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Seeking a challenging position in field of Mechanical Engineering, which compliments and expands my competencies, skill,
education & experience.
PROFILE
EMPLOYMENT RECITAL
Responsibilities:
Design, development, and testing and documentation of products and processes related to thermoforming
machineries and equipments.
Perform engineering calculations, analysis, and proper material & component selection for quality conscious
design including cost, weight, reliability and ease of manufacturing.
Work with engineering, purchasing, production and assembly teams, ensuring that budget goals, time
deadlines and customer’s expectations are met.
Create 3D-models, drawings and bill of materials.
Example Projects:
Design and testing of "Side Sealing System" for Stack Packer. Displayed at PACK EXPO 2006, McCormick
Place. Applied for patent on the process.
Design and Development of “Cup Bagging” machine.
Forming (50in X 40in) mold and Trimming tool design for foam plate
Dynamic analysis and servo motor sizing calculations for "Rack and Pinion Ejector System" to determine
forces on the system, maximum possible speeds and torque requirements. This ejector system is used to eject
trimmed product out of trimming tool
Dynamic analysis and servo motor sizing calculations for "Servo Ejector system (based on slider-crank
mechanism)" to determine dynamic forces on the assembly, maximum possible speeds and torques required to
sustain the speeds.
Finite Element Analysis of a"Form Tool Platen" to determine stresses, strains and stress concentration area
when subjected to forming loads.
Finite Element Analysis of "Gear Tooth", in Rack and Pinion to determine contact stresses.
Contributed to establishing design standards. Standards included protocols for Machine/Tool Design,
individual parts modeling, assembly structure, drawing procedures and file storage.
Company Name: Southern University and A&M College, Baton Rouge, LA, U.S.A
Responsibilities:
Supervising junior manufacturing lab, preparing and grading tests and homeworks.
Conducted classroom instruction of ‘Unigraphics NX’ for 3 semesters.
Responsibilities:
Machine Design.
Thermoforming Tool Design.
Supervising manufacturing of tools.
Testing of Machines and Tools
Example Projects:
Responsible for design and development of Pick and Place Stacker for cup former based on use of vacuum to
pick the formed cups from the mould
Designed mould-rotating mechanism to eliminate the stacking machine. Design concept based on straight-line
generation principle of “Tchebicheff Mechanism”.
Performed structural analysis (FEA) of Machine crank, Machine platen and Machine frame in cutting action
during thermoforming of Thermoforming machine Model 3060®. Machine displayed in K-2004, Düsseldorf,
Germany.
Designed, supervised manufacturing and testing of number of replaceable cavity thermoforming tools ranging
from simple 100ml disposable glasses to 750ml containers with lids. One of the square container tools with lid
displayed in was displayed in K-2004, Düsseldorf, Germany.
INTERNSHIPS
Project:
Design and development of ‘Stacking machine for cup former’ (senior project). Used to stack the randomly
ejected cups from automatic thermoforming machine in organized fashion and number as desired.
In charge of different stages of the product development right from conceptualization, design of components,
procurement of parts, Manufacturing, assembly and testing.
QUALIFICATIONS SUMMARY
Post Graduation:
2004-2005 Master of Engineering (Mechanical Engineering) GPA: 3.75/4.00
Southern University, Baton Rouge, U.S.A
Graduation:
1997-2001 Bachelor of Engineering (Mechanical Engineering) Higher Second Class
K.K. Wagh College of Engineering, University of Pune, India
Project: Design and Development of ‘Stacking Machine for Cup Former’. Sponsored by Wonderpack Ind Pvt
Ltd, India. Machine was exhibited in K-2001, Düsseldorf, Germany.
Schooling
1995-1997 Higher Secondary School Certificate First Class
Maharashtra State Board
OTHER ACHIEVEMENTS
PERSONAL DETAILS
2. Drop testing of various thermoformed foam and solid sheet (Polypropylene, HIPS, etc) to study the stresses induced in
the product.
3. Studying the stresses induced in Cavity and Plug of mold during thermoforming process.
- The results provided an insight on better locations for fastening, vacuum paths, cooling lines/holes, and base support to
minimize the deflection and stress concentrations during each cycle.
4. Finite Element Analysis of “Thermoforming Machine Platen” to determine stresses, strains and stress concentration area
when subjected to load
- Creating 3D model of the design using Solidworks.
- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures, using
ABAQUS CAE.
- Interpreting results from above analysis and making necessary design changes: Improved the design based on the stress
concentrations and deflections observed to make the platen stiffer which in turn enabled using higher loads
5. Structural analysis of thermoforming trimming machine platen, similar sheet metal stamping machine.
- Creating 3D model of the design using Solidworks.
- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures using
ABAQUS CAE.
6. Structural analysis of thermoforming machine frame for deflection during forming. Thermoforming tool usually
experiences forces upto 300 tones per cycle.
- Creating 3D model of the design using Solidworks.
- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures, using
ABAQUS CAE.
- Based on analysis reduced the weight of the fame material being used and switched to single die pillar from two per side.
7. Finite Element Analysis of “Tool Cart” (used for transporting thermoforming tools) to determine structural rigidity and
ensure safety at rated loading.
- Testing the design for structural rigidity/stability when tool is placed on the “Tool Cart”
- Involved creating finite element model to simulate working conditions using ABAQUS CAE.
- Interpreting results from above analysis and making necessary design changes.
8. Finite Element Analysis of “Gear Tooth”, in Rack and Pinion to determine contact stresses.
- Contact stresses are indicator to the wear resistance/life of the part in contact.
- Involved creating finite element model to simulate static and dynamic loading using ABAQUS CAE.
- Estimating predicted life based upon observed values from above step
9. Finite Element Analysis of Foam Sheet Extruder Die to study the deflections induced (based only on the pressure of the
material being extruded).
10. Testing the design of vacuum tank and air tank for the thermoforming machine using ABAQUS CAE.
Thesis : Application of Finite Element Method in Fracture Mechanics Properties Estimation.
Course : Master of Engineering (Mechanical Engineering) - (2004-2005)
Abstract:
Fracture parameters were estimated by finite element method. Commercial software ABAQUS was used for this
research. A total of 63 unique full 3D models were analyzed using multiple processor Itanium-2 computing facility setup at
Southern University. Using some of the features of ABAQUS such as iso-surface plot, output plots along node/element path; it
was possible to visualize the plastic zone shape, variation of stress intensity factor, J-integrals, and variation of stresses and strains
along the crack.
Compact testing (CT) specimen specified in ASTM E399 was used throughout this investigation. In CT specimen of
thickness 40mm the plane strain condition is found to be dominant in 87.5% of crack front length. This type of study will enable
in reducing the number of samples destroyed while following ASTM E399 in trials to achieve plane strain dominance. Plastic
zone shape was obtained using the iso-surface functionality in ABAQUS. Observed plastic zone shape does not conform with
simple extrapolation of 2D zone shapes stretched to 3D, i.e. the dog-bone shape. Variation of K and J-integral values along the
crack front were used to explain this result.
Method for obtaining numerical solution for fracture toughness for CT specimen is formulated here. Load and Load rate
analysis, Optimum a/W ratio determination, Mesh convergence analysis and Parameter variation form the sequence of this
procedure. It is found that for range of load and rates considered the variation in percentage errors is 0.0037 for K and 0.007 for J-
integral. In order to study effect of initial crack length on estimation of K and J, models with varying a/W ratio subjected to same
load are analyzed. It is found that errors are minimum when a/W ranges from 0.45 to 0.55. Mesh convergence analysis is carried
out to obtain optimum element size. Criterions used are stabilization of K and J values and Contour independence of J-integral.
Element volume expressed as a percentage volume of specimen volume of 0.0041% is found to produce convergence. Geometric
form factor f ( a W ) for CT specimen geometry is derived using 33 models of varying B and a/W ratios. ABAQUS values for
f ( a W ) are consistently higher than ASTM E399 values by a value of 0.215.
As a step towards developing a numerical and closed form solution for Mode I + Mode III fracture toughness for brittle
materials modeling of Spiral Notch Torsion Testing (SNTT) specimen has been initiated. The finite element model of this test will
be useful in studying the parameters affecting the mixed mode fracture. Geometric model, crack definition, crack propagation
direction definition and mesh for analysis are in progress.
This successful study marks the beginnings of an array of possibilities. Numerical solutions for non-standard geometries
can be obtained. Fractures in elasto-plastic, perfect plastic modes can be simulated and studied. ABAQUS can be used to
simulate/analyze fracture for flaws in dams and levees, composites, non-metals and weldments, interfacial fracture in thermal
barrier coatings.