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SUMMARY OF EXPERIENCE OF

ANAND (ANDY) RAJAGOPALAN

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• Summary of Qualifications.

• Discussion of work experience: Design & CAE. Manufacturing and Project management.

• Examples to elaborate technical expertise.

• Questions / Conclusion.

AGENDA

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• MSME with over 18 years design experience in several engineering industries.

• Experience in various roles as Engineering Manager, Product Manager, Design Engineer, CAE Engineer, Resident Engineer, Product Development Engineer, Technical liaison for Business Development.

• Project Management Professional (PMP).

• Very adaptable and quick learner.

SUMMARY OF QUALIFICATIONS

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RELEVANT DESIGN & CAE EXPERIENCE

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AMERISTAR FENCE(Jun. 2014 – Jan. 2015)

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Gate Operator Development

• Designed the gears and transmissions for the gate operator. Developed design specifications for the new product after consulting with end users, contractors and sales team. Hands on testing for one prototype.

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Bulletproof Fence

• Developed a concept design for a bulletproof fence to be used in electrical substations. Performed FEA and made recommendations for installation and service.

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Fence optimization

• Performed design optimization studies for weight reduction of fence components, pickets, fence-posts etc. Validated results with testing.

• Optimization studies led to recommendation for major cost savings.

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RAMSEY WINCH (July 2012 – August 2013)

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• Developed a new series of winches accessories for Oil and defense industry applications for marketing in both US and Europe.

• Analyzed and optimized several components for the existing winch products and accessories for cost reductions, weight saving and design improvements.

• Provided technical support for Marketing teams to expand into Asian markets.

RAMSEY WINCH (Jul. 2011 – Apr. 2012)

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FABCO AUTOMOTIVE (Dec. 2007 – Feb. 2009)

• Developed an Auxiliary Transfer case for large commercial vehicles. The work involved design of gears, shafts, keys, casing for the transfer case and bearing selection.

• Researched existing transfer cases to incorporate improvements into Fabco products.

• Managed communication with suppliers and subcontractors for procurement process.

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TYPICAL SPECS FOR GEARBOX

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SPICER 7041 TRANSMISSION

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SPICER 1750 TRANSMISSION

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FORD MOTOR CO. (Nov. 2000 – Nov. 2002)

• Performed design changes and optimizations for several body chassis assemblies and components.

• Interfaced with CAD, CAE and manufacturing teams to resolve component and sub-system level issues.

• Developed field fixes and design modifications to address quality problems.

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BORG WARNER

(Jan. 1997 - Aug. 2000) • Key liaison role between Lohitsa Inc. and Borg

Warner for design and analysis of transfer cases.

• Developed a database of the analyses of transfer case components to assess the factor of safety of parts.

• Developed optimized designs for several components of transfer cases.

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GRADUATE RESEARCH ASSISTANT

(Sept.1994 – Jul.1996)• Performed research at University of Missouri Rolla, funded by Alyeska Pipeline Service company

• Objective was to find solutions for preventing disastrous oil spills due to pipeline explosions in Alaska.

Summer conditions for pipeline

Winter conditions for pipeline

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ANALYSIS OF CORRODED OIL PIPELINE (1994-1996)

• Funded by Alyeska Pipeline Service Co.

• Nonlinear analysis conducted in ABAQUS.

• Axisymmetric models analyzed with corroded walls to benchmark the subroutine developed.

• Full length tests done at Berkeley used to benchmark the full shell model.

• Eighteen simulations done to get data points for loading and corrosion conditions.

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FAILURE ENVELOPE

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FAILURES COMMON IN PIPES

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LOADING CONDITIONS

• INTERNAL PRESSURE.

• LONGITUDINAL LOADING DUE TO EXPANSION.

• BENDING LOAD DUE TO WEIGHT.

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TEST FRAME SETUP

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CORROSION PATCH DESIGNS

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CADD OF INDUSTRIAL GEARBOX (1993-1994)

• Undergraduate project.• BASIC used to design the gearbox. • Inputs

– Hours of Operation– Input RPM, Horsepower, Reduction ratio– Class of duty, Materials, Type of gear used

• Outputs– Dimensions and tolerances of Pinion, Gears,

Shafts, Keyway– All data readily set up as input for drafting

program in AutoLISP.

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CADD OF INDUSTRIAL GEARBOX

• Drafting automated with AutoLISP– Plots Input Pinion, Intermediate Shafts,

Output Shafts, Sleeves, Housing– Software and subroutines sold to industrial

applications

• Developed subroutines involved thorough knowledge of AutoCAD.

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TYPICAL DRAWING OUTPUT

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MANUFACTURING &PROJECT MANAGEMENT

EXPERIENCE• Emphasis on demonstrating knowledge of

Engineering concepts & relevant experience without violating confidentiality agreements.

• Reverse chronologically sequenced

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• Developed a solution for failures of gauges in sour wells. Performed root cause analysis of failure, developed a solution, evaluated alternatives and found a permanent fix to eliminate all future failures in almost every product made at GRC.

• Managing and performing design work for three lines of products.

• Providing Mechanical Engg support as needed.

Sercel GRC(Sept. 2013 – May 2014)

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• Developed a new series of winches accessories for Towing and Recovery and defense industry applications for marketing in both US and Europe.

• Performed market analysis, defined design specifications, performed viability studies, evaluated technical alternatives, managed the design, development, testing and launch of the new product line of winches.

RAMSEY WINCH (May 2012 – Aug. 2013)

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• Established some key relationships with major Middle-East oil refineries and Tier 1 suppliers (Dodsal Group, FMC Tech, Saudi Aramco, Qatar Petroleum), enabling IA Flow elements to double the company’s annual sales between June 2009 and May 2011.

• Managed several large design and manufacturing projects of venturi-meter, orifice plates and flow nozzles for process industry applications.

IA FLOW ELEMENTS (May 2009 – Jun. 2011)

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• Led teams for development of new product for inline liquid density measurement and an illuminated magnifier.

• Managed time sensitive work of several QA Engineers, Project Engineers, and suppliers.

• Coordinated customer communications to ensure projects were completed within time and budget constraints.

IA FLOW ELEMENTS (CONTINUED)

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• Resident Engineer for Radios, Satellite Systems and Family Entertainment Systems installed in four Ford vehicle lines.

• Led a team of Mechanical and Electrical Engineers for Product Launches and Build events at Ford plants and product development process.

• Performed warranty studies and provided solutions. Led work on Product Development and Quality improvement (8Ds).

DELPHI ELECTRONICS(Jun. 04 – Mar. 07)

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• Developed proposals for Engineering and IT projects and services based on market research.

• Initiated several customer contacts with presentations of CAE Tech’s technical capabilities and established several key customer relationships for new clients.

• Evaluated several new business strategies and proposals for the future growth of the company.

CAE Tech(Dec. 02– Jun. 04)

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• Over Eighteen years engineering experience spanning Product Management, Product Development, Design, Computer Aided Engineering (CAE), Design Release, Testing, Resident Engineering and Program Management.

• Masters degree in Engineering from University of Missouri.Project Management Professional (PMP) with extensive project management experience.

• Proficient in CAE and design tools used widely in Engineering Industry. Experienced in NASTRAN, ANSYS, LSDYNA, ABAQUS, PATRAN, Hypermesh, Sofy, Solidworks, ProE, CATIA, IDEAS, AutoCAD, and AutoLISP.

• Sound knowledge of engineering fundamentals with ability to solve complex problems using theoretical “hand” calculations and engineering softwares.

• Proven leader with strong work ethics, communication skills and ability to handle multiple critical projects.

• A self-starter and a quick learner with excellent cross discipline adaptability and a keen business acumen.

• Excellent communication skills with written and oral presentation skills necessary to manage and lead teams.

SUMMARY OF MY EXPERIENCE - CONCLUSION

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QUESTIONS / DISCUSSION

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BACKUP SLIDES / OTHER WORK EXPERIENCES

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BIRD IMPACT ON AIRCRAFT CANOPY (1994)

• Research done for McDonnell Douglas

• Need for methodology to compare performance of several known materials

• Axisymmetric model developed using PATRAN

• Impact analysis using ABAQUS Explicit

• Pressure wave propagation studied as a test case

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1350 N

1350 N

1350 N

1350 N

5410 N

Tank Capacity: 16.1 Gallons

Fuel Density: 760 kg/m^3

Fuel Mass: 46.3 kg

Tank Shell Mass: 7.8 kg

Tank Shell thickness: 5.5 mm

MRA Mass: 1 kg

Tank ASM Total Mass: 55.1 kg

Inertia Load: 10g Gravity

27.5o

1350 N

FT = 1350/Cos(27.5)FT = 1522 N

FT

Strap Tensile Load

SUPPORT DESIGN FOR FUEL TANK

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SUPPORT DESIGN FOR FUEL TANK

• Identify Stress Concentration due to the addition of barbs on fuel tank right strap

• Calculation of barb stresses in strap due to 10g gravity load

• Calculation of effect of added barbs on strap fatigue life

• Design developed using ProE and FEA model done on Hypermesh

42ICV

Fill Pipe Rubber Hose

Stabilizer Bar

Proposed Strap with Barbs

Pusher Block Barbs

SUPPORT DESIGNFOR FUEL TANK

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Proposed Strap With Pusher Block Design Proposed Strap

CAE Proposed Design 2 CAE Proposed Design 1

20 mm Radius

45 mm

5 mm

Spot Welds

DESIGN PROPOSALS

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DESIGN 1 vs. DESIGN 2 STRESS CONTOUR

DESIGN 2Max Stress=39.6 MPa

DESIGN 1Max Stress=31.9 MPa

Gear Contact Analysis

• GENERIC Gear Model developed using PATRAN and Hypermesh

• Analysis performed using ABAQUS

• Loads applied were speculative to understand stress contours

Contact Stresses For Gears Meshing

Close up view of Contact Stress