Hi! This is Kalpak, a mechanical engineer and this is my project portfolio. Please do take a moment to go through my work! I am a masters graduate from Texas A&M University and am looking to work in the field of design and thermal engineering

1. Kalpak Mukund
Dhake
Mechanical Engineering Portfolio

2. About me
• A mechanical engineer obsessed with problem
solving and pragmatism. The realization that
problem is merely an opportunity to improve
quality of life has led me to develop
appreciation and passion for innovation and
smart design
• My goal is to continuously innovate while
learning to brainstorm solutions to such
problems starting from ideation to quantifying
parameter tradeoffs to prototyping
• Interested in contributing to developing
creative, innovative and sustainable products in
a cross functional team environment

3. Projects Timeline
1
Design of workout equipment for office spaces
2
Design and Economic Analysis of Large Scale Powerplant
3
Analysis of Pin Fin Heat Exchanger
4
FVM Solver Algorithm Development
5
Design and Analysis of Riser Pipe Inspection Tool
6
Capstone: Parametric Study & Prototype of Wind Turbine
7
Experimental Study of Emissions Characteristics
8
Numerical Study of Gas Atomization in Powder Production
Aug ‘19 - Dec ’19
Jan ’19 - May ‘19
Aug ‘18 - Dec ‘18
Jan ‘18 - May ‘18
Jan ‘18 - May ‘18
Nov ‘16 - May ‘17
May ‘16 - July ‘16
Nov ‘15 - Jan ‘16

4. Design of workout equipment for
office spaces
Opportunity: Design an ergonomic, compact and
customizable office space workout equipment which
can be used with existing office furniture let employees
to exercise at their desks
• A concise and exhaustive survey was conducted after
initial research. Data gathered from industry and
academic employees was next analyzed and a GANNT
chart was generated for a project roadmap
• The survey data was analyzed and the House of Quality
tool used to determine the interdependence of design
factors used to drive key design decisions. A strength
training application for an office chair was to be
developed
1
⚫⚪⚪⚪⚪⚪ | Team of 6

5. • A complete functional model was made to ease
highlighting and selecting key mechanism and
helped identify primary functions via brainstorming
tools such as mind mapping and affinity diagrams
• A morphological chart was created and decision
matrix was used to create a ranked list for the final
product idea by using different combinations
• A fitness tracking system was formulated to track the
progress of workout using sensors and use data to
incentivize healthier habits for employees
1
Detailed functional model
Requirements
Mechanical
Mass <50 lbs
Load <250 lbs
Physical
Dim: 6’ x 6’
Noise
OSHA
standard (<70
dB)
Stretching
mechanism
Connection to
sensor
Multiple
resistence
level
Safety
Instruction
set
MIL-STD-
142G, BIFMA/
ANSI
standards
Material
BIFMA
standards
Tracking
App
Compatibility
with fitness
applications
Functional
Multiple
muscle
groups
Chair motion
restriction

6. • The 3-D CAD model was generated in SolidWorks while
adhering to BIFMA regulations for equipment design
• First order and Back of envelope calculations were done to
ensure structural and mechanical functionality of the system
• Product benchmarking was performed against similar current
products by comparing engineering characteristics
1
Decision martix

7. • Manufacturing feasibility and material selection was done
for each component and product as a whole
• A BOM was generated for the product
• PFMEA was performed to identify potential failure modes
and causes
1
PFMEA matrix

8. Design and Economic Analysis of
Large Scale Powerplant
Opportunity: Design a powerplant from scratch for a large
university and perform economic analysis to determine
feasibility of final design
• Monthly energy data provided was analyzed and demand
generated for the facility
• H/P or heat to power ratio for the year was used to select the
appropriate prime mover to satisfy the demands for most of
the year which was found to be Gas Turbines.
⚫⚪ | Team of 2
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
1 2 3 4 5 6 7 8 9 10 11 12
H/Pratio
Month of the year
2
Cogeneration system configuration

9. • The PM was modeled in EES using manufacturer’s spec sheet data.
Method of energy recovery from the exhaust of the PM and other
components for satisfying the loads of the facility were fixed
• A Heat Recovery Steam Generator (HRSG) and absorption chiller were
selected based on the energy output. 5 configurations and their
resultant power levels were analyzed to select the best as the base
case via industry indicators like PURPA efficiency, thermal fraction etc.
0
5
10
15
20
25
Electricalpower(MW)
Average demand Design I Design II Design III Design IV Design V
0
5
10
15
20
25
30
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Thermalpower[MMBtu/hr]
Absorption chiller exhaust mass flow fraction, y
Cooling Heating Total thermal
2
Performance of designs
Base case T-S diagram
Resultant loads for design with Chiller

10. 8.0
9.5
11.0
12.5
14.0
15.5
17.0
18.5
20.0
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
0 5,000 10,000 15,000 20,000 25,000
NPV(106$)
PaybackandTimetoNPV=0
(years)
IRRandROI(%/3)
Gas turbine size (kW)
Payback Period Time to NPV = 0 IRR ROI NPV
• Economic report of the base case was generated based on
additional demand using financial parameters like pay back period,
net savings per year, NPV per year, tax rebates etc
• Sensitivity of design parameters to see effect on the performance
done
• Business model for ownership & financing with partnership
options ( Direct, third-party leasing and contracting) drafted
• Final design used a 7.5 MW turbine and utilized a HRSG for
cogeneration and yielded a pay back of 4.5 years
-15
-10
-5
0
5
10
15
20
25
-15 -10 -5 0 5 10 15
PercentagechangeinPayback
time(%)
Percentage change in parameter (%)
Gas turbine
efficiency
Exhaust mass flow
Exhaust gases
temperature
2
Sensitivity studyBusiness model for ownership

11. Analysis of Pin Fin Heat Exchanger
Opportunity: Find the best type of analysis for a given PFHX
and develop an app to optimize PFHX parameter selection
• An air-cooled PFHX array was analyzed three ways: using
simple pin fin method and bank of tubes method which
were compared with base case numerical simulations
• An n-factorial Design of Experiment study was formulated
by varying the fin configuration (transverse-longitudinal), fin
size and flow rates
⚫⚪⚪ | Team of 3
3

12. • The base plate + fin geometry were generated using SolidWorks design table using fixed constraints on
the model
• Numerical analysis was performed using medium meshes and results were post processed while all
output parameters were mass averaged
• Fin analysis was done using operating conditions for a single fin and then extrapolated for rest of the
array
• Bank of tubes theory analyses were performed by using existing Nusselt number correlations for both
configurations of tubes.
𝑇1 𝑇2 𝑇3 𝑇𝑜𝑢𝑡𝑇𝑖𝑛
𝑄 𝑓𝑖𝑛
ሶ𝑚, 𝑇𝑖𝑛
ሶ𝑚, 𝑇𝑜𝑢𝑡
3

13. • As the ratio of fin spacing to fin decreases and mass flow rate
increases, the models diverge
• A simple Matlab app was developed which used the data
generated by the DoE and user input regarding base plate
geometry and inlet conditions to generate the optimum PHFX
array configuration and pressure drop as a result of it
3
Error plots for each configuration

14. FVM solver algorithm development
⚫ | Individual
Opportunity: Develop a program using the Semi Implicit Method
for Pressure Linked Equations (SIMPLE) algorithm to solve 2D
thermo-fluidic problems
• The step by step algorithm formulation started with 1D steady
state FVM program to predict temperature distribution for a
sample geometry
• A Gauss-Seidel method to declare convergence for the
numerical solution was used to determine the optimum over
relaxation factor
• A 2D FVM program with energy equation solving capability
using a 2D sweeping method was added
4

15. • The program built further to simulate 2D laminar flow
through parallel plates
• The classical lid driven cavity was used as the next test case
to further develop the solver by using different mesh sizes
and a grid convergence study. Results were validated with
literature
• Final test case used a heated downstream facing step and
calculate reattachment length for the flow for different
Reynolds numbers.
Reynolds
Number
Calculated
Reattachment
Length (Xr/h)
(Xr/h) from
reference
paper
100 3.38 3.71
200 6.00 6.04
300 7.50 8.36
4
Plots for benchmarking program with literature

16. Design & Analysis of a Subsea Flexible Pipe Riser Internal
Inspection Tool
Opportunity: Design a manufacturable internal inspection tool to detect damage or corrosion in flexible subsea pipe
risers to fit bended pipes of variable diameter and hydraulically powered
⚫⚪⚪ | Team of 3

17. • Initial design review involved selection of driver system and tool
geometry to ensure it can navigate the 20-D bend
• A wheel driven design selected and power generation was done by a
positive displace mud-motor used in directional drilling operation
5
Hydraulic
hose
Rotor
Riser
Mud motor design and power flow

18. • Powered wheel-track system was designed on both ends with a
spring assembly in the middle to ensure right amount of “downforce”
on the wheels to account for the variable ID of the pipe
• An ultrasonic sensor for pipe anomaly detection was chosen to be
kept inside a industrial grade IP5X housing to find the position of
pitting, cracking, stripping, breaking, buckling or other anomalies in
the metallic riser walls
5
Driver design

19. • Alloy 825, a Nickel Iron Chromium alloy with Titanium, Copper and
Molybdenum added, specifically made to give superior resistance in
corrosive oxidizing and reducing environments
• Critical parts for structural analysis were identified and a grid
convergent FEA study was performed on these parts using operating
conditions calculated from first order calculations. The components
were found to be operating well within the FOS specified
5
Structural FEA on critical components

20. Parametric Study & Prototype of Wind Turbine
Opportunity: Perform a parametric study and 3D print a prototype of a
small scale wind turbine (SSWT) to be used to power electronic devices
such as a mobile phone, laptop etc
• The capstone project started with literature review of required turbine
blade and airfoil design along with the required application for this low
Reynolds number case
• Blade Element Theory was used to used to finalize the 3 chord design
equations design using which the nonlinear chord and twist profiles
were generated
⚫⚪⚪ | Team of 3
6

21. • The turbine blades were designed using CATIA modeling software
• The rotor assembly was manufactured using VeroPlastic material
and FDM method of additive manufacturing
• During field tests, When the three turbine blades with a tip-
speed ratio of 6 are exposed to the wind (industrial fan) with a
free stream velocity within 3-8m/s, the setup produces voltage in
the range of 2V-8V and current in the range of 0.05-0.15A which
satisfies the intended application
0.13
0.09
0.07
0.06
0.05
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
5 10 15 20 25
Current(A)
Resistance (ohm)
Current vs Load Resistance at 700rpm
0.11
0.12
0.14
0.17
0.2
0
0.05
0.1
0.15
0.2
0.25
600 700 800 900 1000
Current(A)
Rotational speed (rpm)
Current vs Speed at 3 ohm
6
0
1
2
3
4
5
6
7
200 400 600 800 1000 1200
Voltage
RPM
Voltage vs RPM
Turbine output w.r.t electricity measured

22. Experimental Study of Emissions
Characteristics
Opportunity: Experimentation of Envirofit PCS-1 natural draft cook stove and The Philips HD4012
forced draft cook
• A research project which consisted of conducting controlled tests on both cook stoves. Central
Composite Design (CCD) method of DoE was used to design a set of tests for collecting data which
show dynamic performance of cook stove to the variation of firepower, fuel size, vessel size
⚫ | Individual
H
2
3
4
5
72
03
2
33
2
3
52
02
15
10
5
33
63
iffE
eziSleuF
rewoPeriF
urface Plot of Effi vs Fuel SiS e, Fire Powerz
7
Surface plot of efficiency vs Fuel size vs power

23. • Data collected was bulk mean temperature of water,
ambient moisture level, flue gas spectroscopy and PM
collected using a cyclone collector and all systems were
connected to a DAS
• Tests were conducted while adhering to BIS standards to
ensure repeatable and relevant data for different power
levels, fuel size and firing frequency and surface plots were
generated
• A preliminary mathematical model was developed to
determine the thermal response constant of the systems
Fuel Size15.5
Hold Values
2
3
4
5
3
4
5
10.0
5.7
0.5
5
5.21
10.0
6
OC
ycneuqerF
rewoPeriF
urface Plot of COS s Frequency, Fire Powerv
7
Surface plot of CO level vs Fuel size vs frequency
Real time PM measured data

24. Numerical Study of Gas Atomization
in Powder Production
Opportunity: Numerical analysis of annular nozzle in for liquid tin powder
production
• A CAD model was developed using machine drawings of the component in
ANSYS workbench followed by imparting the right boundary conditions for
numerical model and post processing
• Once hydrodynamic and temperature results were obtained, they were
compared with the experimental data collected in the physical system and its
error analyzed
⚫ | Individual
8

25. Thank you for your time!