Mohana Nandanavanam

Experience

• 

  Indian Railways

  Jun 2012 - Jul 2012

  Project Intern

  Was responsible for the study the upgradation of the WDM-2 class Diesel Locomotive to the WDM-3 class. The main focus of the study was to consider all the mods made to the contraptions of the locomotive to increase it's base horse power from around 2000 HP to a 3100 HP. Modifications made to the Fuel Injection Systems, Exhaust System, Turbo-Super Charger, Air Intake System etc. were studied physically to id the mods.Subsequently a report was submitted to the Indian Railways for consideration. Show less

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  BARC

  Dec 2012 - Feb 2013

  Research Engineer

  Was team leader for projects done under the supervision of Nuclear Fuel Complex, Department of Atomic Energy, Hyderabad.1. The project done under a govt. grant to perform validation analyses on the tooling to eliminate the need for destructive testing and corroborate the dimensional changes in the tooling via an NDT method for tolerance control. Process focus was the manufacture of Zirconium (Zr) billets by extrusion and expansion prior to pilgering, laser cutting, Uranium fuel loading and welding. Study the various stages involved in the manufacture of Dia. 100 x 30 mm tubing for Arjun Class Main Battle Tank(MBT) Gun Barrel by extrusion and perform structural and thermal analyses on the Nose and Die, which are the tooling used in expansion and extrusion processes respectively. Approach: Structural-Thermal Coupled Field AnalysisCAD using: CATIA V5 R19CAE using: ANSYS 14.0 and Pro Mechanica Show less

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  Elecon Engineering Company

  May 2014 - Jul 2017

  •Development of gearing systems for Bombardier, Indian Railways, Rexroth USA and Tata Power locomotive, wind turbine, thermal power steam generation, material handling applications •Integration of reduction gearing pair in axle-drive electric motors.•Maintained process critical activities in product development including GD&T, DFMEA, DFMA, DVP&R & VA/VE•Accomplished 33% in net savings using PM techniques for differential Bevel gears manufacture•Deployed Lean and frugal engineering concepts for development of Gearing Assemblies: DFM achieved by 43%•Reduced the lead-time for release and launch by almost 320% with parametric designs using PTC Creo 3.0 Show less

  • Senior Engineer

    Jun 2015 - Jul 2017

  • Mechanical Engineer

    May 2014 - Jun 2015
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  University of Michigan

  Sept 2017 - Mar 2018

  Research Assistant

  Worked with ME Dept. and was responsible for the design and development of various projects funded by the Ford Motor Co.- Development of 3-point bend fixture for Flexural strength testing of material testing- Analyzing Viscoplasticity of Steels from various Automotive applications- Developing Stereograms/Pole figures and Euler angles using data from X-ray spectrography using M-Tex and J-Tex. Subsequent analysis of mechanical properties of the PMMCs with the crystal orientations

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  Ford Motor Company

  Sept 2017 - May 2018

  Mechanical Engineer

  Interned for a collaboration with University of Michigan for material developmental projects. Worked on the development of novel experimental fracture characterization methods for lightweight materials. Lead the upfront development of a testing method for flexural strength for Graphene based applications.Responsibility:1. Fixturing, tooling, test method, verification and validation. 2. Responsible for critical activities which included CAD, FEA, GD&T, DVP&R and DRBFM.

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  Lear Corporation

  Jan 2018 - Feb 2018

  Innovation intern

  Part of the top two teams selected for the Lear Innovation Challenge 2018. The proposed a design for Occupant protection during a crash event, was accepted by Lear as a highly feasible solution. Proposed design reduces the g-forces up to 75% and risk of injury by 60%.

• 

  Tenneco

  May 2018 - now

  North America Clean Air division- Mechatronics and Controls SME group.Product development, software calibration, validation and test development of electronic systems for a Greener tomorrow!Systems Engineering:Decomposed vehicle system-level requirements into control strategy requirements. Verified control requirements cascading and implementation in Model-Based Design (MBD) systems. Feature Development and Diagnostics of emission system-specific feature requirements for control strategies and diagnostics.Architecture development:Validated system-level architecture, including hardware and software for compliance with EURO7/CN7/EPA-CARB L3 emission standards. Calibrated software logic using Simulink and engineering applications like RLDA, engine, and chassis dynamometers. Developed emissions strategies, including feedforward and storage SCR control. Developed calibration maps for NOx control by integrating ECU and ACU using engine and chassis dynamometer. Integrated various sensors like NOx, Lambda, RTD, and thermocouples. Set up sensors including thermocouples, load cells, accelerometers, and pressure sensors using Somat eDAQ.Hardware-in-the-Loop (HIL) Validation:Configured and used dSpace SCALEXIO for HIL validation. Automated test cases using Python APIs. Worked with plant model creation, sensor configurations, RTICANMM block sets, and experiment creation. Used ALM tools like Codebeamer and PLM tools such as SAP and Windchill.Software Calibration:EPA Emissions Testing and Thermal Management: Conducted EPA emissions dyno testing, pump flow, and thaw control for 12 and 24 VDC thermal management systems. Calibration Maps and Drive-Cycle Analysis. Use CAN protocols using Vector CANalyzer and BusMaster; CCP strategies with ATI Vision and INCA for system validation.Embedded Controller Management: Flashing, booting, and related activities using CAN protocol. Maintained calibration libraries for production and development vehicle programs. Show less Handle and support the design and development process for clean air systems from concept to release. •Develop testing methods for systems needed to achieve customer and product requirements including test fixtures and setups for design changes in mechanical, electro-mechanical components and electronic packaging•Calibration of software logic in engineering applications•Hands on with SAE J1939 CAN protocol- database: CANalyzer and CANdb++; calibration: ATI Vision•Handle validation testing which incl. tests like endurance, freeze and thaw, NVH, Ingress protection, drop testing, Salt and chemical spray, Accelerated corrosion testing, EOL simulation, EMI protection and thermal cycling•Fixture development for material testing on MTS/Instron suites for fracture, yield strength, toughness and other engineering properties. Regression modelling for material testing for mechanical property analysis•Hands-on experience in OBD calibration, harness builds, wiring diagrams, CAN setups, Somat eDAQ and related sensor setups: thermocouples, load cells, accelerometers, pressure sensors etc Show less Ford platforms Design & Release:•Responsible for the packaging verification, FEA, GD&T, system validation, prototype builds and sign-off of vehicle platforms•Own the Product Data Management (PDM) system – BOM generation, blueprint GD&T, release and change management•Handled MCA design activities including ECM, build validations, PPAP, DRBFM, rapid prototyping and FEA to meet international quality standards, resolving supplier quality issues through root cause analysis •Actively involved in design, launch & sign-off reviews for 2 consecutive FY launch cycles and implemented rapid prototyping techniques in builds to reduce DV phase launch time by 33 %•Integrated ERP/PDM process for product lines using SAP systems•Utilized CAE for performing structural & thermal analysis to identify potential failures and improve safety by 1.2 fs•Improved packing by at least 0.3 pxs in 2 vehicle programs between exhaust components and vehicle chassis Show less

  • Senior System Engineer

    Jul 2021 - now

  • Application Engineer

    Aug 2018 - Jul 2021

  • Design Release Engineer

    May 2018 - Aug 2018