Projects and CAD models

1. Engineering and Design
Portfolio
VINAY VIJAYAKUMAR

2. Engine gasket simulation
and design modification for
improved performance
• Project Objective: Simulation and
modeling of the engine rubber gasket
when the initial geometry and test data
are given. The whole project is divided
into 3 tasks: First, determining the
hyper-elastic material model which
gives the best curve fit. Second, non-
linear FEA of the initial geometry and
analysis of the stress and pressure
plots. Third, modifying the design to
achieve uniform contact pressure and
reduced gap.
• COURSE : EGM 6352 – Advanced FEA
Jan 2017- May 2017. The course deals
with advanced topics in Finite Element
Modeling with emphasis on non-linear
problems, contact problems and the
tools learnt can be used for design,
analysis and optimization of
engineering systems.

3. Material model selection based on
the test data and optimization
• The unknown coefficients of the
material model under
consideration – Mooney Rivlin
model and Ogden model were
determined from the test data.
• Curve fitting was carried out to
find material constants, such that
the difference between measured
stress and calculated stress is
minimized
• Overall error for the three tests
were compared and final material
model was selected.

4. Original Design stress and pressure
analysis
• Utilizing ABAQUS, the original
design is constructed and CAE
analysis was done with the given
boundary conditions and load.
• Convergence analysis was also
carried out and after determining
the optimum mesh size, the plots
were generated for hydrostatic
pressure, contact pressure
distribution, Von Mises stress and
load displacement curve.

5. Modified design analysis
• The design was modified, boundary
conditions were set, and mesh
refinement carried out.
• CAE analysis was done to
determine the new pressure
distribution, Von Mises stress and the
load displacement curve.

6. Comparison and Results
• Achieved better load distribution.
• Ensured lesser chances of failure
of over-stressed elements since
the Von Mises stress was lower
than that of the uniaxial tension
yield stress of rubber
• Reduced the distance ‘d’ between
side wall of the gasket and hence
achieved better sealing.

7. FORMULA SAE
• Objective: To conceive, design and
fabricate a formula type car from
scratch following the design
constraints as per the official rule
book and compete with other
formula style cars. Students are to
assume that a manufacturing firm
has engaged them to produce a
prototype car for evaluation as a
production item.

8. Design and Analysis
• As a part of the Suspension and
steering system design team, I was
involved in the design and analysis of
the suspension components : A-arms,
knuckle, tie-rod etc.
• 3D models were created in CATIA
V5 and stress, thermal and maximum
deflection analysis was done using
ANSYS.
• Dynamic analysis was carried out
using ADAMS.

9. Fabrication and
Testing
• Carried out fabrication in-house in
the college workshop.
• Gained valuable hands-on
fabrication, machining, welding and
problem solving experience.
• Worked with great team spirit.

10. Final Events and
Race
• Led the team in the final event held
at the Buddha International Circuit
(B.I.C), Greater Noida.
• Cleared all the technical inspection
rounds, skid-pad test, autocross tests
and competed in the final race.
• Finished 1st in East Zone, 3rd in
skid-pad test, 5th in Marketing and 6th
in Engineering design.

11. Simulation of deep
drawing process
• OBJECTIVE: To simulate the deep
drawing process which is involved in
the manufacturing of the sheet
metal components. The simulation
was carried out for solid and shell
elements and for two different
holder forces and the results and
comparisons documented.
COURSE : EGM 6352 – Advanced FEA
Jan 2017- May 2017. The course
deals with advanced topics in Finite
Element Modeling with emphasis on
non-linear problems, contact
problems and the tools learnt can be
used for design, analysis and
optimization of engineering systems.

12. Solid Element and Shell
Element
• The FE analysis was carried out
for the blank using the C3D8 solid
model.
• Von mises stress, plastic strain
and the deformation(before and
after the punch stroke) was
plotted for the two holder forces.
• The same process was repeated
for the Shell element(S4) and the
respective plots were generated.

13. Comparison
• Stresses are compared for both
shell and solid element and it was
determined that the blank
experienced more stress when
modelled as solid as compared to
shell.
• Plastic strain accumulation was also
determined to be higher in case of
shell and less for solid element.
• For lesser holder force the
deformation was more bending
dominant and for higher holder
force the deformation was tension
dominant.

14. Study and testing of
suspension system of
motorbikes
• Objective: To study the
suspension systems used in
motorbikes and scooters, to gain an
understanding of the suspension of
the existing HERO models and to test
the stiffness and damping
characteristics of 4 existing models.
• Simulation Project done at the
Component Testing wing of R&D of
the Dharuhera plant, Hero MotoCorp
Ltd.

15. Various suspension
system of motorbikes
• The front and rear suspension types
commonly used in the motorbikes
were studied.
• The existing front fork and rear
cushion were disassembled and their
functionality and working was
analyzed.

16. Testing of the front fork
and rear cushion
• The front and rear cushion of 4
different models were tested.
• Stiffness tests were conducted using
two different modes-displacement and
force modes. Damping characteristics
were also tested.
• The final values were documented and
compared w.r.t the standard values for
the respective engine displacement
segment they belonged to.

17. Snapshots of CAD Models