Profile
Senior Mechanical designer & analyst with more than 8.5 years of experience providing technical design of diesel fuel injection system.
Currently working with Woodward India Pvt. Ltd. as Senior Mechanical Engineer (Design & Analysis Engineer).
Technical and analytical capability for High Pressure common Rail Diesel fuel Pumps & Injectors.
Good technical and analytical capabilities for the basic research and development of the efficient and low emission engines.
Expert in creating detailed mechanical 3D models & 2D drawings for the various parts and assemblies with Pro-Engineer (Creo 2.0) & data management with PDM Windchill 10.1 software’s.
(FEA) Structural Analysis of self-designed parts with ANSYS 15.0.
Proto Development, testing, trials, performance evaluation and implementation.
An enterprising team member with abilities in offering multi-skilled motivated teams to achieving organizational goals & industrial best practices.
Key Skills
Diesel Fuel Injection System: Design & development of mechanical and HPCR Diesel fuel Injection Pump & Common Rail Injectors.
Diesel Engine Development: Design and development of DI, IDI diesel engines for the various applications such as PC, LCV and off road application by improving the existing combustion process including fuel management, valve trains, air in-take system and objective was to develop the engine to meet targeted performance and emissions.
3D Design & 2D drafting: Designing of fuel pump, Injector & engines and its components as per the project requirement in Pro-Engineer (Creo 2.0) & data management with PDM Windchill. GD & T, DFM, DFMEA, Tolerance stack up.
Interaction with customers and suppliers: Reporting and follow-up with customer as well as components suppliers for design changes and release, proto type components procurement, engine testing etc.
Engine Testing: Executed the developmental mass emission and type approval emission tests performance tests at ARAI. Evaluations and analysis the test results for configuration optimisation and finalization.
Professional Experience
Current Organisation: WOODWARD INDIA PVT. LTD. PUNE
Designation: Senior Mechanical Engineer-Design & Analyst
Department: Diesel Fuel System (DFS)
Period: From Jan 2011 to Till date
Last Organisation: MAGNA STEYR INDIA PVT. LTD. PUNE
Designation: Design Engineer
Department: Engine & Drivetrain
Period: From Dec 2006 to Dec 2010
CONTENT OF WORK
High-Pressure Common-Rail Systems (HPCR): Design and Development of robust high pressure common rail systems to meet the challenges of future engine design, and the requirements for increasingly higher injection pressures, to support the need to improve engine performance and durability while meeting the relevant emissions targets. Common rail systems are designed for industrial engines with engine leading customers.
Concept design as per the customer requirements, preparation of preliminary design, 3D models, design calculation, DFMEA, tolerance stack up. Detailed 2D drawings drafting. Preparation of Detail Design Review for the design approvals and PPT files as per the Product Life Cycle (PLC) process requirement. Check the drawings, do the check list, preparation of BOM and release the prints for manufacturing as per Woodward process.
Design of Fuel Injection System: Design and development of High Pressure Common Rail Pump and Injector. Engineering changes of existing Fuel Injection mechanical Pump parts considering with modern manufacturing process. Design changes according tolerance study, manufacturing process and structural analysis of parts (ANSYS 15.0). Five times visited to Stuttgart & Aken, Germany for onsite work.
Mechanical Fuel Injection (MFI): Mechanical fuel injection systems operate with helix control on the fuel pump plunger to regulate injection quantity. System includes high pressure injection with nozzle spray holes specifically.
The amount of fuel that is injected is controlled by the rotary position of a specifically designed helix that is machined into the pump plunger that in turn is connected to the engine governor through a linkage system.
Mechanical Unit Injection Systems (MUI): Design and Development of mechanical unit injectors combine the fuel pump and injector into a single unit. Fuel quantity is controlled by means of a helix on the plunger with the unit. The unit is driven by a pushrod and rocker system driven from the engine camshaft.
FEA with ANSYS for self designed parts: Carried out the Structural Analysis of Injector and Pump parts such as Injector nozzle, body, quill & pump housing with help of ANSYS 15.0. Applied the boundary conditions, prepare mesh and prepare the results PPT.
Up gradation of two- stroke petrol engine: Up gradation of existing two stroke 200cc petrol engine for 3 Wheeler to meet BS II regulations. Project includes, design & development of cyld. block from 2 port to 5 port, modification in the cyld. head to incorporate centralise combustion chamber with centralise spark plug, change the mixture induction system from cyld. using Pro-E design software. Cylinder block to the crank case & controlled by reed valve, modification in the piston top land to accommodate the changes in the combustion chamber, modification in the existing ignition system from 6 pole to 12 pole with CDI, development of carburetion system with different venturi size and different fuel circuits & finalisation of the same, development of complete exhaust system with implementation of after exhaust treatment devices such as CAT-CON & secondary air injection system.
Up gradation of 4-lit, 4 cyld. Diesel Engine for Tractor application: Objective was to up grade existing 4lit, 4 cyld. Diesel engine with turbo charger, mechanical fuel pump for the Non-road diesel application (Tractor) as well for the Genset application which is to be upgraded to meet US Tier3 emission standards for tractor application and Central Pollution Control Board-India (CPCB) emission norms for genset application. Emission Improvement Program mainly includes the following:
A. Combustion Optimization by
• Swirl Chamber redesign
• Piston top land modifications and Piston ring repositioning
• Integration of Auxiliary starting device (Pre and Post Glow)
• FIE (Fuel Injection Equipment) system changes
• Turbo Charger selection and boost pressure setting
• Integration of Charge Air Cooler
B. Exhaust gases after treatment with
• EGR system-internal EGR
The project includes the complete design, development of the required new/modified components & finalisation of the engine configuration for the optimisation together with Magna’s Engineering Centre Steyr (ECS) in Austria.
The Design included parts are Swirl port, Piston top land, inlet manifold, cylinder head cover & gaskets with Pro-Engineer.
The design, development & procurement of new/modified components was completed & currently engine & emission optimisation trials in progress at ARAI.
Power train Integrations for demo car for SIAT 2007: MAGNA displayed a demo 3 wheeler–load carrier run on gasoline as well as CNG (bi-fuel). Our role includes in this project to integrate complete power train package including new 4S 175cc petrol engine coupled with CVT transmission system, on the base chassis & related modifications to integrate power train & CNG kit.
CAD Packages
Pro-Engineer, Creo 2.0
PDM Windchill 10.1
ANSYS 15.0
DFMA (Design for Manufacturing and Assembly)
Academics
BE (Mechanical) April 2006 First class with Distinction
Diploma (Mechanical) June 2003 First class
