Pratik Ligade

• Designed and digitally validated driveline components using KIMoS, KISSsoft, Romax, and Gleason tools
• Developed and analyzed spiral bevel, hypoid, spur, and helical gears for conventional and electric axles
• Performed durability, NVH, and efficiency analysis of helical gear pairs and planetary systems in Romax
• Selected and designed bearings, splines, shafts, housings, and associated technology parts
• Prepared DFMEA and DVP documents to ensure design verification and validation across product lifecycle
• Coordinated with CAE, CFD, vehicle integration, validation, and purchase teams for end-to-end design release
• Applied GD&T and conducted tolerance stack-up analysis; strong knowledge of materials and heat treatments
• Generated and implemented VAVE ideas in both new and existing products
• Conducted system- and vehicle-level benchmarking to guide design decisions
• Resolved line and field issues through structured 8D and CAPA methodologies

HRe210 E-Axle Design and Development (Hub Reduction E-Axle for 55T Prima Tractor) – Project Leader

• Conducted benchmarking, concept document preparation, and layout finalization
• Led durability, NVH, and efficiency analysis of helical and hypoid gear pairs and the planetary system in Romax
• Performed spiral bevel gear design and FE analysis in KIMoS
• Carried out design calculations for splines, axle shafts, and input/output shafts, with system-level analysis in Romax and KISSsoft
• Developed a new differential gear pair in KISSsoft
• Managed tolerance stack-up analysis for the complete assembly
• Resolved issues in testing and customer vehicles
• Created virtual RLDA using AVL Route Studio

New RA112 Axle Design and Development

• Designed 465 mm crown wheel and pinion (CWP) with FE analysis in KIMoS and Romax
• Developed new differential gear pair design in KISSsoft

RA109RR Efficiency Analysis

• Conducted system efficiency evaluation in Romax for 12m and 9m electric bus applications

RA1085 SRT Axle Design and Development

• Designed 400 mm CWP using KIMoS
• Performed durability and FE analysis of carrier and housing in KIMoS and Romax

Electric Vehicle Field Issue Analysis and Resolution

• Simulated regeneration-induced crown wheel and pinion failures in KIMoS and implemented corrective actions
• Modeled and analyzed RA110 and RA109RR rear axles in Romax for electric bus applications
• Conducted NVH analysis of RA110 axle in Romax to address noise issues

BS-VI Phase 2 – RDE Design Releases for Rear Axle Aggregate

• Designed new hypoid gear pairs in KIMoS to meet RDE requirements
• Prepared concept documents and performed vehicle application studies for drive head selection

• Led the design and development of gearbox projects for 2/3-wheelers, ICE, and EV applications.
• Performed system performance analyses for 2/3-wheeler ICE, and EV vehicles using Romax and KISSsoft.
• Gear ratio selection, tractive effort diagram, sawtooth curve, power reserve curve, vehicle acceleration curves, gear macro, and micro geometry analysis, along with complete gearbox design in Romax/KISSsoft.
• Utilized KISSsoft for efficient bevel gear design.
• Designed transmission and differential components such as shafts, casings, and bearings for two- and three-wheeled vehicles using UG-NX.
• Line issues, field issues resolution, FTA preparation, and implementation.
• Acquired expertise in gear materials and heat treatment processes.
• Demonstrated expertise in component-level testing and gearbox validation.
• Applied knowledge of GD&T, DFMEA, and design guidelines to ensure quality.

Projects undertaken:

K17E (Pulsar 250N) & K17F (Pulser 250F):

• Romax analysis and design of new primary, secondary, balancer, and oil pump gears, and modification in existing based on proto testing.
• DVP preparation and validation, issue resolution of gearbox components.
• Conducted CAD and drawing reviews following Bajaj standards.

Triumph 400 (Scrambler and Roadster, 250 and 400 CC):

• Gear ratio selection, tractive effort diagram preparation, design, and analysis of gears in Romax, along with the Triumph team.
• DVP preparation and validation, issue resolution of gearbox components.

KTM Duke & RC (125, 200, 390 CC):

• Gear ratio selection, bearing selection, and tractive effort diagram preparation for new generation KTM models.
• Designed and analyzed gears using Romax and KISSsoft for optimal performance.
• Validation monitoring and issue resolution for gearbox components.

RE-101 EV/RE445/RE236/QUTE (3W/4W-EV): Design of a new differential gear pair for electric 3W vehicles.

Core Skills & Responsibilities:

• Performed driveline component design and analysis using Gleason CAGE, Romax, and FEA tools
• Created propeller shaft calculation sheets and optimized layouts for life, angle, and dynamic behavior
• Designed spiral bevel, Zerol, hypoid, spur, and helical gears for various axle configurations
• Engineered shafts, splines, housings, bearings, and key technology parts for driveline systems
• Developed 3D CAD models and engineering drawings for components and assemblies
• Released designs through PLM and IDM systems, ensuring timely approvals and documentation
• Conducted benchmarking of systems and vehicles; analyzed results to drive concept strategies
• Led DFMEA and DVP preparation for system verification and validation
• Linked design tolerances with manufacturing process capabilities for feasibility and cost-effectiveness
• Applied GD&T principles and performed tolerance stack-up analysis for robust designs
• Utilized domain knowledge in castings, forgings, sheet metal, rubber, and plastic parts
• Drove Value Analysis / Value Engineering (VAVE) initiatives for cost and weight optimization
• Coordinated with CAE, CFD, integration, and validation teams for design release readiness
• Resolved field and line issues using structured 8D and CAPA methodologies

Hub Reduction Tandem Axle – HD PRO8000 Series & Volvo

• Led design and validation of spiral and Zerol bevel gearsets (first time in Eicher)
• Developed planetary gear systems, performed full-system analysis, and signed off CAE & RTS
• Executed platform-wide packaging, DFMEA, DVP, and lifecycle validation
• Delivered 5 innovation ideas, leading to approved patents

Single Reduction Tandem Axle – BSVI & Export

• Designed hypoid and helical gear systems using Gleason CAGE and Romax
• Implemented validation feedback, completed tolerance studies, and finalized vehicle integration

Rear Axle Aggregates – BS-VI PRO6000/PRO8000

• Delivered axle housing and carrier assembly designs, finalized drive head selection
• Completed concept modeling, CAE sign-off, NCR and validation documentation

Propeller Shaft – BS3 to BS6 (Domestic & Export)

• Engineered shaft layouts ensuring torsional dynamics, critical speeds, and service life targets
• Drove CAE validation, bracket design, and supplier engagement for CB and ESO sign-offs

470DH / 490DH Axle Series

• Generated gear summaries from RLDA; completed FEA, CAE, and system sign-offs
• Managed full DVP, PAA and packaging for upgraded GVW platforms

458DH Amboid Axle (First in Eicher)

• Developed first-ever Amboid gear layout and lightweight carrier design
• Validated pinion pack bearing design and delivered enhanced durability

Volvo–Eicher Synergy Project

• Created gear life prediction methodology using RLDA + Gleason FEA tools
• Optimized CWP summary and validated across platforms

Non-Auto / Export Projects (Escorts, Terex, ACE)

• Designed custom rear axles, led failure analysis and international customer support
• Delivered driveline systems for PRO5000/6000 export vehicles

Propeller Shaft Design Automation

• Developed design automation tools in Creo using Excel macros to reduce design cycle timeProjects Undertaken:

Hub Reduction Tandem Axle Design and Development (HD PRO8000 Series and Volvo Vehicles)

• Project leader for design, development, and validation
• Designed Zerol and spiral bevel gears (first time in Eicher) and validated designs
• Benchmarking of competition HRT and SRT axles, preparation of concept documents
• Design of planetary system for hub assemblies
• Design calculations and analysis in Gleason CAGE, FEA, and Romax
• CAD design, drawing preparation, and tolerance stack-up
• CAE completion and RTS sign-off from suppliers
• Vehicle-level packaging and communization across platforms
• DFMEA, DVP, and PAA preparation and implementation
• B-C build, production release, and lifecycle validation
• Implemented 5 innovation ideas resulting in approved patents

Single Reduction Tandem Axle Design and Development (BSVI and Export Models)

• C build, validation, and production release
• Hypoid gear design in Gleason CAGE and helical gear design in Romax
• Design modifications based on validation feedback
• Tolerance stack-up, DFMEA, DVP, and PAA preparation
• CAE completion, RTS sign-off, and vehicle integration

BS-VI Design Releases for Rear Axle Aggregate

• BSVI design releases for rear axles across PRO6000 and PRO8000 platforms
• Concept documents, calculations, and drive head selection
• Design of axle housings and carrier assemblies
• Concept modeling, VI sign-off, NCR closure, VDFA/VDAFM sign-off
• CAE completion and RTS sign-off
• DVP and PAA preparation

Propeller Shaft Design and Development (BS6, BS3, BS4 HD Vehicles – Domestic and Export)

• Propeller shaft design and layout finalization considering Beta angle, B10 life, torsional accelerations, and critical speed
• Supplier series selection, proposal reviews, and CB mounting bracket development with CAE validation
• Tolerance stack-up management and adherence to timelines
• DFMEA, white book preparation, cost reduction initiatives
• Supplier DVP finalization, PAA/ESO sign-offs
• VDFA, VI sign-offs, proto build support, and field validation
• Benchmarking and BS6 quick action team support

470DH and 490DH Axle Design and Development

• 470DH CWP summary generation using RLDA and Gleason
• FEA-based design calculations, CAE, and RTS sign-offs
• Vehicle packaging, DVP, and PAA preparation

Revised GVW Project

• Design calculations for CWP, differential gears, axle housings, shafts, and bearings
• Design finalization, vehicle integration, CAE, release, and validation

458DH NextGen Amboid Axle Design and Development

• Amboid gear design (first time in Eicher) and Gleason FEA calculations
• Pinion pack bearing concept design and lightweight carrier validation

Volvo-Eicher Synergy Project

• Hypoid gear life analysis methodology in Gleason FEA tools
• Gear life calculations from RLDA data
• CWP summary optimization using Gleason CAGE

Non-Auto and Export Projects

• Rear axle design for Escorts, Terex, and ACE Motors
• Field failure support and customer interaction
• Export driveline development for PRO5000 and PRO6000

Propeller Shaft Design Automation Project

• Creo design automation with Excel programming
• Developed tools for efficient CAD modeling and reduced supplier dependency