Resume - Resutls-Driven Structural Analysis Engineer

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Resume #78506

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CAREER SUMMARY

Senior Mechanical Engineer with ten years of professional finite element analysis experience performing full vehicle crashworthiness, noise vibration harshness and structural analysis. Acquired strong proficiency in using FEA tools like HYPERMESH, LS-DYNA3D, PAMCRASH, MADYMO, MSC-NASTRAN, ABAQUS, ANSYS, PRO-ENGINEER and PRO-MECHANICA. Broad based knowledge of occupant restraints design and development from concept to launch for side and frontal impact applications. A Certified Six Sigma Green Belt with reputation for being a hard worker who can work independently or as a team member and take initiative readily. Demonstrated ability to meet strict deadlines and maintain high quality standards.

PROFESSIONAL EXPERIENCE

TRW AUTOMOTIVE, Washington, MI 2003-2008
A major international Tier I and II manufacturer of component parts and assemblies

Sr. Product Design Engineer 2006-2008
Responsibilities included vehicle crashworthiness and occupant safety with emphasis on the design and development of airbags and seatbelts from concept to launch.

* Reduced full vehicle IIHS side impact simulation run time by 92% using substructure modeling technique that resulted in annual cost savings of approximately $65,000.
* Improved occupant's performance by optimizing restraint systems in LS-DYNA3D sub-structure model coupled with MADYMO dummy for oblique pole and IIHS test modes.
* Performed, analyzed and presented side impact sled and OOP testing to the customers. Suggested sled door design changes to improve correlation for better bag evaluation.
* Optimized structure and restraints design, to reduce head injury criteria (HIC) in dynamic head impact / FMH simulations, for head ejection containment, FMVSS201 lateral pole, FMVSS214 oblique pole, and linear impactor loadings. LS-DYNA was used as a solver.
* Improved fabric utilization in curtain airbags by optimizing height without compromising coverage and dynamic performance, thereby reducing costs by $445,000 per year.

ESII Application Engineer 2003-2006
Responsible for data acquisition and analysis, modeling and improving occupant restraint systems design based on analysis of FE simulation, laboratory and vehicle crash testing.

* Improved seat mounted head-thorax bag performance for IIHS and FMVSS214 oblique pole barriers using PSM simulation, thereby saving eight Bungee sleds costing $16000.
* Modeled, analyzed and folded side and frontal impact airbags using HYPERMESH, LS-DYNA3D, OASYS PRIMER and Initial Metric Method (IMM) of scaling airbags.
* Identified $23,000 in cost savings by reducing the bag development time, achieved by improving bag performance under different loading conditions of SINCAP, IIHS and ECE
* Successfully completed Finite Point Method (FPM) simulation in PAMCRASH and predicted the compressible flow inside a folded airbag to understand the basics of CFD.

FORD MOTOR COMPANY, Dearborn, MI 1999-2003
A major international vehicle manufacturer

Project Engineer 2001-2003
Responsible for delivering body NVH and durability requirements for Taurus and Panther vehicle programs. Applied optimization techniques to achieve improved NVH performance, also supported these vehicle programs with trim body modal analysis, durability analysis, static bending/torsion analysis, fatigue analysis, design verification plan and report analyses.

* Applied DSA / Optimization techniques and improved the overall vehicle shake (NVH) performance of 2003 Town car by 37% resulting in higher customer satisfaction.
* Achieved approximately 50% improvement in 2003 Town car steering column vertical response occasioned by rough road input by optimizing the Instrument Panel design.
* Improved the 2003 Town car BIW first torsion mode by 32% (stiffness dropped from Structural prototype (SP) to Confirmation prototype (CP) design due to architectural Changes) by applying optimization techniques and met CP build timing and targets.
* Provided CAE support for a few bench tests on 2003 Town car hood and rear door as per SDS requirements/best practices, achieving a high confidence CAE-test correlation, thereby eliminating future hardware tests and resulting in cost saving to the company.
* Performed safety related analyses such as seat belt pull, ISO fix, child tether and static side intrusion on various programs using LS-DYNA3D.

CAE Engineer 1999-2001
Responsibilities included modeling; trim body analyses, fatigue life prediction, static - linear / non linear and dynamic analysis using HYPERMESH, NASTRAN, DYNA3D and ABAQUS.

* Performed FMVSS 214 Non-linear Static Side Door Intrusion Beam Analysis on 2001 Taurus that achieved five star rating in side crash and satisfied federal requirements.
* Performed FMVSS 207 / 210 Non-linear Analysis on 2003 Town car and implemented the proposed MCR design changes on the shoulder belt anchor reinforcement that resulted in meeting corporate FMVSS 207 / 210 seatbelt pull load requirements.
* Successfully correlated 2003 Town car CAE model, to CP hardware for static bending / torsion and demonstrated to the program team, the high quality of CAE model and the accuracy of their predictions. Trim body-on-frame models were analytically evaluated using Nastran / EASi that achieved very good correlation within test-to-test variability.
* Evaluated the strength of 2003 Town car child restraint anchorage system, under FMVSS 225 child top tether and lower anchorage seat belt pull loads.

EDUCATION

M.S. in Mechanical Engineering, Bradley University, Peoria, IL 1998
B.S. in Mechanical Engineering, Osmania University, Hyderabad, A.P., India 1996

COMPUTER SKILLS

Hardware: HP, IBM 530 / 320, SUN and SGI
Software: HYPERMESH, FEMB, SOFY, MSC/NASTRAN, LSDYNA3D, LSTAURUS, ABAQUS, ABAPRE, PAMCRASH, MADYMO, PATRAN, ANSA, SDRC I-DEAS, PDGS, PRO-E, PROMECHANICA, VSIGN, FLAP, VISUAL CRASH DYNA, VISUALSAFE MADYMO, ANSYS, CAESAR, PRIMER, FPM, AutoCAD, MATLAB, MSWord, Excel, PowerPoint

CITIZENSHIP: US Citizen

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