E. Rajasekhar Nicodemus
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)
Custom Code Development
Communication and Coordination Skills
Graduated with Distinction
Master of Technology
Senior Engineer-CAE Methods
Lead Engineer-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
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.
Jawaharlal Nehru Technological University, Hyderabad
- Specialization Mechanical Engineering (88.0%)
- University topper in mechanical branch and overall second of JNTU Kakinada University
Andhra Pradesh State Board of Intermediate Education.
- Completed with Distinction (88.1%)
- Major subjects included Mathematics (98.3%) and Physics(96.6%).
Surface roughness evolution in FEA simulations of bulk metal forming process
Workpiece surface topography plays a major role in metal forming processes due to impact on tribology. Especially process feasibility depends directly upon the ability of the tribological system to separate tool and workpiece during the process and realize good lubrication to minimize wear due to shear friction stresses. This paper presents a new approach to describe the surface evolution of workpiece surfaces during cold forging operations. Results can be used to gain knowledge on tribological loads in forming processes and to formulate better friction models since the description takes into account the evolution of the contact area of the contact partners.
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.
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.
Connecting Rod 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.
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.
Seal Contact and Flow 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.
Friction tool for Engines
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.
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.
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).
Tool for predicting surface friction coefficient of real surfaces
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.
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.
Enhancement of Gas Turbine Performance by Optimization of Air Filtration System
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).
- 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
- Bangalore, India