Balagi Sai

Multi-Body Dynamics (MBD) and FEA Engineer with 3 years of experience developing and correlating system- and vehicle-level simulation models in ADAMS/Car, ADAMS/View, and CarSim, with supporting FEA in ANSYS Workbench and LS-DYNA. Specializes in drivetrain and suspension simulation, Kinematics and Compliance (K&C) analysis, ride and handling, and durability/duty-cycle validation, translating simulation results into design and weight-reduction improvements validated against physical test data. Proficient in MATLAB/Simulink for controls integration and Python for simulation workflow automation, with strong CAD collaboration in UG-NX, Creo Parametric, and CATIA.

Multi-Body Dynamics & FEA Engineer at Detroit Engineered Products (2023-07 – Present)

• Developed and validated ADAMS/View and ADAMS/Car multi-body models for drivetrain and suspension systems, executing K&C and ride and handling analysis to optimize steering response and stability.
• Engineered an ADAMS simulation model for a parking pawl mechanism, cutting design finalization from 5 iterations to 3 and reducing overall prototype iterations by 40%.
• Executed vehicle dynamics co-simulations integrating CarSim with MATLAB/Simulink, including a CNN-based ABS/TCS controller, improving traction response and vehicle stability.
• Performed static, nonlinear, modal, and transient dynamic FEA using ANSYS Workbench and LS-DYNA, correlating results against physical test data to improve simulation accuracy.
• Validated drivetrain component performance across 50,000+ duty cycles through fatigue and durability assessments, achieving zero field failures under real-world loading.
• Identified stress concentrations via contact force and stress analysis, recommending topology-based weight reduction using nonlinear material behaviour.
• Automated simulation workflows with Python (ANSYS APDL, MATLAB API), cutting manual simulation time by 35% and enabling efficient parameter sweeps and sensitivity studies.
• Collaborated with CAD and design teams in UG-NX, Creo Parametric, and CATIA to translate mechanical designs into validated models with accurate boundary conditions and mesh refinement.

M.Tech in Automotive Engineering – Vellore Institute of Technology (VIT) (2021 – 2023)

B.E. in Production Engineering – PSG College of Technology, Anna University (2017 – 2021)

Diploma in Mechanical Engineering – Paavai Polytechnic College (2017)