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Projects

I have an extensive experience in projects which are relevant to CAE Design, Finite Element Analysis FEA, Engineering Design Optimization, Stamping Manufacturing, Digital Twins, Digital Engineering. 

Hybrid Production line (Mini 20): Design Concept Development and FEA Optimization

  • Lead a team of 3 graduate students for the concept development of a 4 station 20 Ton capacity hybrid production line in metal forming applications which mimics heavy duty stamping/forging production line.

  • Designed large and light structures like Hybrid Power Press Machine, 6 Axis Robotic Arm, Linear Actuators, Die System, Feeder, Straightener, & Automated Decoiler in SolidWorks and Creo.

  • Optimized all the products using multi body dynamics DOE techniques and FEA using ANSYS software.

  • Innovated a novel robotic arm mechanism to transfer formed part at random stations to enhance the press fatigue life.

  • Designed a 4-stage tube stamping process using FEA simulation with optimization of dimension, tonnage & product defects.

  • Minimized the product defects with variable Blank Holder Force (BHF) by using non-linear FEA LS-DYNA in ANSYS Forming.

Virtual product development for machine components using Digital Twin Technology

  • Developed Design of Experiment (DOE) schemes & Reduced Order Models (ROM) using FEA based data analytics regression models & Neural Network to predict machine component failure in hydraulic power press machine in real time.

  • Established virtual sensors for manufacturing products to control product quality in real time using closed loop algorithms powered by Python Code.

  • Developing a communication system between virtual sensor and physical press machine by using Ansys Twin Builder.

Optimization of ECO-PRT team’s autonomous self-driving vehicle’s chassis using non-linear FEA crash analysis

  • Worked with ECO-PRT CAE team’s to develop the CAD design of vehicle chassis using Solidworks and Creo.

  • Improved the chassis design by nonlinear FEA Explicit dynamics method and LS-DYNA code using ANSYS.

  • Created a database for frontal and rear impact stress/deformation for aluminum and steel chassis frames.

Simulation and System Dynamics Modeling of Permanent Magnet (PM) based Wave-Harvesting Buoy

  • Modeled and Simulated system dynamics of a prototype wave energy harvesting buoy using Simulink.

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  • Optimized the Power output of linear energy generator by performing FEA simulation using ANSYS MAXWEL.  

Design optimization of vortex-based cavitation for precision manufacturing

  • Optimized the design of cavitation generator (CG) of AMT Lab using numerical simulation-based DoE techniques.

  • Strengthened the cavitation generation depth of CG up to 25%.

  • Presented research paper in the 5th world congress on micro and nano manufacturing.

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