum to 200K/annum.

• Analyzed suppliers and machine capabilities, resourcefully conceptualized the production lines for the manufacturing and assembly of two types of rails.

• Resolved a major issue in rail assembly line by performing root cause analysis for recurring inconsistency in jet flow parameters, using the flow test bench, and isolated the critical operations responsible.

• Successfully prototyped two cylinder common rail component in collaboration with the design team and had it approved for production.

• Upgraded the existing dedicated production line to cater to the manufacturing of additional three varieties of rail.

Design of Open Engineering Systems Laboratory, University at Buffalo, NY Sep ‘09–Feb ‘11

Research Assistant

• Developed function based heuristics for design of reconfigurable and multifunctional products from existing single state products.

• Computed metrics based on function - component relations to evaluate the effectiveness of product combination and further determine the final product architecture.

• A novel approach of product integration, design streamlining and function sharing was proposed –bridging the missing link in existing research methodologies.

Mechanical Engineering Department, University at Buffalo, NY Aug ‘08–Dec ‘10

Teaching Assistant,

Courses: MAE Design Lab, Engineering Drawing/AutoCAD, Manufacturing Process, Design Processes and Methods

• Assisted and taught 120 students in their reverse engineering team project which involves product disassembly and investigation of various design and manufacturing issues

RELEVANT COURSES:

Finite Element Analysis, Advanced Solid Mechanics, Numerical Methods, Road Vehicle Dynamics, Advanced IC Engineering, Vibration and Shock, Hydraulics and Pneumatics, Design of Transmission Systems, Advanced Design Theory, Optimization in Engineering Design

VISHWA KALYANASUNDARAM Page 2

PUBLICATIONS / PAPERS:

• Kalyanasundaram, V., Lewis, K., “A function based approach for product integration”, Proceedings of the ASME 2011 International Design Engineering Technical Conference & Computers and Information in Engineering Conference, Washington, DC (submitted for review)

• Kalyanasundaram, V., Lewis, K., “Multifunctional product configurator - product design framework”, Proceedings of the ASME 2010 International Design Engineering Technical Conference & Computers and Information in Engineering Conference, Foundations of Engineering Design, NSF/ASME Student Competition, Montreal, Canada

• Kalyanasundaram, V., Sankar, K., “Optimization of heat exchanger design using CFD to recover waste heat in dairy farm”, 3rd National Conference for Research Scholars on Application of Emerging Technologies, AICTE-2006, Hosur, India.

TECHNICAL SKILLS:

CAD, Analysis and Simulation:

• Pro/Engineer Wildfire 4.0

• Auto-CAD 2005, Autodesk 2010

• Solid Works

• MATLAB & Simulink

• MAPLE

• NX UGS 5.0

• Pro/E Mechanism Simulation

• CNC Programming

• FEA Tools: ANSYS, HYPERMESH, Pro Mechanica

Platform: MS office

OS: Windows, Linux

PROJECTS:

• DESIGN & FABRICATION OF RETROFIT ADAPTIVE CORNERING HEADLIGHTS, TESTED SUCCESSFULLY IN SUZUKI ZEN CAR((Best Academic Project Award)

Dynamic pair of Headlights additionally installed turns in the same direction in which the wheels turn following the road contour to provide better visibility at tight bends and corners.

• MODELLING, ANALYSIS AND MECHANISM SIMULATION OF RECONFIGURABLE MOTORBIKE-ATV CONCEPT VEHICLE

Modeled and simulated using Pro-E, structural analysis was done using Pro-Mechanica. This concept applies transformation principles to infuse function capabilities of two different cadres of vehicle in one product and overcome each of their drawbacks making it more robust.

• SIMULATION OF BI-CYCLE MODEL OF CAR USING MATLAB

With CG, changing steering input, roll tilt and tire stiffness the bi-cycle model of the car was simulated using ODE solver in MATLAB.

• OPTIMIZATION AND STRUCTURAL TESTING OF PRATT TRUSS BRIDGE & FEA ANALYSIS

Sequential unconstrained minimization technique and golden section method were used to optimize the balsa wood bridge in MATLAB to withstand a payload of 70 pounds and tested. The design was further refined using Pro-Mechanica’s global sensitivity study and GRG algorithm.

• FORMULATING ‘ISO LANE CHANGE TEST’ OF CARS AS A VIBRATION MODEL TO DETERMINE ITS EFFECTS ON ROLL DISPLACEMENT & ACCELERATION

Contribution of the unsprung mass of car acting as the base isolator, the effect of tire and suspensions stiffness and their damping coefficients on roll was studied. A vibration model was developed to determine the optimal values that minimize the toppling of a car.

• MODAL ANALYSIS OF CRANK SHAFT USING ANSYS & THERMAL ANALYSIS OF ENGINE CYLINDER HEAD USING PRO- MECHANICA

The Crank shaft was analyzed for its lowest modes to determine its design feasibility. Thermal Analysis on engine cylinder was performed to determine the optimal size and location of fins.

ACHIEVEMENTS:

• Won the best project award for the year 2007 from the Mechanical Engineering Department.

• Won the first prize in design and racing of RC cars event held in National Level Technical Symposium –MNM Jain.

• Recipient of Tuition Scholarship and Teaching Assistantship from University at Buffalo.

CERTIFICATION/MEMBERSHIPS:

‘Delphi-TVS Industrial Automation’ certification ASME Member SAE Member

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