Prasad Rai

• CMI32680: Torsional vibration damper with enhanced cooling through vapor tube technology
• CMI32689: Various filters used in Engine or transmission with chip technology to track replacement, life, and warning to th user for service
• Regional ESW 95067 (valve train system) specialist

On-Going Project(s):

• Working as Power Cylinder System owner for M15 CPCB-IV Anuradha India VPI program
• Working as Base Engine System owner for Frodo China NS-VI program
• Supporting Applied Mechanics team to develop robust methods to predict bore distortion using FEA under SBPD project number FI-1900302

Handled multiple PQC and FIRG projects in area of Base Engine components, power cylinder components, valve train components, gasket sealing failures

• PQC projects - Valve seat insert dropping, Ball socket failure, EMAT strap braking, Ball shank breakage, Connecting Rod Small End joint field failure (Bush wear) G12 program
• FIRG projects - Cyl head cracking in SLT2, Piston Pin jamming in PJST test
• Cummins Head Gasket Development- Developed analysis approach, analysis led design, prediction of pressure closure through analysis, 3D Head gasket analysis methodology, Gasket Bead formation and sealing capacity predictions under working loads - EP and trade secret have been outcome of efforts
• Metrological process development at CTCI- Gasket bead measurement method using contour tracing tool established, Piston pin bore profile measurement process understanding and transfer knowledge of metrological inspection for power cylinder components to CTCI DM Lab
• Working closely with ESW owners of Valve train, Gaskets, Power cylinder, Base Engine establishing confidence and network across global regions
• Working closely with leadership for assigned work and effectively communicate in different high level meetings like RRG, MRG for assigned work
• Visiting suppliers for core techno-commercial discussions on power cylinder components, valve train components
• Handled non-standard work assignments in analysis domains
• Excellent analysis tool handling capability to capture real world physics and setting up problems by developing boundary conditions and loadings
• Capability development for Engine Knock Sensor Location Identification Analysis
• Dynamic analysis of Engine Mounting system using GT Suite to understand effect of different piston masses
• Developed capability of Engine Lube Pump performance and Lube pump bearing performance analysis
• Documentation of capabilities and standard operating process for several analysis tasks
• White paper on Piston Pin Joint EHD Analysis using AVL-Excite in AVL conference
• Multiple projects carried on Dynamic Analysis (Torsional + Bending) of Engine crankshaft using GT Suite
• EHD Analysis of various joints in Engine using AVL Excite
• Investigation of effect of valve spring stiffness on different components of Valve train system and effect on Cam Contact stress
• Conducted research, gathered information from multiple sources and presented results
• Used critical thinking to break down problems, evaluate solutions and make decisions
• Collaborated with team members to achieve target results

• Design and development of Fractured Split connecting rod
• Fatigue Analysis of Connecting rod and validation of same with physical testing
• Cylinder Block bore distortion FE Analysis and correlation with testing and FEA process standardization
• Engine power train (Block, Piston, Con-Rod, Crankshaft) observation after testing and investigation of failures if any
• Investigation of field failure for a Connecting rod with split bush in detail and re-designing of the split bushing of Big end
• FE Analysis of Piston, Block, Crank Shaft, and Connecting Rod for various load cases and validation with Physical Testing
• Coordination with testing teams for various tests being conducted or needs to be conducted for specific components or engine levels
• Vendor visits to overview the manufacturing process and develop additional design inputs required for components
• Crankshaft damper design and development, Analysis, and testing
• Designing, FE Analysis, and Testing of Engine Power Train for all 2, 3, and 4 Wheelers.

• Structural Analysis and Suggestions for Drilling station
• Engine Jacket / Block and Liner Thermal Stress analysis
• Engine Block structural Transient Analysis for Stress flow investigation considering gas forces
• Post processing structural and Modal analysis using Hyperview
• Modal Analysis of Marine Engine Main frame for various Engine designs
• Structural analysis of Auxiliary cabinets of locomotives
• Transient analysis of Hinge Supports various cars
• Steering system Modal Analysis and Harmonic analysis
• Excavator boom PSD Analysis and G load Analysis
• Impact Simulation of the truck cab using ANSYS Explicit STR tool (Auto-Dyne Solver)
• Simulation of Interference Fit of SS-304 material tube and plug and its effect on adjacent material FEEK450G (Plastic)
• Non –linear Analysis of Solenoid Membrane under external and internal pressures
• Graphite crush and seal type gasket sealing analysis and failure investigation
• Transient Analysis of Doser Nylon bolt in ANSYS Workbench and suggestion with modified Bolt design failing due to tightening
• PSD Analysis of various Silencers (Aftertreatment Systems of Engines) with ISO and BS standard PSD profiles
• Fatigue (Durability) Analysis of various Silencer models for a variety of Engines
• Pre-processing of CAD geometries in ANSYS APDL
• RBM Analysis to detect failure locations at weld toe at flange locations
• Non-Linear Analysis of Sealing gaskets using Explicit STR
• Structural Analysis, PSD, and Fatigue Analysis of various 35 L and 16 L urea Tank Brackets
• Mica Gasket Sealing Analysis of Dosing pump using ANSYS workbench.

• Thermal – Structural couple field Analysis of Compressor casing block
• Hypermesh Deck preparation for Turbo casting to optimize weight
• Modelling of Radiator using Creo
• Harmonic Analysis of same using ANSYS Workbench
• Meshing of assembly for 2 Cylinder Engines of 20 H.P
• Modelling of Engine Parts using Creo for Life Estimation of various Engine Components
• Patching work of Piston Model for Thermal and Structural Analysis
• Modelling of Chassis using Creo Fatigue Analysis of Chassis using ANSYS Fatigue Tool
• Development of Residential Silencer for Engines ranging from 100 H.P to 180H.P in Creo and its Analysis using ANSYS.

• Designing of Chassis for a wide range of D.G Sets from 5 to 320 k.v.a considering 2 conditions due to magnetic braking of Alternator(Generator) i.e Torsional and Static loading
• Assembling of Ashok Leyland 402, 411NTC engine manually Total overhauling of Caterpillar 3406NTC Engine for development of 320 k.v.a D.G Set
• Coupling A.C Alternator with various Engines
• Development of Soundproof canopy for 82.5 k.v.a D.G Set for Vibgyor High school, Kolhapur