Frankalin

Performance-driven CAE Engineer with 3 years of professional experience specializing in Durability, Fatigue Analysis, Linear/Nonlinear Structural FEA, and Multibody Dynamics (MBD) within the automotive domain. Proven track record of delivering CAE-driven insights to optimize BIW, suspension, and chassis components. Adept at bridging the gap between physical testing and virtual simulation using industry-standard tools like HyperMesh, OptiStruct, nCode, and MotionView.

CAE Engineer (Deputed to TVS Motor Company) - Hinode Technology - Chennai, India

(2023-12)

Execute end-to-end structural, durability, and multibody dynamics simulations for production-level automotive components, ensuring structural integrity and compliance with passenger safety standards.

• Developed high-fidelity 2D and 3D finite element models for Front & Rear suspension systems, brake drums, wheel hubs, and chassis assemblies adhering to stringent automotive metrics.
• Executed comprehensive linear and non-linear structural durability analyses on suspension geometries to simulate severe operating conditions.
• Iterated design modifications (thickness optimization, localized reinforcements, and material changes) on suspension components to eliminate high-stress zones and meet strict target loadcases.
• Set up complex solver decks in HyperMesh, defining material non-linearities, contact definitions, boundary conditions, and multi-axial service loads.
• Evaluated stress concentrations, localized plastic deformation, displacement fields, and load-transfer paths using HyperView to guide the product development cycle.
• Processed raw field data and performed signal processing/data reduction using nCode GlyphWorks.
• Applied Road Load Data Analysis (RLDA) to extract damage-equivalent representative load cycles from multi-axial test track data.
• Predicted fatigue life, crack initiation, and safety factors of critical components under real-world loading conditions using nCode HyperLife.
• Extracted, mapped, and validated hard points for Front and Rear suspension systems using MotionView.
• Defined complex suspension kinematics, joints, and constraints to support full-vehicle MBD simulations.
• Generated Modal Neutral Files (MNF) in MotionSolve/OptiStruct by modeling interface nodes with rigid elements (RBE2/RBE3) to bridge FEA and MBD domains.
• Integrated flexible bodies for critical assemblies including commercial vehicle chassis, anti-roll bars (ARB), brake systems, and steering linkages.

CAE Trainee – Intern - Femlogic Technology Pvt. Ltd. - Chennai, India

(2023-03 - 2023-11)

• Gained hands-on expertise in geometry clean-up, mid-surface extraction, and high-quality 2D/3D meshing on plastic trim, sheet metal, and powertrain components.
• Conducted linear static and modal analyses (free-free and fixed-free boundary conditions) to evaluate component natural frequencies and avoid resonance.
• Documented and presented simulation results, highlighting stress margins and recommending localized structural reinforcements.

Bachelor of Engineering (B.E.) - Mechanical Engineering - Velammal Institute of Technology (2019 - 2023) Chennai, India