HARI KISHAN TV

Finite Element Analysis (FEA)

• 4 years of experience in static structural analysis, stress analysis, and linear/non-linear simulations using ANSYS Workbench for automotive and mechanical components.
• Proficient in thermo-mechanical fatigue analysis, understanding material behavior, crack initiation, and propagation under complex loading conditions.
• Developed and validated methodologies for real-time failure correlation by integrating process simulation, static structural analysis, and fatigue simulations.

Material Modeling

Specialized in developing and validating material models for accurate simulation of complex behaviors, including:

• Elastic and Plastic Behavior: Modeled material deformation under different load conditions, incorporating strain hardening and anisotropy effects.
• Non-Linear Material Behavior: Simulated non-linear properties such as hyper elasticity, viscoelasticity, and creep for metals and polymers.
• Material Characterization: Created real test material curves (stress-strain relationships) for steel and aluminum materials using Artificial Neural Networks (ANN).
• Damage and Failure Modeling: Applied damage models to predict crack initiation and propagation in components under high-stress conditions.

Conducted material property studies to ensure precise modeling under various manufacturing and operational conditions, bridging simulation and experimental results.

Meshing Expertise

• Proficient in creating structured, unstructured, and hybrid meshes for complex geometries.
• Skilled in generating high-quality hexahedral, tetrahedral, shell, and beam elements based on simulation needs.
• Experienced in mesh optimization for high-stress zones and applying adaptive meshing for non-linear or large deformation analyses.
• Conducted element quality checks to ensure optimal aspect ratio, skewness, and Jacobian values.
• Hands-on experience with tools like Altair HyperMesh, ANSYS Meshing, and SpaceClaim for meshing large, complex assemblies.

Stamping Simulation

Comprehensive expertise in stamping simulation, including:

• Stamping Tool Design: Designed and optimized stamping tools to improve manufacturability and reduce material waste.
• Blank Optimization: Developed blank layouts and provided design suggestions to minimize material usage while maintaining component integrity.
• Process Simulations:
• Performed simulations for deep drawing, bending, trimming, and blank holder force analysis to enhance forming processes.
• Analyzed wrinkling, thinning, and fracture tendencies to ensure defect-free manufacturing.
• Design of Experiments (DOE): Conducted DOE studies for process parameter optimization and provided design recommendations to enhance stamping outcomes.

Manufacturing Simulation

Expertise in simulating complex manufacturing processes to optimize design and performance:

• Welding Simulations
• Simulated various welding processes to predict weld strength, residual stresses, and thermal effects on components.
• Ensured weld joint reliability through detailed thermal and structural analysis.
• Bulk Metal Forming Simulations
• Conducted simulations of forming processes such as crimping, coining, orbital forming, extrusion, and cutting.
• Predicted material flow, strain, and stress distribution to ensure defect-free forming operations.
• Heat Treatment Simulations
• Simulated heat treatment processes to evaluate thermal gradients, material phase changes, and residual stresses.
• Assessed mechanical property changes post-heat treatment to validate design durability.

Process Simulation and Methodology Development

• Developed results mapping methodologies to transfer data seamlessly from process simulations to FEA platforms like ANSYS and ABAQUS.
• Bridged the gap between simulation results and real-world testing, improving accuracy and reliability of performance predictions.
• Authored standards and work instructions to document best practices and ensure consistent simulation workflows.

Material Behavior and AI Integration

• Created Machine Learning (AI) models to predict real test material curves (stress-strain relationships) for steel and aluminum materials using Artificial Neural Networks (ANN).
• Automated workflows for FEA preprocessing using MATLAB, enhancing efficiency and reducing manual intervention.
• Conducted advanced material property studies to ensure precise modeling under various manufacturing and operational conditions.

Software Proficiency

Advanced user of:

• FEA Tools: Altair Hyperworks(Hypermesh, Hyperview,Hypergraph), ANSYS, Hexagon Simufact, COLDFORM, NX, Inspireform,Autoform, Inspirecast.
• CAD Tools: Creo (Pro-E), SolidWorks, and SpaceClaim.
• Skilled in automating simulation processes and data handling using MATLAB.

Technical Communication

• Proficient in presenting complex technical analyses and findings to diverse audiences, including peers, leadership, and external regulatory bodies.
• Collaborative team player with strong interpersonal skills and a problem-solving mindset.

Key Achievements

• Developed a robust methodology for real-time failure correlation by combining process, structural, and fatigue simulations.
• Delivered significant cost and efficiency improvements by integrating AI-driven workflows and optimizing manufacturing processes.
• Automated simulation preprocessing workflows using MATLAB, reducing time and resource expenditure.

• Training on passenger & cars Engine, Gear box
• Powertrain