Open To Work
RAJESH THAKUR
CAE Engineer
Rochester Hills,MI
Summary
CAE Engineer, responsible for working with Product Engineers to set up a simulation plan and provides FEA and CFD simulation to optimize product performance, Translating design requirements into simulation project specifications. Looking for a challenging job opportunity in CAE field, that utilizes my varied knowledge and ability to work efficiently even under pressure in an efficient manner to meet the challenges and gain further skills.
Overview
18
18
years of professional experience
19
19
years of post-secondary education
Work History
CAE Engineer
Henniges Automotive
Auburn Hills, MI
09.2016 - Current
- Validate designs of sealing and weather strip system such as Molds and Seals as per various vehicle configurations and environments.
- Perform various static, Nonlinear, and dynamic studies on the sealing and weather strip systems to determine different Durability characteristics of the system under different field conditions. Perform Static & Dynamic 2D and 3D CAE of various weather strips. Develop virtual testing methodology for glass and dynamic seals. Develop material models for various in-house and purchased elastomers (TPV and EPDM). Perform CLD, Insertion/extraction, 3D Single plane bending, 3D Multi plane bending load / height loss analysis.
- Optimize designs of sealing and weather strip systems for mass and strength under the specified design constraints. Perform design validations using CAE simulation tools such as MSC Marc and Hypermesh.
- Independently investigate possible solutions to previously unseen issues and generate detailed FEA reports. Discuss results and observations from CAE simulations with the testing departments, Product engineers and recommend changes to designs.
- Work with various groups in the organization to develop and implement design information during the product development cycle to optimize the cost and shorten product development cycles.
- Develop and maintain formalized documentation to assist in analysis and development of current and new products including root cause and correlation to test results.
- Develop new CAE methods and standards. Keeping current developments in the field of Elastomer FEA. To improve FEA group productivity by implementing customized functions and utilizes in Mentat using Python language and MSC. Mentat menu language, and in MSC. MARC using specially developed user subroutines.
- Working with Manufacturing Plants In USA, Europe and China to improve product manufacturing quality with the simulation support including correlation and design option recommendations. Working on Ansys Polyflow to accelerates design time for Extrusion Die's for manufacturing processes. Writing technical reports with the simulation results and findings.
- Cost Efficiency: Led sealing system conversions that maintained durability while significantly reducing costs.
- Production Optimization: Reduced cycle times for Tesla mold designs without compromising product integrity.
- Method Development: Developed advanced CAE methods for weatherstrip systems, enabling faster validation cycles.
- Conducted optimization studies utilizing linear optimization and multiple disciplinary optimization.
- Managed projects from beginning to end, documenting results and presenting proposals to customers.
- Used 3D and 2D CAD tools to design, develop and engineer high-quality models.
CAE Engineer
Satyam Venture Engineering Services
Bingham Farms
04.2014 - 09.2016
- Training and mentoring Offshore team on CAE methods. Handling offshore team activities and assignment of simulations.
- Analyzing vehicle seals and sealing systems and formulating recommendations for improvement.
- Improving simulation methods through the development of new Finite Element Analysis material models and analysis techniques, and through the correlation of experimental data with analysis results.
- Using MSC Mentat FEA pre-processor to build 2D and 3D finite element models of vehicle seals and sealing environments.
- Using MSC Marc FEA Solver to analyze geometry, materials, load history, and boundary conditions for automotive seals.
- Using MSC Marc/Mentat to perform nonlinear analysis of elastomers.
- Analyzing the application of CAE to new areas, including manufacturing process modeling, to improve quality and lower costs.
- Developing educational materials on CAE.
- Liaising with customers to clarify technical specifications and defend simulation results and suggesting modifications in materials, design, and vehicle environment.
- Performing design of experiments to optimize product performance developing product design enhancements for vehicle seals.
- Using CAE to collaborate in the development of advanced engineering and innovation projects Interpreting FEA results for part performance relative to product engineering to meet design goals.
Senior Analyst
Satyam Venture Engineering Services
Hyderabad
09.2010 - 04.2014
- Building 2D and 3D finite element models performing static, nonlinear and dynamic studies to determine durability characteristics under different field conditions; validating design of components according to vehicle configurations; using MSC Marc/Mentat, LS-DYNA, and Abaqus software; developing new CAE methods and standards; and generating Finite Element Analysis reports.
Project Engineer-FEA
Kalyani Infotech ltd
Pune
07.2009 - 09.2010
- Finite element modeling & Analysis.
- Estimating the resource efforts.
- Handling all Types of Meshing works used for the analysis.
- Project planning and time estimation for assembly level simulations.
- Coordinating assembly meshing projects among team members in order to meet the project Deadlines.
Project Engineer-FEA
Zuti Engineering Services
Hyderabad
09.2007 - 06.2009
- Build completed mesh assembly for Automobile (BIW, integration for Durability as well as crash), Automotive seals, Heavy Engineering & Construction, Locking Systems and home appliances products.
Education
Master of Engineering - Mechanical Engineering (CAD/CAM)
Osmania University
Hyderabad,India 12.2011 - 10.2013
Bachelor of Technology - Mechanical Engineering
J.N.T.U
Hyderabad, India 08.2002 - 04.2006
Higher Secondary Education - Maths,physics,chemistry
Board of Intermediate
05.2000 - 04.2002
SSC - Prek3,4 ,Elementary And Junior School
Secondary School Board
06.1988 - 04.2000
Skills
- Altair products Hypermesh
- Optistruct
- Radioss
- Msc Marc
- Mentat
- Ansys Mechanical
- Ansys Fluids
- Polyflow
- Nastran
- Abaqus
- Lsdyna
- Solid works
- Pro-E
- Catia V5
- MS-Office
- Unigraphics
- Moldex3D
- Python
- C/C
- Ansys Fluent
- Ansys Motion
- Structural FEA
- Thermal FEA
- Static simulations
- Nonlinear simulations
- Dynamic simulations
- MSC Marc
- LS-DYNA
- Material Science
- Elastomers
- TPV
- EPDM
- Polymers
- Structural alloys
- CAD Tools
- SolidWorks
- Creo
- UG NX
- Technical leadership
- Cross-functional collaboration
- Global teams
- Ansys Polyflow
- Design for Manufacturability
- DFM
Work Preference
Job Search Status
Open to workWork Type
Full TimeLocation Preference
HybridOn-SiteSalary Range
$130000/yr - $200000/yrExecutive Summary
Significant experience developing and leading global teams performing complex mechanical design and analysis duties., Self-motivated leader who identifies areas for improvement and drives innovation within internal and partner teams, such as developing advanced CAE methods for faster validation., Excellent cross-functional collaboration and communication skills, with a proven ability to align simulation insights with product design goals., Strong knowledge of solid mechanics with extensive experience using implicit and explicit finite element analysis (FEA) in support of high-stakes product development., Passion for creating cutting-edge products in fast-paced environments, evidenced by 18+ years of engineering excellence in the automotive and manufacturing sectors.
Timeline
CAE Engineer
Henniges Automotive
09.2016 - Current
CAE Engineer
Satyam Venture Engineering Services
04.2014 - 09.2016
Master of Engineering - Mechanical Engineering (CAD/CAM)
Osmania University
12.2011 - 10.2013
Senior Analyst
Satyam Venture Engineering Services
09.2010 - 04.2014
Project Engineer-FEA
Kalyani Infotech ltd
07.2009 - 09.2010
Project Engineer-FEA
Zuti Engineering Services
09.2007 - 06.2009
Bachelor of Technology - Mechanical Engineering
J.N.T.U
08.2002 - 04.2006
Higher Secondary Education - Maths,physics,chemistry
Board of Intermediate
05.2000 - 04.2002
SSC - Prek3,4 ,Elementary And Junior School
Secondary School Board
06.1988 - 04.2000