Material Testing and Development Engineer

• Sep 2020 - Present

Develop new experimental setups integrated with advanced metrology sensors • Expertise in developing new experimental setups integrated with advanced measurement sensors (including but not limited to 2D and 3D DIC, high-speed DIC, 3D scanning, strain gauges, load cells, etc.) • Development of methods for verification and validation of experimental results obtained from custom test setups. Perform custom material & component tests with Digital Image Correlation (DIC): • Strong… Show more Develop new experimental setups integrated with advanced metrology sensors • Expertise in developing new experimental setups integrated with advanced measurement sensors (including but not limited to 2D and 3D DIC, high-speed DIC, 3D scanning, strain gauges, load cells, etc.) • Development of methods for verification and validation of experimental results obtained from custom test setups. Perform custom material & component tests with Digital Image Correlation (DIC): • Strong expertise in setting up and using 2D/3D DIC systems for deformation measurements in material and component tests. • Excellent hands-on skills in the use of a wide range of testing systems (including universal testing machines, hydraulic presses, servo-hydraulic testing machines, high-speed testing machines, cameras, data acquisition systems). Experience in operating such systems for performing standard material tests as well as custom tests (focus on automotive sheet metal tests, battery material tests, crash tests, component performance tests). Perform DIC analysis and write custom scripts to generate material test results • Strong expertise in using DIC software to analyze material deformation projects. • Demonstration of coding skills to write custom scripts/macros for DIC software, in order to generate specific test results in particular formats. Material modeling and numerical analysis for forming and crash simulations • Identifying the suitable mathematical (constitutive law/ fracture) models to accurately predict the material behavior in forming and crash applications in LS-DYNA. • Use the test data to calibrate complex mathematical models that describe the deformation and fracture behaviors of those materials. Show less Develop new experimental setups integrated with advanced metrology sensors • Expertise in developing new experimental setups integrated with advanced measurement sensors (including but not limited to 2D and 3D DIC, high-speed DIC, 3D scanning, strain gauges, load cells, etc.) • Development of methods for verification and validation of experimental results obtained from custom test setups. Perform custom material & component tests with Digital Image Correlation (DIC): • Strong… Show more Develop new experimental setups integrated with advanced metrology sensors • Expertise in developing new experimental setups integrated with advanced measurement sensors (including but not limited to 2D and 3D DIC, high-speed DIC, 3D scanning, strain gauges, load cells, etc.) • Development of methods for verification and validation of experimental results obtained from custom test setups. Perform custom material & component tests with Digital Image Correlation (DIC): • Strong expertise in setting up and using 2D/3D DIC systems for deformation measurements in material and component tests. • Excellent hands-on skills in the use of a wide range of testing systems (including universal testing machines, hydraulic presses, servo-hydraulic testing machines, high-speed testing machines, cameras, data acquisition systems). Experience in operating such systems for performing standard material tests as well as custom tests (focus on automotive sheet metal tests, battery material tests, crash tests, component performance tests). Perform DIC analysis and write custom scripts to generate material test results • Strong expertise in using DIC software to analyze material deformation projects. • Demonstration of coding skills to write custom scripts/macros for DIC software, in order to generate specific test results in particular formats. Material modeling and numerical analysis for forming and crash simulations • Identifying the suitable mathematical (constitutive law/ fracture) models to accurately predict the material behavior in forming and crash applications in LS-DYNA. • Use the test data to calibrate complex mathematical models that describe the deformation and fracture behaviors of those materials. Show less

Material Testing and CAE Engineer

• Aug 2019 - Aug 2020

• Leading and supervising a team of young engineers for planning, execution, and timely delivery of testing projects. • Subject-matter expert for advanced mechanical testing of materials and components using optical metrology techniques, specially 2D and 3D-DIC, and their integration with the standardized and custom test setups in support of research and development efforts. • Reference person for testing projects, and highly skilled in performing standard qualification tests… Show more • Leading and supervising a team of young engineers for planning, execution, and timely delivery of testing projects. • Subject-matter expert for advanced mechanical testing of materials and components using optical metrology techniques, specially 2D and 3D-DIC, and their integration with the standardized and custom test setups in support of research and development efforts. • Reference person for testing projects, and highly skilled in performing standard qualification tests, standard evaluation testing, customized testing on material and components for material suppliers, Tier-1 and 2 suppliers, and OEMs for transportation and consumer electronics industry. • Specialized in performing mechanical tests (tension, bending, sheet formability, biaxial, bulge, tension-compression cyclic, fracture, Hole expansion ratio, etc.) on traditional and Advanced High Strength Steels (AHSS), aluminum, titanium, composites, additive and other advanced materials in the form of sheets, plates, foils, joints, at a wide range of temperature, at varying speeds (low/intermediate/high speed/crash) and generating high quality data for research. • Technical Consultations with customers for understanding their project needs and suggesting mechanical testing packages suited for their requirements. • Assisting customers in numerical modeling, ranging from tailoring the mechanical test data to support their needs, providing support for fitting material models, writing user-defined material cards (UMAT) in LS-DYNA to be used in their finite element projects to running complete fracture model calibrations (Generalized Incremental Stress-State Dependent Damage Model (GISSMO) FE card including rate effects), developing lab-scale experimental validation models. Show less • Leading and supervising a team of young engineers for planning, execution, and timely delivery of testing projects. • Subject-matter expert for advanced mechanical testing of materials and components using optical metrology techniques, specially 2D and 3D-DIC, and their integration with the standardized and custom test setups in support of research and development efforts. • Reference person for testing projects, and highly skilled in performing standard qualification tests… Show more • Leading and supervising a team of young engineers for planning, execution, and timely delivery of testing projects. • Subject-matter expert for advanced mechanical testing of materials and components using optical metrology techniques, specially 2D and 3D-DIC, and their integration with the standardized and custom test setups in support of research and development efforts. • Reference person for testing projects, and highly skilled in performing standard qualification tests, standard evaluation testing, customized testing on material and components for material suppliers, Tier-1 and 2 suppliers, and OEMs for transportation and consumer electronics industry. • Specialized in performing mechanical tests (tension, bending, sheet formability, biaxial, bulge, tension-compression cyclic, fracture, Hole expansion ratio, etc.) on traditional and Advanced High Strength Steels (AHSS), aluminum, titanium, composites, additive and other advanced materials in the form of sheets, plates, foils, joints, at a wide range of temperature, at varying speeds (low/intermediate/high speed/crash) and generating high quality data for research. • Technical Consultations with customers for understanding their project needs and suggesting mechanical testing packages suited for their requirements. • Assisting customers in numerical modeling, ranging from tailoring the mechanical test data to support their needs, providing support for fitting material models, writing user-defined material cards (UMAT) in LS-DYNA to be used in their finite element projects to running complete fracture model calibrations (Generalized Incremental Stress-State Dependent Damage Model (GISSMO) FE card including rate effects), developing lab-scale experimental validation models. Show less

Graduate Research Assistant

• Jan 2017 - Jul 2019

Clemson University International Center for Automotive Research (CU-ICAR) * Formability study on Lightweight materials, specializing in Advanced High Strength Steels. * Sheet metal forming of Aluminum and Advanced High Strength Steels (material testing and characterization, constitutive modeling, Finite Element simulations, …) * Perform material testing on hydraulic press with the help of digital image correlation (DIC) technique * Advanced material testing (Biaxial testing… Show more Clemson University International Center for Automotive Research (CU-ICAR) * Formability study on Lightweight materials, specializing in Advanced High Strength Steels. * Sheet metal forming of Aluminum and Advanced High Strength Steels (material testing and characterization, constitutive modeling, Finite Element simulations, …) * Perform material testing on hydraulic press with the help of digital image correlation (DIC) technique * Advanced material testing (Biaxial testing, high temperature testing, high rate deformation, forming limit curves) for advanced high strength steels, aluminum and magnesium

Graduate Teaching Assistant

• Jan 2017 - May 2017

Co-op: Supplier Quality Assurance

• Aug 2016 - Dec 2016

* Developing tools to track the status of PPAPs for specific projects, to be used by SQEs and managers for data monitoring and analysis . * Support SQEs in various activities. * Analysis of quality problems for categorization and preparation of technical reports/ presentations for upper management.

Summer Intern: Supplier Quality Assurance

• Jun 2016 - Jul 2016

* Support in arrangement of supplier training events to introduce Volvo systems and processes to new suppliers * Support SQEs in various activities

Executive Engineer, Parts Quality, Supplier Quality Assurance

• Jul 2013 - Jul 2015

Responsibilities • Reduced line loss due to quality problems to achieve daily target of max 5 minutes per shift • Responsible for incoming inspection of non-direct-on-line (NDOL) parts • Performed inspection of electrical and proprietary parts using gauges and inspection instruments for root cause analysis of quality problems and developed countermeasures • Supported quality management system based on ISO/TS 16949 technical specifications. • Collaborated with more than 40 tier-1… Show more Responsibilities • Reduced line loss due to quality problems to achieve daily target of max 5 minutes per shift • Responsible for incoming inspection of non-direct-on-line (NDOL) parts • Performed inspection of electrical and proprietary parts using gauges and inspection instruments for root cause analysis of quality problems and developed countermeasures • Supported quality management system based on ISO/TS 16949 technical specifications. • Collaborated with more than 40 tier-1 suppliers for countermeasure implementation at their production line • Coordinated inspection, analysis and countermeasure against market quality problems to achieve zero re-occurrence • Performed Quality Assurance Visits (QAV) at tier-1 and tier-2 suppliers • Minimized vehicle quality problems due to bought out parts to achieve defects per vehicle (DPV) model targets • Computed and analyzed rejection Quality Parts per million (QPPM) for weekly supplier performance rating • Minimized rejection of bought out parts due to quality issues to achieve supplier QPPM target of 60 • Impacted continuous improvements by Kaizen, 5S and presented New Honda Circle (NHC) - Team ‘Kiran’ at President level • Responsible for assurance of new model parts for pre-production trials Accomplishments • Gained exposure in after-sales customer service, sales and marketing, purchase, supplier quality assurance, press shop, low pressure die casting and high pressure die casting for overview of all processes and overall functioning of a company, as a part of Graduate Engineer Trainee program • 'Mid-year Performance Award- 91Ki' for performance 'Exceeding expectations' • Led worst supplier management (WSM) program to improve the quality level of suppliers, reduced QPPM level of a tier-1 supplier by 76% within a period of 3 months Show less Responsibilities • Reduced line loss due to quality problems to achieve daily target of max 5 minutes per shift • Responsible for incoming inspection of non-direct-on-line (NDOL) parts • Performed inspection of electrical and proprietary parts using gauges and inspection instruments for root cause analysis of quality problems and developed countermeasures • Supported quality management system based on ISO/TS 16949 technical specifications. • Collaborated with more than 40 tier-1… Show more Responsibilities • Reduced line loss due to quality problems to achieve daily target of max 5 minutes per shift • Responsible for incoming inspection of non-direct-on-line (NDOL) parts • Performed inspection of electrical and proprietary parts using gauges and inspection instruments for root cause analysis of quality problems and developed countermeasures • Supported quality management system based on ISO/TS 16949 technical specifications. • Collaborated with more than 40 tier-1 suppliers for countermeasure implementation at their production line • Coordinated inspection, analysis and countermeasure against market quality problems to achieve zero re-occurrence • Performed Quality Assurance Visits (QAV) at tier-1 and tier-2 suppliers • Minimized vehicle quality problems due to bought out parts to achieve defects per vehicle (DPV) model targets • Computed and analyzed rejection Quality Parts per million (QPPM) for weekly supplier performance rating • Minimized rejection of bought out parts due to quality issues to achieve supplier QPPM target of 60 • Impacted continuous improvements by Kaizen, 5S and presented New Honda Circle (NHC) - Team ‘Kiran’ at President level • Responsible for assurance of new model parts for pre-production trials Accomplishments • Gained exposure in after-sales customer service, sales and marketing, purchase, supplier quality assurance, press shop, low pressure die casting and high pressure die casting for overview of all processes and overall functioning of a company, as a part of Graduate Engineer Trainee program • 'Mid-year Performance Award- 91Ki' for performance 'Exceeding expectations' • Led worst supplier management (WSM) program to improve the quality level of suppliers, reduced QPPM level of a tier-1 supplier by 76% within a period of 3 months Show less

Project Intern, After-Sales Service

• Jan 2013 - Jun 2013

Responsibilities • Project on "Continual analysis and reduction of technical DISS tickets in the network open for more than five days” DISS ticket is a parameter in the global Skoda service system which directly indicates the lead time a car spends inside a dealership for service. The project dealt with the study of various root causes of pendencies associated with technical DISS tickets in the network open for more than five days and devising techniques to resolve… Show more Responsibilities • Project on "Continual analysis and reduction of technical DISS tickets in the network open for more than five days” DISS ticket is a parameter in the global Skoda service system which directly indicates the lead time a car spends inside a dealership for service. The project dealt with the study of various root causes of pendencies associated with technical DISS tickets in the network open for more than five days and devising techniques to resolve them. Accomplishments • Received an enriching exposure of the overall functioning of an automotive dealership • Achieved a reduction in the number of pending tickets by 71% (all time low) in a period of 2 months Show less Responsibilities • Project on "Continual analysis and reduction of technical DISS tickets in the network open for more than five days” DISS ticket is a parameter in the global Skoda service system which directly indicates the lead time a car spends inside a dealership for service. The project dealt with the study of various root causes of pendencies associated with technical DISS tickets in the network open for more than five days and devising techniques to resolve… Show more Responsibilities • Project on "Continual analysis and reduction of technical DISS tickets in the network open for more than five days” DISS ticket is a parameter in the global Skoda service system which directly indicates the lead time a car spends inside a dealership for service. The project dealt with the study of various root causes of pendencies associated with technical DISS tickets in the network open for more than five days and devising techniques to resolve them. Accomplishments • Received an enriching exposure of the overall functioning of an automotive dealership • Achieved a reduction in the number of pending tickets by 71% (all time low) in a period of 2 months Show less

Project Trainee, Aluminum Machining

• May 2011 - Jul 2011

Responsibilities • Project on “Quality problem understanding in crank case-KWP”. The project targeted at studying and suggesting ways to minimize the rejection due to quality problems in the production of left and right crank cases of Honda Activa scooter. Accomplishments • Achieved significant reduction in rejection quantity of crank cases • Suggested a new method of setting the tool insert changing frequency which got accepted and implemented on the production line Responsibilities • Project on “Quality problem understanding in crank case-KWP”. The project targeted at studying and suggesting ways to minimize the rejection due to quality problems in the production of left and right crank cases of Honda Activa scooter. Accomplishments • Achieved significant reduction in rejection quantity of crank cases • Suggested a new method of setting the tool insert changing frequency which got accepted and implemented on the production line