Syed Faisal Haider

(217) 358 2549 · sfhaider1@yahoo.com

OBJECTIVE Seeking a challenging career in the field of Computer aided Analysis and Design with a strong desire to explore new and innovative tools and techniques in the field of virtual product development.

SUMMARY

• Over eight years of experience in design, analysis and testing of machine components in the Material handling and Heavy vehicle industry.

· Proven technical, analytical and problem solving skills that are progressively developed and enhanced while working on theoretical and real world problems.

· Demonstrated good oral and written communication skills in report writing, process documentation, business meetings, and management presentations.

· Possess strong leadership skill that has been greatly enhanced while leading and working with cross-functional teams.

EXPERIENCE

Tata Consultancy sevices – Structural analyst

On-site at Chrysler Corporation – Front wheel Drive CAE, Auburn Hills, MI July 21, 2006 – Present

• Responsible for structural design validation, analysis, durability calculation and NVH analysis for the small car platform including Linear and Nonlinear analysis.
• Solved several launch critical issues including Fuel tank rupture, K-Member cracks, ERM redesign.
• Performed Sheet metal fatigue, Modal fatigue, Spot and Seam weld fatigue analysis for several components and full car models..
• Performed Exhaust hanger location optimization using the RMS method.
• Performed several closure analysis including Door Slam, Sag/ Set, Overcheck, Hood Slam, Decklid slam etc using Abaqus and Dyna.
• Experience in performing Modal analysis, Forced response analysis, Bending and Twisting , Point mobility and Idle shake analysis and in using DMIGs.

Introduced Virtual shake table analysis using NASTRAN and durability analysis using fe-safe in the group.

Volt Technical services – Structural analyst

On-site at Caterpillar – Mining and Construction equipment division - Decatur, IL Dec 06, 2004 – Sep 2006

• Responsible for structural design validation, analysis, durability calculation and optimization.
• Introduced Virtual shake table analysis using NASTRAN and durability analysis using fe-safe in the group.
• Performed Transient/ Random response analysis using IDEAS for different components including mufflers, engine cover, fenders, fuel tanks, mirrors, walkways and ladders etc.
• Experience in Flex body model creation, linear static, Inertia relief, G-load, Modal, Forced response and limited Non-linear static analysis.
• Participated as a DMEDI green belt in a 6 Sigma project on Topology optimization software selection.
• Performed structural design and analysis of the 60/70-ton Tier III truck from the concept to the operational stage which included tow hook, lift, bolted joint, stress and durability analysis. Successful application of sub-structuring helped create detailed models of several components to facilitate better evaluation of different design alternatives.
• Performed virtual shake table analysis on 620, 630 and 650 Tier III Wheel tractor Scrapers.
• Performed several other G-load and modal analysis on different components of several machines.
• Performed Bolted joint analysis with contacts in ABAQUS for a motor grader blade.
• Performed Roll over protection (ROPS) analysis using ABAQUS.
• Performed multi-body dynamic (MBD) analysis of a small off-highway truck using the in-house MBD software. Several truck operations were modeled virtually and loads were developed to perform numerous design iterations during the concept phase. Validations were also performed during the pilot phase of the program to verify the analysis results. The validated model was then used to design the truck for production.

Mechanical Design Engineer

Ace World companies – Fort Worth, TX Sep 13, 2004 – Dec 03, 2004

Responsible for the analysis and design of Hoists, Load blocks, End trucks, Bridge Cranes and Gear boxes for various applications, Component selection, BOM creation, Assembly drawings and documentation in an ISO 9001 environment.

• Designed several hoists ranging up to 100 ton capacity for several applications.
• Designed motorized load blocks.
• Designed End trucks, gantry and bridge cranes for up to 100 ton capacity in different configurations for indoor and outdoor usage.
• Performed Bolted joint and weld calculations, Axle calculation, Bearing selection, Wheel design, and Hoist drum design.

Mechanical Design Engineer

ProservAnchor Crane Group (Anchor Crane), Irving, TX June 1998 - August 02, 2004

· Responsible for the analysis and design of Bridge cranes, Runway systems, Monorails per AISC and CMAA code, Jib cranes, and Switches, Component selection, BOM creation, Assembly drawings and documentation in an ISO 9001 environment.

· Responsible for getting quotes on products and getting products designed per customer’s specification from vendors.

Achievements:

· Successfully redesigned and implemented a Pneumatic Interlocking Mechanism to interlock two monorails or cranes.

· Automated the process of analysis (Stress calculation and deflection) giving optimized selection of material for crane design.

· Automated the process of Gear and Motor selection for motorized rotation jibs.

· Standardized the design for Davits and Hand geared and Motorized jibs.

· Created Lisp routines for aiding in the creation of assembly drawings.

Graduate Teaching Assistant

University of Texas at Arlington Feb 98 - Jun 98

Assisted in teaching the computer aided robotics course. Duties involved explaining the design methodology and assisting students with the evaluation of results.

Engineering Assistant – University of Texas at Arlington

Texas manufacturers assistance center, Fort Worth, TX Nov 96 - Jan 98

Duties included assisting TMAC field engineers in expediting a variety of projects related to the local industry.

EDUCATION

MS in Mechanical Engineering, Aug 1998 - The University of Texas at Arlington

BE in Mechanical Engineering, May 1992 - N.E.D University of Engineering and Technology, Karachi-Pakistan

PUBLICATIONS/ PRESENTATIONS:

· P. S. Shiakolas, and S. Faisal, "Optimum Module Selection and Design Based on Kinematics and Dynamic Task Requirements Using DADS and Genetic Algorithms," Sensor Fusion and Decentralized Control in Robotic Systems II, SPIE Symposium on Intelligent Systems and Advanced Manufacturing, Boston, MA, 19-22 September, 1999.

· P. S. Shiakolas, and S. Faisal, "Optimum Robot Design Using DADS and Genetic Algorithms", LMS CADSI 1999 Global Users Conference, Coralville, Iowa, 28-29 April 1999

ACADEMIC/ OTHER PROJECTS:

· Used DADS & GA to create a virtual prototyping environment to optimize several robotic configurations based on task requirements and minimum torque.

· Designed a controller to balance the two sticks in the vertical position of an Inverted double pendulum by applying a proper horizontal input force using DADS.

· Wrote a program in 'C' to assemble robot manipulators based on a defined module library by reading D-H parameters as input thus eliminating the need of user interaction with DADS for model creation. It also calculates the mass, inertia, mass moment of inertia and deflection of the links.

· Developed a program for calculating beam tip deflection using pseudo-rigid body model (Flexible link) and elliptic integrals using MATLAB for compliant mechanisms and modeled a 4 bar mechanism with one flexible / compliant link.

· Implemented a methodology for the Topology Optimization of 2D problems using F.E.A & genetic algorithms in MATLAB.

· Developed a 2D Truss, Beam and Frame analysis software using JAVA.

· Modeled a Pedal Crank in PRO-E, imported in ANSYS, analyzed for stress and deflection, then used Pro/Manufacturing for machining the model.

· Wrote a code in 'C' to design spur gears and create its profile in AutoCad13.

RELEVANT COURSES:

Structural Statics / FEA Structural Optimization

Structural Aspects of Design Robotics

Advanced F.E.M. Dynamic systems modeling

Analysis and synthesis of control systems Computer aided design

COMPUTER SKILLS:

Languages: Basic, C, JAVA, LISP, Tcl/Tk

FE Software: ABAQUS, NASTRAN, Hypermesh, Pro-Mechanica, IDEAS, LS-DYNA, ANSA

Optimization: Optistruct, TOSCA.

CAD: AutoCAD, Pro/E, CATIA

Simulation: DADS, Matlab, Dynasty

Other: MS Word, Excel, Lotus, Power Point, Project, Access, SysPro.

REFERENCES: Available upon request

IMMIGRATION STATUS: Green Card