Summary
Overview
Work History
Education
Skills
Accomplishments
Languages
Affiliations
Timeline
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Sai Akhil Tata

Hyderabad

Summary

Dynamic and proactive FEA Engineer with 4.5 years of experience in NVH analysis, durability evaluation, and structural optimization of electric powertrains. Skilled in collaborating with cross-functional teams to integrate NVH and fatigue requirements into electric and hybrid drivetrain designs. Proficient in advanced simulation techniques, methodology development, and data-driven insights to improve product performance and reliability. Adaptable, fast learner, and motivated to contribute effectively in challenging environments.

Overview

4
4
years of professional experience

Work History

Senior Engineer (FEA)

ZF India Private Limited
Hyderbad
03.2023 - Current
  • Performed NVH analysis on electric powertrains using comprehensive FEA models, contributing to improved acoustic performance in commercial and passenger vehicles.
  • Developed FE models to analyze Local Dynamic Attachment Stiffness of mounts and bearing seats, recommending design modifications to achieve NVH targets.
  • Mentored team members and tested CAE automation tools, supporting validation of simulation methodologies.
  • Evaluated structure-borne and air-borne noise in E-Drives from motor and gear excitations, identifying root causes of resonance peaks through Operational Deflection Shape analysis.
  • Conducted gear body topology optimization to reduce mass and transmission error while meeting frequency performance targets.
  • Optimized stator and rotor material properties using DOE and Experimental Modal Analysis data, improving accuracy of FE models.
  • Applied advanced CAE techniques to ensure strong correlation between simulations and physical test outcomes for E-Drives.
  • Collaborated with Testing and Design teams to develop E-Drives that meet rigorous criteria and deliver superior NVH performance.
  • Experience in managing the expectations of global clients, such as Audi, BMW, Paccar, and MBAG.

FEA Engineer

QuEST Global Engineering Services Private Limited
Bangalore
07.2021 - 03.2023
  • Performed FEA on casings, impellers, and various turbomachinery components to support projects for Elliott and Siemens clients.
  • Prepared simulation setups for FEA analysis, including geometry cleanup, meshing, and application of boundary conditions.
  • Collaborated with the Elliott Group Engineering Support team to perform No-Linear static and modal analysis of compressor casings and blade-disk assemblies.
  • Handled multiple projects independently, responsible for analysis, result interpretation, and on-time project delivery to clients.
  • Conducted meetings with onsite clients to communicate project progress, present results, and align on timelines.
  • Contributed to continuous improvement by proposing suggestions and actively participating in problem-solving to enhance teamwork.
  • Trained junior engineers on methodologies and best practices to enhance overall productivity.

Education

Master of Engineering(M.E.) - Desig Egineering

BITS PILANI
Hyderabad, India
01-2020

Bachelor of Engineering (B.E.) - Mechanical Engineerinng

Osmaia University
Hyderabad, India
01-2018

Skills

  • Finite Element Analysis
  • Hypermesh, Simlab
  • Topology Optimization
  • Ansys
  • ABAQUS
  • Siemens NX
  • Optistruct
  • Simulation validation
  • NVH
  • Durability
  • Test Vs Simulation Correlation
  • Altair Hyperworks

Accomplishments

  • Received the On the Fly Award in October 2022 for the successful completion of critical projects and on-time delivery to the clients
  • Received Excellence Award (August 2024) for gear body optimization by minimizing mass and transmission error while achieving frequency targets.

Languages

English
First Language
English
Proficient (C2)
C2
German
Beginner
A1

Affiliations

Avid runner with a passion for endurance sports, completed four full marathons, reflecting discipline, perseverance, and a commitment to continuous improvement

Timeline

Senior Engineer (FEA)

ZF India Private Limited
03.2023 - Current

FEA Engineer

QuEST Global Engineering Services Private Limited
07.2021 - 03.2023

Master of Engineering(M.E.) - Desig Egineering

BITS PILANI

Bachelor of Engineering (B.E.) - Mechanical Engineerinng

Osmaia University

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Sai Akhil Tata