RAJNISH KUMAR

Project Portfolio Link: thttps://skill-lync.com/profiles/rajnish-kumar-459

Mob. No: +917985473146 |E-mail: rajnish025@gmail.com |Add: Pune Maharashtra-431002

Objective
Looking for Full-Time Design & Development Engineer opportunities in Research & Development CAD domain with a special
interest in Plastics trim Interior & Exterior, Sheet metal and BIW Design using CATIA V5 & NX11.0 in the Automotive industry

Education
Design Engineer Master’s Program, Online Industry Relevant Project Skill – Lync. Jun 2020 – Present
B.Tech, Manufacturing Technology, A.P.J.T University– Lucknow (73.86%) 2019
Post Diploma, Tool Design & CAD/CAM, IGTR– Aurangabad (69.61%) 2015
Diploma, Plastics Mould Technology, CIPET – Aurangabad (83%) 2012
Experience
LG Electronics India Pvt. Ltd, Pune Sep 2020 – Present
Engineer: New Product Development Plastics & Sheet Metal Parts for Refrigerator Body in R& D Department.
Responsibilities:
 Developing the New Refrigerator Model in Structure Part Design& Development Plastics & Sheet Metal Part.
 3D and 2D Drawing of New & Existing Plastics & Sheet Metal Parts Design for each Models Using NX-11.
 Design of Plastics Parts Duct Multi, Grill Fan, Guide Rail, and Handle Décor in Change the Thickness, Ribs, Slots etc.
 Design of Sheet Metal Parts Centre Plate, Bottom Plate, Lower Plate, Reinforcement, and Cabinet as per Requirement.
 Development of New Condenser and Modification in Case Inner for Structural and Energy Improvement in Models.
 Taken Trail Design Validation for New Parts Development Fitment during Product Assembly at Manufacturing Line.
 First Parts Approval (FPA) Activities for New Design Implementation in Parts Modification.
 Preparing ECN, DRBFM, and FMEA for the Change in New Parts Development.
Achievement:
 Make New Prototype for Grill Fan Plastics Parts in which Change Streep Length, Side Gap and Air Exhaust Angle.
 New Development Duct Multi-Plastics Parts in which change Cover Filter supporting C Slot Height for base Strength of Parts
 Development of Guide Rail Plastics Parts in Change HIPS to PP Material due to Control Plastics-Deformation during Sliding.
Force Motor Ltd, Pune Jul 2015 – Jun 2016
Engineer Trainee: Design of Jigs & Fixture for Real Axle Parts for Trax, T1, and Tractor in PE Department.
Responsibilities:
 Design Development and Assembly Jigs & Fixtures for Front and Rear Axle Transmission Parts using CATIA V5.
 3D-Modeling 2D Drawing Jigs & Fixtures for Front & Rear Axle Parts Rear Axle Housing, Tubes, and Stub Axle tubes.
 Modification in Fixtures Plate Locating and Clamping for Mounting Brackets U, L & I Types at Axle Parts Assembly.
 Taken Trail-out Jig and Fixtures for Proper Parts Fitment with Front and Rear Axle Parts during Machining Operation.
 Prepare Process Parts Sheets for Design, Manufacturing and Assembly of Jigs & Fixtures for Front Rear Axle Parts
 Research New Methods, Materials Handling, Processes and Parts Assembly for Reduce the Cost of the Product.
 Organize and Maintain Existing Engineering Records, Preparation of BOM, SAP & Part Catalogue for Rear Axle Parts
Achievement:
 Completed the Project Backing System 4x4 in Traveller 22 Setter and Trax Cruise.
 Development of Chip-Formation Fixtures for Machining of Rear Axle Hosing and Differential Housing Parts.
 Design New Fixture for Rear Axle Assembly Parts Axle Housing, Pinion Bevel Gear, Pins, Axle, Differential Case.
Cosmo Films Ltd, Aurangabad Nov 2012 – Jun 2014
Assistant Production: BOPP Films in Production Department.
Project: Installation of Extrusion Machine Manufacturing of BOPP Films for Food Packaging.
Responsibilities:
 Installation of Films Extrusion Machine Installs Hydraulic & Pneumatic Circuit in TDO & MDO Zones.
 Handled the Controlling Parameters Extruders Zone, Chill Roll Cooling Zone, Die Lips Zone and Die Bolts Torque.
 Process Changeover New Product Parameter Material Change, Machine Temperature and Cooling Zone Change.
 Filter Change and Cleaning of Main Extruder and Co- Extruder as per New Product Requirement
Achievement:
 Completed the Project Installed Bruckner Extrusion Machine and Started Manufacturing of BOPP Films.
 Reduced Trouble Shooting Defect in Manufacturing of BOPP Films During Production.
 Maintained the Production Targets and Quality of BOPP Films During Production.
Automotive Industrial Projects
Body-In-White Design Jun 2020 – Present
Hood Design
 Designed Hood Inner Panel as per Euro NCAP Regulations. Took into account the Forces Dissipated by Frontal
Crash & Pedestrian Crash Safety & Developed Embosses Accordingly.
 Designed Appropriate Hinge, Latch & Striker Reinforcement. Based on Hinge Axis determined the Latch and Striker
 Took into Account the Manufacturing Process & Incorporated Appropriate Tool Tolerance for Stamping and
Hemming Requirements in the Design.
Front Fender Design
 Based on styling Data of Fender, Determined the Side Reference line to define Respective Wrap-Around or Wrap-in Hood.
 Designed different Mounting flanges like Sill, A-Piller, Bumper, Baffle, Body and Drip Mounting.Designed a front
fender using the stylish surface as my input and checked stylish surface as the European standard regulation.
 Consider the designed parameter & calculate the section modulus of the Hood.
Roof Design
 Designed Ditch Area to Join the Roof with the Body Side. Considered Heat Distortion Criteria, Snow Load criteria & thereby
calculating the number of Bow Roofs required & the Position of Bow Roofs.
 Designed Front Roof Rail, Centre Roof Rail & Rear Roof Rail Reinforcements by considering the Front & Rear view criteria.
Backdoor Design
 Followed the Design Methodology & Designed Tailgate Inner Panel, Emboss Definition, Hinge & Latch Placement.
 Incorporated Design of Sealing Flange, Determined Gas stay Position & Designed Gas stay Reinforcements.
 Considered & Designed Rear Wiper Mount & Back Door Trim Part as per requirement.
Advanced Sheet Metal Design
Design of Casing & Box Assembly
 Designed of Casing by considering the Functional Requirements & its Application, Dimple & Beads added for Strengthening
of the Casing.
 Designed of Box with Opening & Closing lid. Link also designed to attach the Box with lid & for the easy Operation.
Design of Odd Shaped Parts
 In Industry there are some Parts having very Odd Shapes & which are not suitable in Sheet Metal Working due to its Shape.
Worked on this kind of Part & Learnt the Workflow to convert that part to Suit the Sheet Metal Environment by using some
Advanced Sheet Metal Commands.
Plastics Trim Design
B-Pillar of the car (Interior Trim)
 The given A-surface was checked for sharp edges and errors and, the Tooling direction for A-surface was created
 B-surface, C-surface, and Engineering Features (Ribs, Dog House, 4-Way Locator) were created according to the given
Master section with design guidelines of OEMs.
 Draft analysis on the body was studied to check the manufacturing feasibility of the plastic body and the attachment features.
Car Door Trim Panel (Plastic trim)
 Segregated the given surfaces into A-surfaces of door panel components (Map Pocket, Map pocket lower part, Lower
Substrate, Arm Rest) and checked for sharp edges and errors.
 A-surface components were gone through feasibility check and tooling axis were created for every component and sliding
axis for required components and Draft analysis of A-surface of different components was studied.
 Created B-surface and C-surface and created Engineering Features (Flanges, Heat stakes, Doghouse’s with Push clip, Screw
Bosses) according to the master section with design guidelines of OEMs.
Inner Fender Cover (Exterior Trim)
 Design of Inner Fender Satisfied Manufacturing Recruitment Gap Calculation of Wheel Arch between Car Body to Inner
Fender Mounting Location and Martial ABS Wall Thickness 1.5mm & Draft Angle 5 Degree and use Design Features Ribs,
Fillet and Holes for Improving Strengths and Reduce Weight Parts.
Inner Side Door (Plastic trim)
 Design of plastics inner side door trim considering manufacturing requirement martial Nylon wall thickness 1.8 mm and the
rest of the features are various thickness and draft angle 3 degree with smooth surface and
 Design & development of Bosses, Rib, Draft angle, Snap fitting, Wall thickness and Under-cut in Inner Side Door

Geometric Dimensioning and Tolerance

 Using the NX Modelling I Created Butterfly Valve and their components like lever, Disc, Nut, shaft, Retainer. Drafted of the
butterfly Valve and applied Geometric Tolerance, Geometric feature, MMC & LMC conditions at required Point.
Software Packages
▪ Modelling: CATIA V5, UG NX11.0, and AutoCAD ▪ Statistical Data Analysis: Minitab, EES, MS-Excel