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Resume Sunil

Sunil Kumar is a mechanical engineer with over 6 years of experience in finite element analysis (FEA). He has worked for multiple companies analyzing aerospace, automotive, and industrial components. Currently, he is a business analyst performing FEA for GE Aviation through Genpact. His skills include using ANSYS Workbench, HyperMesh, and CAD tools. He has expertise in structural analysis, vibrations, and modeling techniques like meshing. Representative projects include analyzing components for the GE9X, GE Marine, GE Leap, and GE Catalyst engines.

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110 views4 pages

Resume Sunil

Sunil Kumar is a mechanical engineer with over 6 years of experience in finite element analysis (FEA). He has worked for multiple companies analyzing aerospace, automotive, and industrial components. Currently, he is a business analyst performing FEA for GE Aviation through Genpact. His skills include using ANSYS Workbench, HyperMesh, and CAD tools. He has expertise in structural analysis, vibrations, and modeling techniques like meshing. Representative projects include analyzing components for the GE9X, GE Marine, GE Leap, and GE Catalyst engines.

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suni7d
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RESUME

SUNIL KUMAR D
Mobile: 8618399987
E-mail: [email protected]

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)

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