B Amaresha

Structural and Dynamic Simulation Engineer with 4 years of experience in CAE analysis of axle housing, drivetrain and braking systems. Expertise in static, dynamic, and fatigue simulations using ANSYS and nCode, along with strong experience in RLDA-based durability evaluation and test correlation. Proven ability to optimize designs for weight, strength, and manufacturability while collaborating with cross-functional teams to deliver robust engineering solutions.

Additionally, possess working knowledge of vibration analysis of brake assemblies, including prestressed, modal, harmonic, and transient analysis to evaluate dynamic behaviour and system performance.

Structural and Dynamic System Engineer at Cummins India (CDBS) Pvt Ltd (2022-08 – Present)

• Managed end-to-end CAE analysis for drivetrain, inter-axle differential, differential components, and disc brake systems from concept through DV phase, validation, and production release, ensuring performance, manufacturability, and cost targets were achieved through optimal utilization of CAE tools.
• Analyzed the functional behavior of individual components within assemblies and applied appropriate loading conditions at the component level to perform system-level analysis in ANSYS Workbench, enabling effective finalization of component designs.
• Performed structural analysis at the assembly level to correlate hotspot regions with test results and ensure a safe design by maintaining stresses below the material yield limit.
• Possess a good understanding of multi-body dynamics (MBD) behaviour in axle housing systems.
• Utilized RLDA (time-series) data with nCode to predict crack initiation life and correlate simulation results with test data.
• Achieved 20% weight reduction in casting design optimization by minimizing stress and improving stiffness through geometry refinement, wall thickness optimization, and smooth load transition features.
• Developed and implemented ANSYS automation scripts (Python-based), reducing simulation setup time by approximately 80% compared to conventional methods, improving accuracy and efficiency.
• Collaborated with cross-functional teams (design, manufacturing, and quality) to conduct DFMEA, resolve casting and machining issues, and implement design improvements.
• Led design reviews and effectively communicated CAE insights to stakeholders, enabling faster decision-making and design approvals.

Master of Technology in Machine Design – RV College of Engineering

Bachelor of Engineering in Mechanical Engineering – Alva's Institute of Engineering and Technology

Diploma Technical Education – DRR Government Polytechnic