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.
