Kumar Alok
Pune
Summary
Core Hydraulic Design Engineer with 5+ years of experience in hydraulic and electromechanical product development, specializing in vane pumps, vane motors, and hydraulic systems. Strong hands-on expertise in hydraulic design calculations, pressure-containing components, rotor-vane systems, bearings, porting, sealing, fatigue life, and validation testing. Proven capability in taking products from concept, sizing, design, simulation, DVPR, endurance testing, and production release, while driving VAVE, DFSS, and cost optimization for global markets.
Overview
11
11
years of professional experience
Work History
Product Engineer
Danfoss Power Solution
Pune
01.2023 - Current
- Designed and validated pressure-loaded components for applications up to 300+ bar, ensuring performance and reliability of covers, bodies, ports, and plugs.
- Lead core hydraulic design of vane pumps and vane motors, including rotor, vane, bearing, cam ring, side plates, covers, and porting.
- Perform hydraulic sizing calculations for displacement, flow, torque, power, volumetric & mechanical efficiency across speed-pressure envelopes.
- Execute sealing design (O-ring size, groove width/depth, squeeze, extrusion gap) for high-pressure hydraulic applications.
- Conducted fatigue and durability improvement studies to optimize fillet design, reduce stress, and enhance lifespan of rotors and covers.
- Perform FEA (static & fatigue) to correlate analytical calculations with test results.
- Defined DVPR and endurance test plans to support comprehensive burst, fatigue, and performance testing.
- Delivered 30%+ reduction in design, material, and process cost through VAVE initiatives, alternate materials, and supplier optimization.
Design Engineer
Secure Meters Ltd
Udaipur
07.2018 - 12.2020
- Designed electromechanical and fluid-handling products, ensuring seamless transition from concept to production.
- Strong foundation in DFM, DFA, GD&T (ASME Y14.5) and tolerance stack-up.
- Hands-on experience with SLA/FDM prototyping, validation, and Six Sigma quality tools (Cpk ≥ 2.0).
- Managed engineering changes, coordinating ECR/ECO/BOM processes to maintain project timelines and accuracy.
Summer Internship
Tata Motors
Jhamshedpur
05.2016 - 07.2016
- Streamlined assembly processes in proto-shop, improving workflow and reducing delays.
- Resolved noise issues in model-LPK 492, ensuring reliable operation and enhancing user experience.
Internship Student
NHPC Limited
Sikkim
05.2015 - 07.2015
- Project 1: Project on working principles of Francis Turbine, turbine components, parts etc.
- Project 2: Optimization of draft tube for Micro Hydro Turbine which was funded by UCOST and was delivered to IIT ROORKEE.
Education
M.Tech - Design Engineering
Birla Institute of Technology And Science
Pilani12.2022
B.Tech/B.E. - Mechanical Engineering
DIT University
Dehradun06.2018
XIIth - PCM
NSVM, CBSE
Ballia, UP04.2013
Xth - PCMB
NSVM, CBSE
Ballia, UP04.2011
Skills
- 3D CAD (SolidWorks / Creo / NX)
- Hydraulic design
- Polymer design
- Metal part design
- Tolerance Stack-up Analysis
- GD&T
- DFMEA
- DFSS
- FEA (Static & Fatigue)
- Prototype testing
- DfX
- VAVE/ Cost Out
- Root cause analysis
- PLM Teamcenter
- VMA certified
- Cross-Functional Collaboration
- Attention to detail
Projects
- Premium Metering Products from Concept, Design, Simulation, DFM, DFA, Testing , Packaging to UK, Italy , India and ROW market. 1. Premier 300/500 Link :- https://www.securemeters.com/in/product/distribution-transformer-metering/premier-500/
- Boiler Controls , Programmable Thermostat , And Tempreture Sensors Products For UK market & ROW. Link :- https://www.securemeters.com/product/programmable-room-thermostats/c1727/
- Vane Pump/ Motor – New Product Development Developed a competitive vane pump & Motor from concept to production release.
Courses Certifications
- Geometric Dimensions & Tolerance
- ANSYS ABACUS
- DFMA
- NPTEL Online Certification ( Steam and Gas Power Systems )
- Value Methodology Associate - SAVE International (Valid upto 06/2028)
Languages
- Sanskrit
- Hindi
- Maithili
- Marathi
- English
Awards
- Bright Beginner Award in Danfoss-2024
- Best Recreation Award in Danfoss - 2024
- Star Award in Danfoss - 2025 ( 2 + million $ saving projects )
Hobbies and Interests
- Travelling
- Technical blogging
- Reverse Engineering
Timeline
Product Engineer
Danfoss Power Solution
01.2023 - Current
Design Engineer
Secure Meters Ltd
07.2018 - 12.2020
Summer Internship
Tata Motors
05.2016 - 07.2016
Internship Student
NHPC Limited
05.2015 - 07.2015
M.Tech - Design Engineering
Birla Institute of Technology And Science
B.Tech/B.E. - Mechanical Engineering
DIT University
XIIth - PCM
NSVM, CBSE
Xth - PCMB
NSVM, CBSE