Rahul Kumar

Software Engineer

Bengaluru, Karnataka, India5 yrs 8 mos experience

Most Likely To Switch

Key Highlights

5 years of experience in CAE/FEA domain.
Expert in structural analysis of automotive components.
Conducted training for government and private organizations.

Stackforce AI infers this person is a skilled CAE Engineer specializing in Automotive and Aerospace industries.

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Skills

Core Skills

Finite Element Analysis (fea)Ansys WorkbenchAnsys Mechanical Apdl

Other Skills

Ansys Composite PrepPostAnsys DesignModelerAnsys FluentCATIAHypermeshLeadershipMatlabMicrosoft OfficeSiestaSolidWorksSpaceClaim

About

I am a Senior CAE Engineer at Spark Minda, currently working in an Automotive domain with total 5 years of experience in CAE/FEA domain. Academically, I hold a M.Tech degree in CAD CAM & Automation from National Institute of Technology, Silchar (2020). In my current role, I focus on structural analysis of automotive components, particularly connector housing assemblies and EV charger connectors, using ANSYS Workbench software. I provide solutions for various design challenges. Some of the projects that I have worked on in the industries are HyperElastic Analysis of rubber seal/gasket, Non-linear Analysis of connector housing I&R, EV charger, Aero Engine HPT components, Wind load analysis, buckling analysis of transmission towers, wind turbine foundation and Tractor attachment strength analysis. Additionally, I have conducted ANSYS FEA training for government organizations (DRDO, BARC, MSME) and private organisations. I have a keen interest in virtual testing/simulation of physical components. Along with FEA Skills I have learnt MATLAB & Python from Skill-lync course completed few projects also. I have published 3 research papers along with my colleague and am passionate about applying FEA skills to solve core engineering challenges and drive innovation. CAE Tools: ANSYS Workbench, APDL, Hypermesh CAD Tool: ANSYS Spaceclaim, Programming: Python Project Domain: Automotive, Aerospace, Wind load

Experience

Spark minda

Senior CAE Engineer

May 2024 – Present · 1 yr 10 mos · Bengaluru, Karnataka, India

Key Responsibilities:
Performing Finite Element Analysis (FEA) of Automotive connectors for our in-house products.
Completed Projects:
➡️ HyperElastic Analysis: Connector Sealing
Evaluated rubber seal stretching, fitting, and compression in EV charger connector housing assembly.
Evaluated nominal pressure on seal surfaces as per ingress protection (IP) criteria & insertion force during compression.
➡️ HyperElastic Analysis: Wire Sealing
Analyzed wire seal insertion and compression in the terminal housing of the EV charger, assessing both surface pressure and insertion force for IP compliance.
➡️ Non-linear Analysis: Terminal I&R into housing
Analyzed the EV charger terminal insertion & retention into the housing pole.
Evaluated insertion & retention force, latch breakage force, plastic strain, permanent deformation, and total deformation characteristics.
➡️ Non-Linear Analysis: EV HV Charger Connector Housing
Assessed housing strength under outward pulling forces from different angles.
Evaluated groove deformation, strain at breakage, and overall structural integrity under force criteria.
➡️ Vibration Analysis: EV HV Junction Box
Performed Harmonic response analysis of both junction box assemblies and evaluated the structural
response (Stress, deformation) under a certain harmonic acceleration load.
➡️ Electric Thermal Analysis:
Performed this analysis on the EV charging cable connector terminal assembly to find out the maximum temperature distribution over the terminal and in the contact region during charging.
➡️ Bolt Pretension Analysis:
Performed bolt pretension analysis over the bolt-busbar assembly in the EV junction box.
Domain: Automotive (Connector)
Tools: Ansys Workbench & SpaceClaim

Ansys WorkbenchSpaceClaimFinite Element Analysis (FEA)

Quest global

FEA Analyst

Feb 2023 – Apr 2024 · 1 yr 2 mos · Bengaluru, Karnataka, India

Key Responsibilities:
Performing Finite Element Analysis (FEA) of an Aero Engine components for GE Aerospace client.
Completed Projects:
➡️ LEAP-1A HPT Case S7Port:
Conducted mesh morphing and static analysis on S7port model with multiple inner edge dents.
Performed LCF Ni & Np lifing using Siesta tool to determine critical life and maximum stress, ensuring accuracy with sanity checks.
➡️ LEAP-1B HPT Case Rabbet Interface:
Determined contact force and status at the rabbet interface during the time mission.
Performed static analysis with varying contact values and re-evaluated post-processing results.
➡️ LEAP-1A HPT case fillet:
Conducted static structural analysis on the Global 3 o'clock NC model by updating mesh near S2B fillet.
Performed post-processing including Ni lifing, and compared the results with the actual global model.
➡️ LEAP-1A Aft flange TCF Case:
Performing the 3D tetra solid mesh on Aft flange TCF case in hypermesh software under certain quality criteria.
➡️ LEAP-1A HPT case Global:
Performing the static analysis up to certain cycles and evaluating the post-processing such as all three stress at critical features, reaction forces and Ni lifing.
Domain: Aerospace (Aero-Engine)
Client: GE Aerospace
Tools: Ansys APDL, Hypermesh and Siesta

Ansys Mechanical APDLHypermeshFinite Element Analysis (FEA)Siesta

3d engineering automation llp

2 roles

FEA Simulation Engineer

Promoted

Dec 2021 – Feb 2023 · 1 yr 2 mos · Pune, Maharashtra, India

Key Responsibilities:
Performing Finite Element Analyses (FEA) for large assembly models from clients and internal Design Team.
Provide ANSYS SpaceClaim and ANSYS Workbench training to defense accounts and private companies.
Completed Projects:
➡️ Neom City-Wind Turbine Foundation:
Wind load analysis of the WT foundation to ensure its structural integrity and stability under wind pressure on the foundation.
➡️ Antenna Radome:
Evaluated structural behavior in drop tests, transient thermal conditions, hailstone impact, Sin on Random (SOR) vibration and random vibration scenarios.
➡️ Transmission Tower:
Conducted wind load and buckling analyses, alongside CAD modeling, of a transmission tower (55m) for its reliability and safety.
➡️ Solar Tracker with Dual Reflectors:
Optimized base structure weight, after evaluating the strength based on wind load analysis.

Ansys Mechanical APDLAnsys WorkbenchSpaceClaimFinite Element Analysis (FEA)

FEA Consultant Engineer

Sep 2021 – Nov 2021 · 2 mos · Pune, Maharashtra, India

Key Responsibilities:
Conducting structural analysis of large assembly models from clients.
Exploring various types of analysis techniques.
Completed Projects:
➡️ Lattice Tower:
Wind load analysis of frangible lattice tower with and without ice-cover:
Assessed stability and deflection.
Considered different wind speeds, front and side directions.
➡️ Lattice Tower 2nd Model:
Wind load analysis of 2nd model of frangible lattice tower (6 meters tall).
Under same loads by changing the geometry aspect.

Ansys WorkbenchSpaceClaimFinite Element Analysis (FEA)

Ki technologies

2 roles

FEA Trainee Engineer

Jan 2021 – Aug 2021 · 7 mos

Key Responsibilities:
Working on structural analysis of large assembly model received from the Client.
Completed Projects:
➡️ Tractor-Dozer:
Structural analysis of tractor-dozer attachment under different working conditions to evaluate the strength.
➡️ Tractor-Grader:
Structural analysis of tractor-grader attachment under different working conditions to evaluate the strength.
➡️ Tractor-Boom Pole:
Structural analysis of tractor-grader attachment at different heights of loading.
➡️ Disc-Harrow:
Structural analysis of double action tandem disc harrow under two working conditions including soil force on different blades and stuck condition.

Ansys WorkbenchAnsys DesignModelerFinite Element Analysis (FEA)

CAE Engineer Intern

Oct 2020 – Nov 2020 · 1 mo

Thermo-mechanical analysis of four-cylinder engine block using ANSYS WB.
Strength evaluation of Gear Box housing using structural analysis in ANSYS workbench.

Ansys Workbench

Simulation lab ™

CAE Research Intern

Aug 2020 – Oct 2020 · 2 mos

• Aerodynamics simulation of the wing of NACA A2412 airfoil by adding a sphere feature below the wing surface to increase the aerodynamics efficiency.

Ansys Fluent

National institute of technology silchar

Research Scholar

Jul 2019 – Jun 2020 · 11 mos

Project 1: Probing the Stochastic Dynamics of Coronaviruses: Machine Learning Assisted Deep Computational Insights with Exploitable Dimensions
Project 2: Free Vibration analysis of bio-inspired composite circular plate - An Annual Ring Model
Project 3: Free Vibration analysis of fiber-reinforced composite structure - A Spider-web Model
Software used: ANSYS APDL/WB V19.1