Mechanical Engineering Design Portfolio. Syed Ibrahim Dilawer (B.Eng Mechanical, MSc Manufacturing Management)

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1 Mechanical Engineering Design Portfolio Syed Ibrahim Dilawer (B.Eng Mechanical, MSc Manufacturing Management)

2 INDEX Mechanical Projects:- Analysis and design of Epicyclic Gear Trains Designing SAE BAJA (ATV) Gear Box Design V10 Engine Design Machine Design Components Fuel Ejector Open Differential Universal Coupling Connecting Rod Plumber Block Steam Engine Crosshead Industrial Projects:- Convertible Table Gym Bench Press Computer Table Miscellaneous Welcome, and thank you for taking the time to view my portfolio. The Goal of this portfolio is to give you a deeper insight into my experiences and skills I have gained over my recent history. It is my hope that this will allow you to better assess how my skills can be applied to your company. I would be happy to talk in more detail and can be reached using the contact information at the bottom of this page.

3 ABOUT ME Performance delivering design engineer, passionate about designing, proficient in CAD modelling and Drafting with 1 year experience in designing gears in Solid works as a research assistant at MJCET. Demonstrated ability to work as a team in multiple deadline bound projects. I am driven by the desire to gain knowledge and work hard to achieve the desired goals. Completed MSc in Manufacturing Management. Available for relocation Objective: Seeking for the position as a Design Engineer within an organization that progresses dynamically and provides me an opportunity to enhance my skills and update my knowledge. Core Competencies 1 year experience in designing in solid works as a research assistant at MJCET. Proficient in the use of Solid works, Auto Cad, Solid Edge, Catia, Arena, FEA and Drafting Techniques. Proficient Knowledge of manufacturing processes and Technologies. Education and Qualifications University of Bradford, UK (MSc Manufacturing Management Engineering,2:1) Principal modules: Manufacturing Planning and Control (78%), Managing Knowledge in Organizations (78%), Risk Management (71%), Six Sigma for Business Excellence (69%), Advance Manufacturing Technology (70%), Aerospace Manufacturing Management (73%). Project: Development of performance measurement tool for automotive green supply chain Developed an excellent knowledge of key concepts in supply chain, risk management, knowledge management, manufacturing planning and the manufacturing operations and techniques Osmania University, India (BEng Mechanical Engineering, 2:1) Principal modules: CAD/CAM, CAD Lab(Solid works, Solid edge, Catia), FEA(finite element analysis), Design of Machine elements, Engineering Drawing, Machine Drawing, Production Drawing, Product Design and Process Planning, Manufacturing Processes, Mechanics of Materials, Automotive Engineering. Final year Project: Modeling and Analysis of Epicyclic Gear Trains using Solid works and Ansys. Role: I was involved in designing and detailing of the individual parts of epicyclic gear train in Solid Works software, also calculating loads on gears, giving presentation to tutors to describe the project and regular meetings with the team members to apply different techniques to solve the issues regarding the development of the model. Result: Successful Development and analysis of the epicyclic gear trains. Achieved A grade in the project Developed an excellent knowledge on designing and analysing different components using solid works

4 INTERESTS, ACTIVITIES and ACHIEVEMENTS I like making 3d models in solid works; won 1 st prize in Solid works modelling competition in Adsophos 2009 in(mjcet, Osmania University). President of the Club Mechanix in MJCET; Organized and Coordineted events of design and analysis using SolidWorks. Organized and Coordinated two events of EWB Hyderabad chapter in MJCET. Co-ordinated two events in national level Adsophus 2008 in (MJCET, Osmania University). Team Lead of Advance Manufacturing Technology Group (College of Engineering, Bradford University). I like to Sketch in my free time, 8 of my sketches were published in Bradford University newspaper and were also displayed in ART Exhibition in Bradford. I also love photography and editing photos, two of my photos were selected and displayed in the Gallery 2 exhibition in Bradford and also won 1 st prize in state level Picasa painting competition. Work Experience Research Assistant at MJCET Assisted in the project of Designing and Analysis of Gear Trains; modelled gears in solid works, conducted stress analysis, Conducted load calculations on internal and external gears. Conducted modelling of different components. Helped in developing detailed drawings of various components Former member of SAE-BAJA TEAM MJCET Fostered support in the form of designing components of an All-Terrain Vehicle BAJA using SolidWorks, testing and fabricating it by conforming to the regulations for SAE BAJA 2010, national-level competition, for Team MJCET Volunteering work in UK Online Training Centre in Manchester. Hyderabad Charity Fair. Ecoversity in University of Bradford. VOLUNTEERING PROFESSIONAL AFFILIATIONS Member: Institute of Mechanical Engineers (IMechE). Former member: Society of Mechanical Engineers India, Engineers without borders. Former Member of SAE BAJA-MJCET

5 Design and Analysis of Epicyclic Gear Trains Project Title:- Design and Analysis of Compound Epicyclic Gear Trains Aim:- To Design Model and Analyze by Varying different Variables for a particular model for compound epicyclic gear train(with all its components) taken from a real model so that the gears will not fail for a particular power input and material. Approach:- First all the dimensions of the Gears (i.e. sun, planet and annulus), shafts( input and output power shaft), keys, Gear arms, keyways etc are calculated. In Designing we also calculate all the loads on all the Gears and eventually on the complete Gear Train which included dynamic, Static and Wear tooth loads manually. Designing Also included selection of the material for the Gears. The Modeling in the project was carried on Solidworks and analysis on Cosmos Solid works and Ansys. The manufacturing processes of the different components were also determined. The Loads are calculated by varying the modules of the gears. Power acting on the compound epicyclic gear trains is also varied and graphs are plotted to see the load behavior. The plotted graphs can be used to verify the compound epicyclic gear train model for different favorable conditions. This was developed as a chart which shows all the favourable conditions for different set of specific gear trains. Manufacturing process of components were also determined.

6 Steps to Draw a Gear:- First the pitch circle, addendum circle, dedendum circle and root circle are drawn. Center lines are drawn and a point is located on the pitch circle. The distance of the point gives the tooth thickness. The point on the pitch circle is joined to the center of the circle by a line. A vertical line also passes through the same point. A line of 200 with the vertical is also drawn; this indicates the pressure angle. All the unnecessary lines are trimmed to form half shape of the tooth profile. By using a spline curve the tooth profile is formed Fillets at the radius of the tooth and the tip of the tooth are given. The wire frame model of half tooth profile is mirrored with respect to the vertical axis. Deleting and trimming all the unnecessary lines, circles and other entities; leaving only the tooth profile and base circle. Give the command circular pattern. As the result of previous step we get the wire frame model of the gear. Give the command extrude Boss/Base. The command prompts to give the width of the gear. Enter the value. We get the required model of the gear.

7 Analysis:- By taking a particular material for the gear and by varying its module, power input etc, the different loads (tangential, dynamic, static and wear tooth loads) were determined for all the gears(sun, planet and annulus) in the epicyclic gear train. This was again done for various materials and all the different values were determined. These values were them plotted into graphs and the results were analyzed. A complete chart was created by which any gear with its preferable conditions could be selected by analyzing all the variables. Simultaniously a saperate analysis on Ansys was also carried out The above image shows the section of two gears train The above image shows the sectional vies of the epicyclic gear train The image shows different loads acting in different modules of gears with particular power input and a particular material. Results:-. The Complete Design with all the specifications of the gears were determined, all the loads were also calculated. A complete working Model was developed in Solidworks CAD software with all its specifications. Analysis of the epicyclic Gear Train was successfully completed with all its results collected and presented in the form of charts. The stresses were also calculated with the help of Ansys. The manufacturing process of different components were also determined. The loads with respect to the module, material and power could be seen from the graphs and a complete chart was created by which any gear with its preferable conditions could be selected by analyzing all the variables affecting it.

8 Designing SAE-BAJA (All-Terrain Vehicle) Project Title:-ATV (All terrain Vehicle) Main Aim:-To Design and Build the ATV for Team MJCET and win the SAE-BAJA competition. My responsibilities:-to design the framework and other components of the All-Terrain vehicle taking into account the Standard specifications and rules of SAE-BAJA. SAE-BAJA Specifications At the race

9 Below is the analysis of SAE vehicle Frame in the intermediate stage Below is the Drawing of SAE vehicle Frame with three standard views and one isometric view. The above image is the rendered vervion of the ATV Designed in the Solidworks CAD software The few important features used in the modeling of this component are the structural Member in Weldments (Solidworks), Trim and other basic features. Results:-A successful framework and other components design, analysis was carried out and an All-Terrain Vehicle was built for the SAE-BAJA competition. The team won 26 th position out of 173 teams participating in the competition.

10 Two Stage Gear-box Project Title:-Gear Box Design Aim:-To design the gear box with all its components with assembled final product and with including Drawings. Result:-A complete Two Stage Gear Box was designed including the assembled product and Drawings and Presentable Rendering with motion analysis. The Above Picture is a rendered version of the Gear box Designed and Modelled in the Solidworks CAD software

11 The above images are the rendered version, with and without the outer gearbox cover The screws of the assembly are hidden for the purpose of clarity The above image is the exploded view of the gearbox The above image is the exploded view shown as a Drawing in Solidworks with BOM included.

12 Project Title:-V-10 Engine Engine Aim:-To design the v-10 Engine with all its components with assembled final product and with including Drawings. To design a complete V-10 Engine (excluding the timing belt and some other components) was designed including the assembled product and Drawings and Presentable Rendering with animation. This was a modeling project. The Above Picture is a rendered version of the V10 Engine Designed and Modelled in the Solidworks CAD software

13 2 inlet and 2 exhaust valves openings for each cylinder Few Engine Components Grooves for the cam shaft connected to the followers and to the inlet or the exhaust valves Pump Fuel Injector Few components have been omitted from the design for clarity Timing Pulley Valve Fly wheel Cover Piston Head Engine body with piston grooves Air inlet valves Connecting Outer cover Rod Oil Pan Crank Shaft Cam Shaft Fuel Rail

14 Engine Assembly Component locations

15 Engine Assembly Stages The above image is the exploded view of the engine assembly The above image is the exploded view of the engine assembly with BOM in the Drawing Sheel modeled in the Solidworks Results:-To design a complete V-10 Engine (excluding the timing belt and some other components) was designed including the assembled product and Drawings and Presentable Rendering with animation. This was a modeling project.

16 Project Title:-Automotive Engine Fuel Injector Aim:-To design the automotive fuel injector Fuel Injector The above image is the exploded view of the Fuel Ejector assembly Result:-Successfully designed the automotive fuel injector with the help of solid works CAD software with all the drawings of parts and assemblies The above image is the exploded view of the Fuel Ejector Drawing assembly

17 The Open Differential Project Title:-Open Differential Aim:-To Design and model the open differential. Below is the Eploded view of the open differential assembly with BOM in the Drawing sheet modeled in Solidworks Above image is the Rendered version modeled in the solidworks with and without the cover. Result:-Successfully designed the Open Differential with the help of solid works CAD software with all the drawings of parts and assemblies

18 Universal Coupling Project Title:- Universal Coupling Aim:-To design and model the Universal Coupling Rendered model of exploded Universal Coupling Rendered model of Universal Coupling assembly modeled in Solidworks Result:-Successfully designed the Universal Coupling with the help of solid works CAD software with all the drawings of parts and assemblies. Above is the Universal joint with exploded view, isometric view and three standard views shown in the Drawing sheet in Solidworks CAD software

19 Project Title:-The Automotive Connecting Rod Aim:-To design and analyze the Automotive Connecting Rod Connecting Rod Above is the rendered model of Connecting Rod designed in Solidworks Result:- Successfully designed the Connecting Rod with the help of solid works CAD software with all the drawings of parts and assemblies Above is the Universal joint with exploded view, isometric view and three standard views shown in the Drawing sheet in Solidworks CAD software

20 Plumber Block Project Title:-Plumber Block Aim:-To design and analyze the Plumber Block Above is the rendered model of Plumber Block Assembly designed in Solidworks Result:- Successfully designed the Plumber Block with the help of solid works CAD software with all the drawings of parts and assemblies Above is the Plumber Block with exploded view, isometric view and three standard views shown in the Drawing sheet in Solidworks CAD software

21 Project Title:-Steam Engine Crosshead Aim:-To design and analyze the Steam Engine Crosshead Steam Engine Crosshead Above is the rendered model of Steam Engine Crosshead Assembly designed in Solidworks Result:- Successfully designed the Steam Engine Cross with the help of solid works CAD software with all the drawings of parts and assemblies Above is the Plumber Block with exploded view, isometric view and three standard views shown in the Drawing sheet in Solidworks CAD software

22 Industrial Products (Convertible Table) Project Title:-Convo Table Aim:-To design a convertible Table for a small apartment which could be used as a small and large table with minimum raw material and which was not expensive. Description:-This was a small project done in a CAD design competition. Analyzing Problems:-The general convertibles are very expensive, heavy and complicated in design Solution:-To Design a convertible which addresses all the above problems. Brainstorming few ideas

23 Simple, Cost effective and elegant The above image shows the procedure, how to fold the convertible table.

24 Isometric View Side View The full long convertible table is thrice the length of the table when it is folded. Bottom view Isometric View Side View

25 The above images are the different aspects which will influence the sustainability of the material which was selected with the help of solidworks. A report was also created showing the improved sustainability options of the new material selected and its effects on the environment. The above image shows the analysis of the table supports which was tested for some higher forces on the table Results:-A convertible table was successfully designed which addresses all the problems which other tables had with presentable catalog, Drawings, manufacturing processes, sustainability report and analysis of the final product. The convertible table was designed for the small apartment was simple, Cost effective and elegant in design. The full table when it will be converted to a mini table will be three times shorter than before saving more space in the appartment The above image is the drawing of exploded view in the drawing sheet with BOM done in solidworks

26 Industrial Products (Bench Press) Project Title:-Bench Press Aim:-To design and analyze the Bench Press with all the bench press part drawings. The above sketch is the rendered version modeled in Solidworks. The above sketch is the exploded rendered version of Bench Press modeled in Solidworks.

27 The above sketch is the rendered version part model of frame, modeled in Solidworks. The above sketch is the part model of the Bench Press modeled in Solidworks. The above sketch is the Part drawing of the frame of Bench Press.

28 The above images are the different aspects which will influence the sustainability of the material which was selected with the help of solidworks. The above sketch is the Part drawing of the frame modeled in Solidworks. Results:-A Bench Press was successfully designed with Drawings and analysis of the final product. A Sustainability report was also created showing the improved sustainability options of the new material selected and its effects on the environment. The above image shows the intermediate analysis of the weight bar which was tested for some higher weights on the bar

29 Industrial Products (Computer Table) Project Title:-Bench Press Aim:-To design and analyze the Bench Press Sliding Mechanism for the keyboard base The above image is the rendered version of the assembled computer table modeled in Solidworks. The above image is the exploded rendered version of the assembled computer table modeled in Solidworks.

30 The below image is the Exploded version of the assembled computer table modeled in Solidworks. The above image is the assembled computer table modeled in Solidworks. Results:- A Complete Computer Table with all the parts were modeled including all the assembly drawings and Sustanability material options.

31 Toy Car Outer Frame:- Miscellaneous In my free time I like to model 3d objects in solidworks, few examples are shown below. Bath Tub Frame:- Rendered image done in Solidworks Car Model Designed in Solidworks Some of the important features used in this model are surfaces, Surface trim etc Rendered image done in Solidworks Bath Tub model designed in Solidworks Some of the important features used in this model are Loft extrude, Loft cut etc

32 The Energy Savings Light Bulb The real life image of an Energy Savings Light Bulb Tire with Rim:- The Solidworks model Designed image of an Energy Savings Light Bulb Some of the important features used in this model are Loft, extrude etc The Solidworks Rendered model image of an Energy Savings Light Bulb Rendered image done in Solidworks Tire and Rim modeled in Solidworks Some of the important features used in this model are Revolve base boss, Circular Pattern etc etc

33 The Groove Pendant Aim:-To Design Groove Pendant, a product of the Architectural Lighting Works under suspended category. Approach:-To Model the product with the help of the downloadable content from the main site of the company Groove Pendant The above image is the product information page for Groove Pendant from the main Company site of Architectural Light Works

34 The above image shows the sketch (as a picture) of the Groove pendant was inserted into the solidworks for reference for the shape of the product as the specifications were unavailable Company image of the product Modeled in solidworks/sectional View Result:- Successfully modeled the Groove Pendant product of the Architectural Lighting Works Company Company image of the product The above two images are modeled in Solidworks (Normal, Rendered I would be happy to talk in more detail and can be reached using the contact information given below.