E. Rajasekhar Nicodemus

Mechanical Engineer


 rajasekhar.nicodemus@gmail.com
 
PROFILE

I am a Post graduate in Mechanical Engineering working in area in Structural Analysis and Custom Code Development in Automobile Sector.


M.Tech.(Master of Technology) from I.I.T Roorkee/TU-Darmstadt in Machine Design, Mechanical Engineering with Automotive experience (From Aug 2010 to till now) and Black Belt Certification (DFSS) in the area of Structural Analysis and Custom Code Development.

  • Finite Element Methods (FEM)
  • Structural Analysis
  • Custom Code Development
  • Communication and Coordination Skills

2004-08

Graduated with Distinction

2008-10

Master of Technology

2010-2015

Senior Engineer-CAE Methods

2015-Now

Lead Engineer-CAE Methods

RESUME

EMPLOYMENT
 Lead Engineer-Powertrain CAE Methods
 General Motors Technical center-India

  •  Conduct research into the feasibility, design, operation and performance of powertrain components and systems.
  •  Develop methods/procedures for Computer Aided Engineering (CAE) Analysis support for engine and transmission groups.
  •  Investigate mechanical failures or unexpected maintenance problems and develop solutions to mitigate these failures.
  •  To analyze engine and transmission components using non-linear structural FEA analysis and to assess and /or modify structural design of these components to meet the design requirements.
  •  Apply state of the art analytical tools including, Abaqus, Matlab, MASTA and AMESim to develop engine and transmission virtual models.
  •  Generate technical solutions for complex design problems in current, new and major engine and transmission programs
2010 - Now

EDUCATION
 Masters of Technology
 Indian Institute of Technology (IIT) Roorkee, Roorkee

  •  Specialization: Machine Design (CGPA:9.8/10.0)
  •  Project work done at Technische Universität Darmstadt, Germany for duration of 9 months through DAAD scholarship.
2008-2010
 Bachelor of Technology
 Jawaharlal Nehru Technological University, Hyderabad

  •  Specialization Mechanical Engineering (88.0%)
  •  University topper in mechanical branch and overall second of JNTU Kakinada University
2004-2008
 Intermediate
 Andhra Pradesh State Board of Intermediate Education.

  •  Completed with Distinction (88.1%)
  •  Major subjects included Mathematics (98.3%) and Physics(96.6%).
2002-2004
PROJECTS

VIEW PROJECT

Valve guide Failure (Thermo-structural and Lubrication) Analysis:
Field Failure Issue

The aim of the work is to develop a CAE procedure which can predict and analyze the valve guide failure due to high temperature, large thermal/structural deformation and insufficient load carrying capacity of the oil. A methodology based on Thermo-structural and lubrication analysis has been developed and the methodology correlates well with tests.

VIEW PROJECT

3-Body Abrasive Wear Model
CAE Method Development

The aim of work is develop a model to study the effect of wear due to contaminants (debris) in the reciprocating and rotating components. A novel model based on cutting and rolling wear has been developed. The method has been validated with experimental data.

VIEW PROJECT

Connecting Rod Structural Analysis
Structural Analysis

The work describes a FEA (Finite Element Analysis) Simulation to study the structural integrity of the automobile connecting rod. The fatigue factor of safety for big end and small end were evaluated for different connecting rod designs for inertial, gas and bearing loading.

VIEW PROJECT

Crescent pump lubrication analysis
Field Failure issue

The aim of the work is to develop a method to describe the pump failure and to study the effectiveness of various design changes to mitigate failure. A method has been developed using CFD and lubrication analysis. The failure rate of the pump has been reduced due to design changes provided by the study.

VIEW PROJECT

Seal Contact and Flow Analysis
Structural Analysis

The aim of the work is to develop a procedure to study the seal performance. A procedure was developed using structural and lubrication analysis. The seal deformation (viscoelastic material) was studied using structural analysis. The deformation was then used to study seal performance (leakage rate and power loss) using lubrication analysis.

VIEW PROJECT

Friction tool for Engines
Tool Development

The aim of the project is to develop a tool to predict the engine friction losses based on engine architecture. The test data of engine friction losses component-wise for different engine was collected. Non-linear regression analysis was used to develop relationship between friction losses and design parameters. The tool has helped designers to design more efficient engines.

VIEW PROJECT

Methodology for Estimating Gear Scuffing Probability
CAE Method Development

The aim of work is develop a methodology for estimating scuffing probability of gears. A model has been developed to calculate the minimum oil film thickness and gear scuffing probability based on literature and AGMA standard. The method has successfully used in various transmissions.

VIEW PROJECT

Improvement of Abaqus user subroutine for roller/ ball bearing
CAE Method Improvement

In manual transmissions structural analysis, roller/ball bearings are modeled using user subroutine in Abaqus (reduced contacts/computation time). The aim of the work is to improve/enhance upon the existing user element in Abaqus. The user subroutine has been modified to account for various different bearing types like deep groove ball bearing. The user subroutine results have compared with test data and also with commercial software’s data (MASTA).

VIEW PROJECT

Tool for predicting surface friction coefficient of real surfaces
Tool Development

The aim of the work is to develop a tool which can accurately predict the friction coefficient values of real surfaces. The tool has been developed in Matlab using an iterative contact algorithm based on principles of contact mechanics. The results from the tool are in close agreement with experimental data. The tool helps designers in accurate prediction of friction losses of engine components. Also, accurate friction coefficient values are being used in various analyses.

VIEW PROJECT

Turbocharger Thrust Bearing Design Sensitivity Analysis
Standard work execution

Several design parameters affect the Turbocharger thrust bearing performance characteristics. The quantitative measure of effect of each of these parameters is unknown. DOE has been developed and Kriging was used to perform Annova analysis. The understanding from the study helped designers to design better thrust bearings in lesser time.

VIEW PROJECT

Enhancement of Gas Turbine Performance by Optimization of Air Filtration System
B.Tech Project

In a Gas-Turbine plant the performance of the air filtration system plays a crucial in the performance and total operational cost of the plant. The project work was aimed to develop a new filter modification to optimize the air filter performance (pressure drop and filtration efficiency).The developed filter design has been validated by testing in devloped test rig (ASHRAE 52.2-1999).

RESEARCH PUBLICATIONS

  • E. Rajasekhar Nicodemus, Satish C. Sharma, “Influence of Wear on the Performance of Multirecess Hydrostatic Journal Bearing Operating with Micropolar Lubricant”, ASME Journal of Tribology,2010;Vol:132,Issue:2, pp:021703.
  • E. Rajasekhar Nicodemus, Satish C. Sharma, “A Study of Worn Hybrid Journal Bearing System with Different Recess Shapes under Turbulent Regime”, ASME Journal of Tribology, 2010; Vol: 132, Issue: 4, pp: 041704.
  • Satish C. Sharma, E. Rajasekhar Nicodemus “A Comparative Study of a Multirecess Hybrid Worn Journal Bearing System Operating in Turbulent Regime Compensated With Different Flow Control Devices” STLE/ASME 2010 International Joint Tribology Conference, IJTC2010,October 17-20, 2010, San Francisco, California, USA, Paper no: IJTC 2010-41027,pp.77-79
  • E. Rajasekhar Nicodemus, Satish C. Sharma, “Orifice Compensated Multirecess Hydrostatic/Hybrid Journal Bearing System of Various Geometric Shapes of Recess Operating with Micropolar Lubricant”, Tribology International, 2011, Vol: 44, Issue: 4, pp.284-296.
  • Satish C. Sharma, E. Rajasekhar Nicodemus, Nathi Ram “A Study of Misaligned Micropolar Lubricated Membrane Compensated Hybrid Journal Bearing System”, ASME Journal of Tribology, 2011, Vol: 133, Issue: 3, pp.031703.
  • E. Rajasekhar Nicodemus, Satish C. Sharma, “Performance Characteristics of Micropolar Lubricated Membrane-Compensated Worn Hybrid Journal Bearings”, Tribology Transcations, 2012, Vol: 55, pp.55-70.
  • Jorg Stahlmann, E. Rajasekhar Nicodemus, Satish C. Sharma, Peter Groche, “Surface roughness evolution in FEA simulations of bulk metal forming process”, Wear, 2012, Vol: 288, pp.78-87.
Tool/Method/Secret (GM Internal Publication )

  • A novel methodology for predicting 3-body abrasive wear in lubrication contacts
  • A novel methodology for predicting friction coefficient of real surfaces
CONTACT


  •  Bangalore, India
  •  rajasekhar.nicodemus@gmail.com
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