RESUME

SUNIL KUMAR D
Mobile: 8618399987
E-mail: sunilkumar959151@gmail.com

OBJECTIVE
A result oriented Mechanical Engineer (FEA Domain) with 6 years 1 months Experience in the
Design and Analysis of Aerospace/Automotive components/Industrial Applications Industries.
PROFESSIONAL EXPERIENCE SUMMARY

CURRENT EXPERIENCE:
Position: Business Analyst as FEA Engineer
Employer: GENPACT INDIA PVT LTD, Bangalore.
Client: GE-AVIATION
Duration: June 2021

PREVIOUS EXPERIENCE:
Position: FEA Engineer
Duration: Aug 2019 to March 2021
Employer: FLOWSERVE, Bangalore.

PREVIOUS EXPERIENCE:
Position: Senior Associate as FEA Engineer
Employer: GENPACT INDIA PVT LTD, Bangalore.
Client: GE-AVIATION
Duration: Dec 2017 to July 2019

PREVIOUS EXPERIENCE:
Position: CAE Engineer
Duration: Jun 2016 to Nov 2017
Employer: NOVA GLOBAL TECHNOSOFT PVT LTD, Bangalore.

Key skills:
CAE tools: ANSYSWORKBENCH, HYPERMESH & ANSYS Classic
CAD tools: Solid Edge, Catia & NX Cad

TECHNICAL PROFICIENCY:

➢ Expertise in the structural and Vibration Analysis

➢ In depth knowledge of FEA of Mechanical Components
➢ Proficiency in ANSYS with a good knowledge of preprocessing, solution and post processing with
Performing modal, structural and nonlinear Analysis
➢ Proficiency in HYPERMESH for Finite Element Modeling with Shell Mesh, Solid Hexahedral/Tetrahedral
Mesh, and Hybrid (HEXA &TET) Combination Mesh.
➢ Sounds knowledge in Mechanical Engineering Fundamental like Engineering Mechanics, Fatigue and Fracture
Mechanics
Key Projects:

➢ GE-9X Engine support system components

➢ GE-Marine Engine support system components
➢ GE-Leap Engine support system components
➢ GE- Catalyst Engine support system Components
➢ FLOWSERVE Pump and value componets

Current Roles & Responsibilities:

➢ Providing support to GE-Aviation in design validation of Gas turbine and external engine system components.
➢ Product design using combination of analytical skills, CAD and CAE tools
➢ The CAD models are de- featured i.e. Geometry cleanup
➢ FE Modeling of various components, viz. Ducts, Fittings, Support panels, Tubes, Valves, supporting brackets,
Composite Brackets and Flanges of Aero Engine components using ANSYS and Hypermesh
➢ A Quality check has been done for the mesh with T‟ connections and free edges are checked
➢ Materials properties, Thickness and Boundary conditions are assigned as specified by the clients
➢ Performing the Modal, LCF, HCF and Static Analysis
➢ Interaction with the clients and understanding intended requirements.
➢ Preparation of detailed Stress report and indicating the appropriate design changes.

Previous Roles & Responsibilities:

➢ Providing Global support to FLOWSERVE in design and Analysis of PUMPS and VALVES.
➢ Product design using combination of analytical skills, CAD and CAE tools
➢ The CAD models are de- featured i.e. Geometry cleanup
➢ FE Modeling of various components, Pump components using ANSYS and Creo Simulation
➢ Materials properties, Loads and Boundary conditions are Assigned
➢ Performing the Modal, Static and lifting Analysis
➢ Design Modification Pumps as per API standards
➢ Interaction with the clients and understanding intended design modification requirements.
➢ Preparation of detailed Stress report and indicating the appropriate design changes.

DETAILED ANALYSIS OF PROJECTS

I. THERMO STRUCTURAL ANALYSIS OF IC ENGINEBLOCK

1. MESHING:HYPERMESH
➢ Geometry clean-up was done in HM
➢ Higher order meshing is done to capture fillets & min 3 elements across the fin thickness was considered
➢ A Quality check has been made on the mesh for jacobian,warpages, skew angle and aspect ratio
➢ Volume mesh (higher order tetrahedrons) is created and quality check on 3D elements Tet collapse is doneand
„T‟ connection and free edges are checked for 2D and 3D model
➢ The mesh is exported to ANSYS as *.cdb file with SOLID 187element
➢ Nodal collectors are created in HM, which are required for thermal analysis.
2. THERMAL ANALYSIS:ANSYS CLASSIC
➢ Ic engine block meshing read into ANSYS, free nodes and free elements are checked
➢ For thermal analysis ,ANSYS structural elements are switched to thermal elements
➢ Heat flux is applied at the inside of the IC engine block
➢ Heat transfer coefficient is applied at the exterior surface of the engine block
➢ IC engine block is applied with Aluminum thermal properties
➢ Model is solved and thermal results are obtained.
3. LINEAR STATIC ANALYSIS:ANSYS CLASSIC
➢ Convergence study is carried out on a bracket with fillet and the IC engine block is meshed with result an mesh size
obtained from the convergence study
➢ ANSYS structural model(solid187) is applied with the generated thermal results
➢ Proper material properties are applied into the model
➢ Engine is fixed in all DOF‟ at the bolt mounting location
➢ Stresses are observed at the fillet location and are compared against the material allowable limits
➢ Observed stresses are more than the material yield limit of 324MPa
➢ It is decided to carry out sub modeling analysis for better capture of stresses at the observed critical region.
4. SUBMODELING ANALYSIS: HYPERMESH AND ANSYS CLASSIC
➢ Sub model split is done away from the critical zone as per the st,Venant‟sprinciple
➢ Thermal mapping is carried out to apply temperatures from thermal results file
➢ Thermal plots of sub model and global model are compared
➢ Cut boundary displacements are taken from the (structural global model) linear analysis results
➢ The cut boundary displacements are applied at all the cut faces in the sub model
➢ It is observed that the stresses are more than material yield limit of 324MPa at the critical zone
➢ Further to capture strain at the critical location, material non-linearity analysis carried out.
5. MATERIAL NONLINEAR ANALYSIS:ANSYS CLASSIC
➢ Sub model is applied with the stress strain curve in ANSYS with TBDATA
➢ Stress strain information is applied as MISO(multi linear isotropic) material information
➢ ANSYS default solver (Sparse) is used
➢ The observed strain is less than the materials percentage elongation limit of 13%.
6. BOLTED FLANGE MODELING: HYPERMESH,ANSYSCLASSIC
➢ Bolts and nuts are assembled in IC engine bolt hole location
➢ Bolt and nut are Mesh with higher order hexahedral Solid186 element
➢ Pretension element 179 is created at the bolt shank in ANSYS
➢ Preload is calculated based on materials yield limit
➢ The calculated preload is applied at the pretension section
➢ Surface to surface contacts (standard) are created between bolt head to flange and nut to flange
surface Also friction is provided in the model
➢ Contact element type174 and target170 are created and contact normal’s are checked
EDUCATIONDETAILS:

CLASS DISCIPLINE UNIVERSITY/BOARD SCHOOL/COLLEGE SCORE

(%)

MTech ENGINEERING VTU,Belgaum MVJCollegeofEngineeringB 71.04

ANALYSISAND angalore
DESIGN
B. E MECHANICAL VTU,Belgaum EastPointCollegeofEngineeringandTe
chnology,Bangalore 70.0
XII PCMB Karnatakapre-university Vijayapre-UniversityCollege,
board Bangalore 61.33
X SSLC Karnatakastateboard Citizen High
School,HoskoteBangalore(R) 79.20

DECLARATION:
I consider myself familiar with Mechanical Engineering aspects. I am also confident of my ability to
work in a team. I hereby declare that the information furnished above is true to the best of
myknowledge

DATE :
PLACE: Bangalore (SUNIL KUMAR D)