Resume - CAE Durability Engineer

1. SAI SNEHITH KODURU
Sterling Heights, MI| (815)517-6196 | snehithsai@gmail.com
PROFESSIONAL SUMMARY
A result oriented CAE engineer with four and half years of industry experience in the Chassis Durability analysis of automotive components. Ability
to apply CAE skills effectively to evaluate the performance of machine components and optimize their designs. An excellent team player with
polished organization, communication and presentation skills.
EDUCATION
Master of Science in Industrial and Systems Engineering August 2015-December 2016
Northern Illinois University, DeKalb, IL GPA: 3.6/4.0
Bachelor of Technology in Mechanical Engineering October 2007-June 2011
Jawaharlal Nehru Technological University, Hyderabad, India GPA: 3.5/4.0
COURSEWORK
Finite Element Analysis Theory of Machines Design of Machine Members
Advance Quality Control Lean Manufacturing Systems Solid Mechanics
Engineering Project Management Six Sigma Manufacturing Technology
Advance Production and Planning Control Machine Tools Economic Analysis
SKILL SET
Design Tools: CATIA, Auto CAD, Altair Inspire, SolidWorks
CAE/FEA Tools: ANSA, Hypermesh, Hyperview, Hypergaph, Simlab, Abaqus, Nastran, MSC Patran, Optistruct
Statistical Tool: Minitab
Operating System : Windows and Linux
Microsoft Tools : MS Excel, MS PowerPoint, MS Word
WORK EXPERIENCE
Application Engineer Intern (CAE) June 2016-Present
Altair Engineering, Troy, MI
 Supported engineers in OEMs in solving the queries related to Hypermesh, Hyperview and Hypergraph
 Trained in performing optimization of components using Optistruct
 Performed linear and non-linear finite element analysis (FEA) for Durability and NVH using Optistruct
 Assisted software development team for developing innovative options for Hypermesh
 Maintained the database of different queries and solutions which helped the support team to respond quickly
Research Engineer, Chassis Durability
4+ Years of Experience in Computer Aided Engineering (CAE) October 2011-July 2015
Hyundai Motor India Engineering (R&D), Hyderabad, India
 Performed finite element meshing and applied boundary, loading conditions using preprocessor Hypermesh for chassis components
 Analyzed the results involving von-mises stress, forces and displacement using Hyperview post processor
 Plotted curves and graphs of the result data using data analysis tool Hypergraph for Durability and NVH analysis
 Conducted structural analysis of various automotive components
 Performed fatigue cycle count analyses
 Handled projects related to NVH, Strength and Stiffness analyses of Chassis components
 Worked closely with the product development teams and provide CAE support to validate the designs
 Recommend design improvements based on CAE results
 Optimized designs to improve vehicle chassis durability by reducing fatigue and failure commonly found around weld regions
 Reduced the mass of the road alloy wheel by 10% which significantly minimized the overall vehicle mass criteria
 Assisted design teamwith various projects for developing vehicle chassis at different design stages
 Maintained the database of different projects which was useful in reducing modeling time and comparing vehicles of different platforms
 Proposed cost reduction techniques without compromising on the quality of the component to the design teams for road alloy wheel, engine
mounting bracket, steering housing, and suspension parts
 Developed Standard Operating Procedures (SOP) for CAE analysis of Automotive Chassis components
 Created comprehensive presentations to report results obtained and conclusions to the higher management
 Trained new employees in the use of Hyperworks software relevant to work projects
PROFESSIONAL PROJECTS
Cornering and Radial Fatigue test for Steel Road Wheel
Tools: Hypermesh, Abaqus, Msc Fatigue, Hyperview
 Steel wheel is meshed with provided durability quality and standards
 Different boundary and loading conditions are assigned for cornering and radial (compressive) fatigue test respectively
 Strength analysis is carried out using Abaqus and stress values are determined
 Results obtained are used for performing fatigue life analysis and corresponding Safety Factor is calculated to check whether the steel wheel is
meeting the desired quality criteria
Non-linear analysis of Impact and Rim Deflection of Road Alloy Wheel
Tools: Hypermesh, Abaqus, Hyperview
 Alloy wheel is tetra meshed by following the meshing requirements with durability quality and standards
 Contacts are generated between barrier, wheel and striker
 Impact load is applied on the barrier and the corresponding impact safety factor is determined for the wheel
 Load is applied in the Y direction on the striker which hits the wheel and the permanent deformation of the rim is determined

2. Structural analysis of Stabilizing bar and Brake pedal
Tools: Hypermesh, Abaqus, Hyperview
 Stab bar and Brake pedal are meshed with Hexa elements by following modeling guidelines
 Rigids, Constraints are created and loads are applied as per the requirements
 Structural analysis is performed and corresponding stresses and displacements are determined for stab bar and Brake pedal
Non-linear Full Turn Impact Analysis of Steering System
Tools: Hypermesh, Abaqus, Hyperview
 Structural analysis is conducted of Housing, Rack, Tie-Rod and Tie-end of Steering System
 Strength and Stiffness of the Steering components are determined
 Also Rack is checked for its intersection with the housing when the impact load is applied on the Road Wheel when it is in the full turn condition
Normal mode and Dynamic stiffness analysis (NVH)
Tools: Hypermesh, Nastran, Hyperview, Hypergraph
 Normal mode analysis is conducted to check for modeling connectivity problems and determine mode shapes, frequency of various chassis
structures
 Dynamic performance of Road Alloy Wheel is conducted and its frequency response is determined after exciting at the required point
Optimization of Engine Mounting Support Bracket (EMSB)
Tools: Hypermesh, Optistruct, Hyperview
 Structural design changes are applied for the EMSB which was failing in strength and fatigue analysis earlier
 EMSB is optimized without increasing in its original mass and structural analysis is conducted on it
 New design of EMSB is passing the required criteria of safety factor greater than 1 in strength and fatigue analysis
ACADEMIC PROJECTS
Process Improvement of assembly using Lean Principles January 2016-May 2016
Northern Illinois University, DeKalb, Illinois
 Observed the material and information flow for a clock product family of Time Wise solutions and identified the sources of wastes in the
process
 Performed 3 different Lab simulation rounds for improving the process by implementing LEAN tools such as 5S, Standardized Work, Visual
Management, Plant Layout, Set up Reduction, Batch size Reduction, Point of use Storage, Quality at the Source
 Identified and implemented the Kaizen events to improve the effectiveness of Time Wise Solutions in production of Black Diamond and Blue
Sapphire clocks
 Represented the Current State process and the Future State process with implemented improvements using Value Stream Map and
documented the Lab simulations
 Achieved improvement in the assembly process with lowered WIPs, Improved Cycle time and Reduced Production Lead time
Six Sigma Tools and Techniques Implementation January 2016-May 2016
Northern Illinois University, DeKalb, Illinois
 SIPOC and Critical to Quality (CTQ) tools helps in defining and understanding the customer and solve problems in shop floor
 Measured the problems faced in the assembly lines using check sheets and compared them by drawing Pareto Charts
 Analyzed the problems using Failures modes and effect analysis (FMEA), Time series plots and various tests like Kruskal wallis tests, Mood’s
Median tests, one-way ANOVA
 Improving the repair cycle time and reducing defects by implementing six sigma DMAIC methodologies at Caterpillar Inc., Aurora, Illinois
Aerodynamic Investigations in the return channel of a Centrifugal compressor January 2011-April 2011
BHEL (R&D), Hyderabad, India
 Assembled various parts of a centrifugal compressor; tasks included: layout, flow path setting, instrumentation and positioning of the return
channel of the test-rig of a centrifugal compressor
 The main objective of this project was to find out the static pressure recovery coefficient and total pressure loss coefficient of the fluid in the
return channel of a centrifugal compressor through experimental methods
 These parameters were calculated for different mass flow rates of test rig by changing the speed of the blower
PROFESSIONAL TRAININGS
 Trained on design and Optimization Software Inspire and at Troy, MI by Altair Engineering
 Training on process oriented finite element modeling software Simlab by Altair Engineering
 Training on Advanced Abaqus tool usage at Hyundai Motors, Hyderabad by Simulia
 Advanced Training on Hypermesh at Hyundai Motors, Hyderabad by Altair Engineering
 Training on Msc Patran at Hyundai Motors, Hyderabad by Msc Software
AWARDS &ACHIEVEMENTS
 Paper presentation: “Scripting with Hypermesh to automate the process of assigning the loads in RFT test for road wheels,” Altair Technical
Conference, 2015
 “Best Employee of the Year” Award, Computer Aided Engineering, Hyundai Motors, Hyderabad, 2014
 1st Prize, Death Valley Event Competition, National Level Technical Fest, Droidz'10, Aurora's Engineering College, 2010
 Participant, Film Making Competition, Microsoft Dream Spark Yatra, April 2010
 Participant, “All Terrain Bot” and “Track Bot,” National Level Technical Fest “Xtractus'10,” J. B. Institute of Engineering & Technology, 2010
 Participant, “Robo Race” and “Robo Bee Chase,” National Level Technical Fest “Resilience'10,” Vignan Institute of Technology & Science, 2010