Arun S
Chennai
Summary
Experienced CAE Engineer with over 14 years of experience in automotive structural analysis. Skilled in linear/non-linear FEA, explicit simulation, durability analysis, dynamic analysis, and forming analysis using CAE tools. Proven ability to lead simulation teams, and drive cost and weight optimization through data-driven engineering.
Overview
15
15
years of professional experience
Work History
Deputy Manager
Royal Enfield
chennai
09.2013 - Current
- Acted as a Lead CAE Engineer, providing technical guidance, mentoring, and review support to team members for all chassis simulation activities. Validated team-delivered results, reports, and ensured analytical accuracy, and compliance with standards.
- Performed detailed stiffness analysis for various frame and swingarm assemblies to evaluate overall structural rigidity and load distribution.
- Conducted linear static analysis for frame and swingarm components to assess load-bearing capability, deformation patterns, and structural performance under operational loads.
- Executed non-linear static simulations for chassis subcomponents—including the footrest, brake pedal, handlebar, grab rails, center stand, side stand, and similar parts—to evaluate overload performance and identify failure risks.
- Carried out forming analysis to assess FLD curves, thinning percentages,spring back displacement and drawability for sheet-metal components, such as fuel tanks, brackets, gussets, and pressings. Delivered design recommendations to enhance manufacturability, and improve forming quality.
- Performed VAVE (Value Analysis & Value Engineering) studies to optimize the weight and cost of chassis components by proposing effective, validated design modifications.
- Executed adhesive–cohesive simulations and developed a new CAE methodology that improved adhesive joint prediction and engineering reliability.
- Conducted multiple CAE simulations, correlated with field failures and lab test setups, enhancing model accuracy and predictive capability for real-world performance.
- Performed dynamic analysis of chassis components to identify peak frequencies, evaluate vibration behavior, and provide design recommendations to prevent resonance-driven failures.
- Executed fatigue analysis under linear static loading conditions to estimate fatigue life, durability, and long-term reliability of critical chassis components.
- Created Standard Operating Procedures (SOPs) for various vehicle-level,subsystem level simulation workflows to standardize processes and improve CAE team efficiency.
- Developed and maintained a CAE dashboard capturing project data, simulation metrics, and software utilization for monthly CAE review meetings.
- Performed root-cause analysis for simulation-reported failures, identified critical issues, and provided corrective design recommendations to the product design team.
- Collaborated closely with the testing team to define physical test setups, improve CAE–test correlation, and enhance overall predictive accuracy.
- Developed full-vehicle FE models for horizontal and vertical overload cases to assess structural robustness under extreme loading conditions like off road and Pave.
- Performed comprehensive explicit dynamic analysis for full-vehicle scenarios, including side-fall events, impact simulations, and complete vehicle drop tests. Responsibilities included building high-fidelity FE models, defining material and contact behaviors, setting boundary conditions, running Radioss simulations, and evaluating deformation, failure modes, and structural integrity. Delivered actionable design improvements to enhance safety performance, durability, and OEM compliance.
- Executed vehicle-level topography and topology optimization, refining structural layouts and load paths to enable high-fidelity simulations and more reliable CAE results
- Enhanced simulation expertise by attending simulation-driven conferences and professional training sessions.
CAE Engineer
Hero Motocorp Ltd
Delhi
05.2013 - 09.2013
- Performed FE modeling and dynamic analysis of various two-wheeler automotive components, including the engine, frame, chassis parts, and structural sub-assemblies. Responsible for handling multiple CAE projects end-to-end, while coordinating execution with team members to ensure timely and accurate delivery.
- Performed linear and Non linear static analysis of sub structural parts of vehicle components and enable stiffness analysis of vehicle frame.
- Generated high-quality tetrahedral and hexahedral FE Modelling for engine components, frame structures, and other critical parts, ensuring optimal element quality for better convergence and accurate representation for FEA simulations.
Project Engineer
Nova-Global Techno soft Private ltd ,Deputed to Axis cades Private Ltd
Bangalore
06.2011 - 05.2013
- Completed FE Modeling and enable connections for aerospace components, including all 1D,2D and 3D methodologies.
- Transformed CAD inputs into simulation-ready CAE models, adhering to project guidelines.
- Established rigid connections based on specifications to optimize load transfer in simulations.
- Performed comprehensive quality assessments on FE models, verifying compliance with internal standards.
- Provided support to senior engineers through pre-processing and model setup assistance and enable structural comparative analysis and static analysis
Education
M TECH - Computer Aided Design
SRM University
Chennai01-2017
B.E. - Aeronautical Engineering,
V.S.B College of Engineering
Karur01-2011
H.S.C, -
Kamaraj Matric Higher Secondary School
Chidambaram01-2007
SSLC -
Kamaraj Matric Higher Secondary School
Chidambaram01-2005
Skills
- Structural analysis (linear, non-linear, modal, static, dynamic)
- Fatigue and durability analysis (FE-Safe, CAE Fatigue)
- Vehicle drop analysis, side fall analysis, and impact analysis (explicit simulations using Radioss)
- Forming analysis (FTI forming suite, Hyperform)
- CAE tools: HyperMesh, HyperStudy, HyperView, DEP, Abaqus, Nastran, OptiStruct, Radioss, FTI Forming Suite, HyperForm, FE-Safe, CAE Fatigue
- CAD: Creo, CATIA
- Team leadership and project management
- Correlation studies (test vs CAE simulation), field failure analysis, and vehicle optimization
- Simulation report preparation
- SOP development and process automation
Personal Details
Date of birth : 01-01-1990
Languages known :English, Tamil, and Hindi (basic)
Place : Sholinganallur,chennai
Timeline
Deputy Manager
Royal Enfield
09.2013 - Current
CAE Engineer
Hero Motocorp Ltd
05.2013 - 09.2013
Project Engineer
Nova-Global Techno soft Private ltd ,Deputed to Axis cades Private Ltd
06.2011 - 05.2013
M TECH - Computer Aided Design
SRM University
B.E. - Aeronautical Engineering,
V.S.B College of Engineering
H.S.C, -
Kamaraj Matric Higher Secondary School
SSLC -
Kamaraj Matric Higher Secondary School