Design Engineer

Uday Prasade

* ********** ******, *** *

Naperville, IL 60540

Cell: 630-***-****

OBJECTIVE

To use my 18+ years of experience to drive and evolve the design processes for components, sub -

systems and systems, for economical and simplified manufacturing and assembly processes.

To find a position that allows me to use my experience and knowledge in machine design and

evaluation.

AREAS OF EXCELLANCE

SOLIDWORKS 2009

COSMOSWORKS 2009

M ATHCAD R14

ALTAIR/MOTIONVIEW V7.0

ADAMS V2005

ADAMS/Pre V11

HYPERMESH V7.0

nCode: nSoft Basic, Studio and ICE-flow GlyphWorks

MSC/NASTRAN V70.7 : Static, Modal,

Design Sensitivity & Optimization

Linear Transient Dynamics

Superelements

Non-Linear Analysis

IDEAS Simulation: Static, Modal,

Linear Transient Dynamic

MSC/AKUSMOD: Pre, Post Processor for acoustic analysis

M ATLAB R12

ALTAIR/OPTISTRUCT

ALTAIR/HYPERGRAPH

IDEAS MS6, CATIA V4.2.3

MSC/NVH_MANAGER

EXPERIENCE

04/2008 – 08/2009

Senior Analysis Engineer, Whiting Corporation, Monee, IL

Validated the design of the foundation legs of a motor based on the customer specified loading

conditions. All possible load cases were analyzed using SOLIDWORKS for modeling and

COSMOSWORKS for stress analysis.

Design optimization studies were done on a load girt of the trolley mounted on overhead crane. The

scope of the project was to reduce the weight of the load girt without reducing the structural integrity

of the assembly. Several designs were analyzed taking into considerat ion material availability and

manufacturing feasibility. A 28% reduction in weight with only 37% increase in stress was achieved in

the final design. COSMOSWORKS was used for the analysis.

Complete modeling and assembly of an overhead crane trolley in SOLIDWORKS was done without

any formal training in the software.

Design analysis of a lifting beam to check whether it can lift a weight of 200 Tons. The lifting beam

was modeled in SOLIDWORKS and analyzed using COSMOSWORKS. Several features like contact

between surfaces and bolt connectors were used for the first time. Found the design to be

inadequate. Suggested 4 different modifications to reduce the stresses taking into consideration

material availability and ease of manufacturing.

Analysis of trolley and bridge components of a 100 Ton crane to check if it can handle 108 Ton load.

All analysis was carried out using principles of machine design to analyze structural members,

weldments and bolted joints. Identified over stressed areas and suggested design modi fications to

handle the 108 Ton load.

Created MATHCAD documents for “Crane Skewing Force Analysis”. The existing handwritten

document was converted to MATHCAD documents. Three different documents were designed based

on availability of inputs. The documents increased the efficiency of the Crane Product Group

engineers. The documents were created without any formal training in MATHCAD.

Created MATHCAD document for “Fixed Bogie – Girder End Tie Design”. The existing handwritten

document was converted to MATHCAD document. This document aids in the design of the end ties

for girders, thereby increasing the efficiency of the Crane Product Group Engineers.

Carried out design analysis of a 150 Ton crane to check whether it can lift a 200 Ton load. A design

analysis was already carried out on a similar crane earlier. Design differences between the two

cranes were identified by studying drawings and bill of material. Where necessary components were

analyzed to determine the adequacy of the design. Identified over stres sed areas and suggested

design modifications to handle the 200 Ton load.

Carried out design analysis of a 50 Ton crane to check whether it can lift a 53 Ton load. Analysis was

carried out on the structural members, mechanical components, weldments and bolted joints.

Identified over stressed areas and suggested design modifications to handle the 53 Ton load.

Created a MATHCAD document for “Overhead Crane Girder Analysis” using CMAA #70 (Version

2004) Structural Design Guidelines.

W orked with Company’s Nuclear Division from May, 2009 to contribute to activities of the Division

based on experience as a Senior Mechanical Engineer. The following activities were successfully

carried out during my association with Nuclear Division.

Created a “Matrix of Comparison” between guidance given in NUREG 0554, ASME NOG-1 2004,

Nuclear Energy Institute’s NEI 08-05 Document; and Whiting Corporation Process and Competitor

Designs for the design, manufacture, testing and installation of a Single Failure Proof Crane. T his

Matrix was used to identify the areas in which Whiting Cranes need to be improved to make them

compliant with NUREG 0554 and ASME NOG-1.

Created a document “Features of a Single Failure Proof Crane for Compliance with NUREG 0554”

based on the knowledge gained during the creation of “Matrix of Comparison”. This document lists

the structural design, mechanical design, electrical design, testing and installation requirements for a

Single Failure Proof Crane Design.

Prepared Job Inquiry Data Sheets (JIDS) based on Request For Quotation received from Nuclear

Division customers. This involved understanding of customer needs/problems and outlining solutions

and estimating time and cost, based on which detailed Proposals can be developed.

Developed Proposals for Customer Projects based on JIDS.

Involved in Purchase Order Evaluation for Purchase Orders received from Customers. This work

involved comparison of Purchase Order with Proposal, creating work schedule, identifying project

documentation and deliverables and reviewing Terms and Conditions.

W orked on creating a “Design Document for Single Failure Proof Trolley” which will be compliant with

NUREG 0554, ASME NOG-1 and NUREG 0612.

W orked on creating a SOLIDWORKS Parametric Model for a trolley truck. The goal of the Project

was to create Design Tables, Weldment Cut Lists and linking SOLIDWORKS and MATHCAD.

05/2003 – 03/2008

CAE Engineer, Load Analysis Section at Chrysler

Developed a beam element based leaf spring model using Altair/Motionview. This is the first time

such a model was built at Chrysler. Such a model improves the prediction of suspension attachment

loads for leaf spring suspensions. The model can be used to build a variety of leaf spring

suspensions.

Successfully used the model to build the Leaf Spring Rear Suspension for Dodge Ram Truck and it

was analyzed using ADAMS V2005 for both static and dynamic loads. Compared the results from the

model with 3-link leaf spring model and measured data from proving grounds. The model gives good

results for chassis to suspension attachment points for vertical, fore/aft and lateral loads. Specifically

the lateral loads are better than 3-link leaf spring model. This work can eliminate 12 data channels in

a data acquisition vehicle, which can cost $1000 per data channel and also 5 weeks of time in

including these channels on the vehicle.

Presented a paper at the 2006 SAE World Congress on work done on the beam element based leaf

spring model.

Responsible for prediction of road load inputs to the frame, body and engine mounts using hybrid

loads analysis method developed by Chrysler. Durability assessment of the Vehicle program during

Design Phase is critically dependent on the accurate prediction of loads.

W ork involves suspension data collection and model building using Altair/Motionview, analysis using

ADAMS V2005 and results post processing using Matlab, nCode ICE-flow GlyphWorks.

Successfully completed road load predictions for Dakota, Dodge Ram Trucks, Durango, Dod ge Nitro,

Jeep Liberty, and Durango HEV programs. The predictions help to identify the effect of suspension

design changes and also to recommend design changes. More than 45 different projects have been

completed so far in a timely manner.

Jeep Commander front suspension upper ball joint contact to body and over travel study using hybrid

loads analysis method for both linear and non-linear suspension bushings. Found that ball joints do

not exceed over-travel limits and non-linear bushing rates are important for this type of study.

Identified power hop issues with new Dodge Ram trucks and suggested the design engineers to

modify the suspension design to eliminate the problem.

Identified the high frequency content in the diesel mount inputs for loads and creat ed a standard

procedure for filtering the data before using it for loads analysis.

Responsible for the complete load analysis support for Jeep Wrangler program. This work required

interaction with several Engineers from different departments.

Contributed expert knowledge to the Company’s Load Analysis Best Practices team, which is

developing best practices for different areas of road loads analysis. Created the Best Practice for load

and displacement results.

Served as team member of Design for Six Sigma Project on Suspension Component Load

Robustness. The objective of the team was to evaluate the sensitivity of the suspension component

loads to design tuning changes and manufacturing tolerances, wear and temperature effects. The

team suggested suspension design changes to improve the durability of a critical suspension

component by 50% without compromising on durability of other components.

10/2000 – 04/2003

CAE Engineer, Truck Road Load Engineering Section at Ford

Responsible for the prediction of road load inputs into the suspension and frame from different road

surfaces.

Used ADAMS/Pre V11 & ADAMS V11 to simulate both static and dynamic load cases.

Successfully completed road load predictions for Escape, Explorer, Explorer Sport Trac and F Seri es

Trucks.

Determined the critical design parameters and sensitivity of their variation on road loads using

ARLDOE for F Series Trucks. This work helped to reduce the number of prototypes for durability

testing from two to one.

Contributed to the development & implementation of new technologies in the field of Analytical Road

Loads. Some of the technologies are inclusion of flexible frame and body using ADAMS/Flex and

FEA based methods in Road Loads prediction.

Responsible for the implementation of static load cases derived from statistical studies on measured

proving ground road loads and making it the standard method of predicting road loads in the early

phase of design.

Responsible for development of MATLAB Routines used for Road Load data processin g.

CAE Engineer, Mahindra & Mahindra Ltd., Mumbai, India 5/1995- 8/2000

CAE Group Leader:

Responsible for evolving CAE work plans and allotting resources.

Responsible for the execution of CAE projects by CAE Service providers such as Altair Engi neering,

India.

Involved in price negotiations, data supply, frequent interaction and monitoring of work.

Gave presentations to Senior Management on CAE activities and prepared analysis status reports.

Provided guidance to colleagues.

Body Analysis:

Stiffness, modal and stress analysis of body structures both in untrimmed and trimmed condition

using MSC/Nastran. Completely responsible for integrating all the body components and sub -systems

into a whole body FE model.

W ell aware of stiffness targets and also targets for important body and body sub -system modes.

Frequency targets for trimmed body were obtained from the Modal Alignment Chart for the Vehicle.

Carried out stress analysis of trimmed body using Ford TVC load cases and MSC /Nastran Inertia

Relief Method. Modified designs of high stress areas to reduce stresses to target levels taking into

consideration manufacturing and design constrains based on inputs from design engineers.

Altair/Hypermesh was used for FE model building and results post processing.

Carried out weight optimization studies on Trimmed Body models using MSC/Nastran Design

Sensitivity and Optimization Analysis process, with global modes as design constrains. The work

resulted in weight savings of 8 kgs and Rupees 500.

Carried out Point Mobility Analysis on Trimmed Body models using MSC/Nastran Modal Frequency

Response analysis.

Modal analysis was carried out on the acoustic cavity model of the body developed using

MSC/Akusmod. This was a technology demonstrator project at the Company.

Complete responsibility for driving the design of new Utility Vehicle body structure through CAE.

W orked in Hawtal Whitting, U.K. on Concept & Feasibility phase of new Utility Vehicle as M & M's

CAE Specialist.

During the design & development phase of the new Utility Vehicle body, worked with body system

engineers to improve the overall body design within the manufacturing and assembly constrains, so

as to meet body NVH and durability performance targets.

Chassis Analysis:

Responsible for stiffness, modal and stress analysis of chassis of different vehicles.

Suggested design modifications wherever necessary to meet targets. Familiar with stiffness targets

and also frequency targets for important modes.

Responsible for Point Mobility analysis of chassis structure using MSC/Nastran Modal Frequency

Response analysis.

Analysis of closures:

Carried out stiffness and stress analysis of bonnet & doors using IDEAS Simulation software.

Modified designs using CAE inputs wherever required, taking into consideration the manufacturing

and assembly constrains.

Sub-system & Component Level Analysis:

Carried out stress analysis on spring hanger brackets, shock absorber brackets, engin e mounting

brackets, radiator support brackets, battery support brackets and HVAC mounting bracket using

IDEAS MS6 and MSC/Nastran.

Carried out brake pedal support area analysis and hand brake support area analysis and modified the

designs to meet design targets.

Carried out modal analysis of Steering Column & Instrument Panel using MSC/Nastran and modified

the designs wherever required to meet NVH targets.

Scientist 'B', Defense Research & Development Laboratory (DRDL), India 5/1991 - 5/1995

Developed FE based software using FORTRAN 77, for Free Vibration Analysis of missiles and used it

to predict a band of frequencies for different types of missile structures considering real life mass &

stiffness variations.

Developed a program using MATLAB to predict the response of missiles to harmonic loading. Used it

to predict angular velocity and transverse acceleration at sensor locations on missile structures,

which is a very useful data for Control System Design.

Developed software based on Flexibility Matrix approach to study the effect of flexibility of missiles on

aerodynamic loads. This technology was developed for the first time in the Company and was

successfully used on one missile project.

Prepared test plans for vibration testing of missile structures and components.

Analyzed and compared the results from the tests to validate the FE models developed. The FE

models were found to be accurate in determining the free body modes of the missile structures.

EDUCATION

Master of Engineering (Engineering Design)

PSG College of Technology, Coimbatore, India.

Thesis Work during Master of Engineering Program:

“Influence of joints and shear deformation on the dynamic response of aerospace vehicles”

PAPERS

“Beam Element Leaf Spring Suspension Model Development and Assessment Using Road Load Data”

Presented at 2006 SAE World Congress

Contact this candidate