RAHUL BETGERI

Row House 2, Enarch, Sambhaji Chowk, Untawadi Road, Nashik 422002, MHPh. No. (0253) 2311334, 07709175220. Email: rahulbetgeri@gmail.com

OBJECTIVE

Seeking a challenging position in field of Mechanical Engineering, which compliments and expands my competencies, skill, education & experience.

PROFILE

Over 5 ½ years of Machine Design and Tool Design experience Experience of handling complete projects from design to delivery Good at interacting internally with other departments and externally with clients, suppliers and subcontractors. Experience with CAD Programs:

o Solidworks: Years of experience – 8 Modules Used: Parts, Assembly (over 2500 unique parts), Drawings, Surfacing, Sheet Metal, Mold Tools,

Weldments, Solidworks Motion, Solidworks Simulation, Photviewo AutoCad: Years of experience – 8

Modules Used: Drafting, AutoLISP Programming (Introductory Level) Experience with Analysis Programs:

o ANSYS: Years of experience: 1 Modules used under ANSYS Workbench: Static Structural, Fluid Flow (CFX) (wind tunnel

simulation), Steady State Thermal, Fluid Flow and Structural Coupled analysis (Importing Loads from CFX to static structural, ex: studying stress in blade standing in 40MPH wind)

o ABAQUS/CAE: Years of experience: 2 Modules used: Geometry, Assembly (for contact analysis), Material Models, Sections, Fasteners,

Springs, Static stress/displacement analysis, Dynamic stress/displacement analysis, Used for Fracture Mechanics Properties Estimation, Visualization Tools.

o MATLAB Modules Used: Mathematics Toolbox, Image Processing Toolbox, Matlab Compiler.

EMPLOYMENT RECITAL

Company Name: Irwin Research and Development, Yakima, WA, U.S.ALeading manufacturer of thermoforming machines, tools and ancillary packaging equipment.

Position: Mechanical Engineer, Jan 2006 – Till date

Responsibilities: Design, development, and testing and documentation of products and processes related to thermoforming

machineries and equipments. Perform engineering calculations, analysis, and proper material & component selection for quality conscious

design including cost, weight, reliability and ease of manufacturing. Work with engineering, purchasing, production and assembly teams, ensuring that budget goals, time

deadlines and customer’s expectations are met. Create 3D-models, drawings and bill of materials.

Example Projects: Design and testing of "Side Sealing System" for Stack Packer. Displayed at PACK EXPO 2006, McCormick

Place. Applied for patent on the process. Design and Development of “Cup Bagging” machine. Forming (50in X 40in) mold and Trimming tool design for foam plate Dynamic analysis and servo motor sizing calculations for "Rack and Pinion Ejector System" to determine

forces on the system, maximum possible speeds and torque requirements. This ejector system is used to eject trimmed product out of trimming tool

Dynamic analysis and servo motor sizing calculations for "Servo Ejector system (based on slider-crank mechanism)" to determine dynamic forces on the assembly, maximum possible speeds and torques required to sustain the speeds.

Finite Element Analysis of a"Form Tool Platen" to determine stresses, strains and stress concentration area when subjected to forming loads.

Finite Element Analysis of "Gear Tooth", in Rack and Pinion to determine contact stresses. Contributed to establishing design standards. Standards included protocols for Machine/Tool Design,

individual parts modeling, assembly structure, drawing procedures and file storage.

Company Name: Southern University and A&M College, Baton Rouge, LA, U.S.A

Position: Teaching Assistant (Part Time), Aug 2004 – Dec 2005

Responsibilities: Supervising junior manufacturing lab, preparing and grading tests and homeworks. Conducted classroom instruction of ‘Unigraphics NX’ for 3 semesters.

Company Name: Irwin India Pvt Ltd, Nashik, MH, IndiaLeading manufacturer of thermoforming machines, tools and ancillary packaging equipment.

Position: Design Engineer, Feb 2002 – Aug 2004

Responsibilities: Machine Design. Thermoforming Tool Design. Supervising manufacturing of tools. Testing of Machines and Tools

Example Projects: Responsible for design and development of Pick and Place Stacker for cup former based on use of vacuum to

pick the formed cups from the mould Designed mould-rotating mechanism to eliminate the stacking machine. Design concept based on straight-line

generation principle of “Tchebicheff Mechanism”. Performed structural analysis (FEA) of Machine crank, Machine platen and Machine frame in cutting action

during thermoforming of Thermoforming machine Model 3060®. Machine displayed in K-2004, Düsseldorf, Germany.

Designed, supervised manufacturing and testing of number of replaceable cavity thermoforming tools ranging from simple 100ml disposable glasses to 750ml containers with lids. One of the square container tools with lid displayed in was displayed in K-2004, Düsseldorf, Germany.

INTERNSHIPS

Company Name: Wonderpack Ind Pvt Ltd, Nashik, MH, IndiaManufacturer of thermoforming machines, tools and ancillary packaging equipment.

Position: Project Engineer, (Part Time) Aug 2000 – Mar 2001

Project: Design and development of ‘Stacking machine for cup former’ (senior project). Used to stack the randomly

ejected cups from automatic thermoforming machine in organized fashion and number as desired. In charge of different stages of the product development right from conceptualization, design of components,

procurement of parts, Manufacturing, assembly and testing.

Company Name: Wonderpack Ind Pvt Ltd, Nashik, MH, IndiaManufacturer of thermoforming machines, tools and ancillary packaging equipment.

Position: Trainee Engineer, June 2000 – July 2001

Highlights: Gained knowledge of thermoforming process and plastic extrusion technology. Familiarized with automatic

thermoforming machines and extruders. Learned thermoforming tool and product design. Also exposed to trim-in-place and form-trim techniques in

thermoforming.

Identified the need and proposed concept of ‘Stacking machine for cup former’.

QUALIFICATIONS SUMMARY

Post Graduation: 2004-2005 Master of Engineering (Mechanical Engineering) GPA: 3.75/4.00

Southern University, Baton Rouge, U.S.A

Award: Outstanding Graduate Student (Mechanical Engineering Dept) 2004 -2005Thesis: Application of Finite Element Method in Fracture Mechanics Properties Estimation.

Graduation:1997-2001 Bachelor of Engineering (Mechanical Engineering) Higher Second Class K.K. Wagh College of Engineering, University of Pune, India

Project: Design and Development of ‘Stacking Machine for Cup Former’. Sponsored by Wonderpack Ind Pvt Ltd, India. Machine was exhibited in K-2001, Düsseldorf, Germany.

Schooling1995-1997 Higher Secondary School Certificate First Class

Maharashtra State Board

1994-1995 Secondary School Certificate First Class Maharashtra State Board

TRAINING PROGRAMMES ATTENDED

Industrial Hydraulics – Conducted by MICO (BOSCH GROUP) Industrial Pneumatics – Conducted by MICO (BOSCH GROUP)

OTHER ACHIEVEMENTS

Interschool Table Tennis Champion. Awarded “Best Cadet of the Year (1996)” at Patangrao Kadam Annual Sports Camp, Sangli.

PERSONAL DETAILS

Date of Birth: 17TH June 1979

Languages Known: English, Hindi, Marathi and Kannada.

Hobbies & Activities: Reading, Running, Bodybuilding, Cooking, Trekking

Example Projects in ABAQUS CAE

1. Defection testing of various thermoformed products

- Products tested included:

o Foam Plates: φ9inch plate, φ12inch plate, φ7inch plate, Meat trays

o Foam Plates (compartmented): φ9inch plate, 10”X9” Lunch Tray, 20”X12” Apple tray

o Foam Bowls: 12oz bowl (φ6inch), 30oz bowl (φ8inch)

o Hot dog containers

- Creating 3D model of the design using Solidworks.

- Creating FEA models using ABAQUS CAE, to simulate loading of the products and study the deflection and stress level

characteristics. For example in Apple Tray, loading was simulated using models of apples and support simulated was

similar to tray being held in both hands at extreme ends. Or in case of lunch tray, tray being held with one hand and

compartments filled with assigned volumes.

- Modify the design based on the above observation, like changing the curvature of the draw, adding ribs, adding

reinforcing features which also enhance cosmetic value, increasing the section modulus where possible (compartmented

products), changing the sheet thicknesses at desired sections.

- Presenting the results to the Customers and get product approval.

2. Drop testing of various thermoformed foam and solid sheet (Polypropylene, HIPS, etc) to study the stresses induced in

the product.

3. Studying the stresses induced in Cavity and Plug of mold during thermoforming process.

- The results provided an insight on better locations for fastening, vacuum paths, cooling lines/holes, and base support to minimize the deflection and stress concentrations during each cycle.

4. Finite Element Analysis of “Thermoforming Machine Platen” to determine stresses, strains and stress concentration area

when subjected to load

- Creating 3D model of the design using Solidworks.

- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures, using

ABAQUS CAE.

- Interpreting results from above analysis and making necessary design changes: Improved the design based on the stress

concentrations and deflections observed to make the platen stiffer which in turn enabled using higher loads

5. Structural analysis of thermoforming trimming machine platen, similar sheet metal stamping machine.

- Creating 3D model of the design using Solidworks.

- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures using

ABAQUS CAE.

6. Structural analysis of thermoforming machine frame for deflection during forming. Thermoforming tool usually

experiences forces upto 300 tones per cycle.

- Creating 3D model of the design using Solidworks.

- Creating finite element model to include boundary conditions, operating parameters like loads, temperatures, using

ABAQUS CAE.

- Based on analysis reduced the weight of the fame material being used and switched to single die pillar from two per side.

7. Finite Element Analysis of “Tool Cart” (used for transporting thermoforming tools) to determine structural rigidity and

ensure safety at rated loading.

- Testing the design for structural rigidity/stability when tool is placed on the “Tool Cart”

- Involved creating finite element model to simulate working conditions using ABAQUS CAE.

- Interpreting results from above analysis and making necessary design changes.

8. Finite Element Analysis of “Gear Tooth”, in Rack and Pinion to determine contact stresses.

- Contact stresses are indicator to the wear resistance/life of the part in contact.

- Involved creating finite element model to simulate static and dynamic loading using ABAQUS CAE.

- Estimating predicted life based upon observed values from above step

9. Finite Element Analysis of Foam Sheet Extruder Die to study the deflections induced (based only on the pressure of the

material being extruded).

10. Testing the design of vacuum tank and air tank for the thermoforming machine using ABAQUS CAE.

Thesis : Application of Finite Element Method in Fracture Mechanics Properties Estimation.

Course : Master of Engineering (Mechanical Engineering) - (2004-2005)

Abstract:

Fracture parameters were estimated by finite element method. Commercial software ABAQUS was used for this

research. A total of 63 unique full 3D models were analyzed using multiple processor Itanium-2 computing facility setup at

Southern University. Using some of the features of ABAQUS such as iso-surface plot, output plots along node/element path; it

was possible to visualize the plastic zone shape, variation of stress intensity factor, J-integrals, and variation of stresses and strains

along the crack.

Compact testing (CT) specimen specified in ASTM E399 was used throughout this investigation. In CT specimen of

thickness 40mm the plane strain condition is found to be dominant in 87.5% of crack front length. This type of study will enable

in reducing the number of samples destroyed while following ASTM E399 in trials to achieve plane strain dominance. Plastic

zone shape was obtained using the iso-surface functionality in ABAQUS. Observed plastic zone shape does not conform with

simple extrapolation of 2D zone shapes stretched to 3D, i.e. the dog-bone shape. Variation of K and J-integral values along the

crack front were used to explain this result.

Method for obtaining numerical solution for fracture toughness for CT specimen is formulated here. Load and Load rate

analysis, Optimum a/W ratio determination, Mesh convergence analysis and Parameter variation form the sequence of this

procedure. It is found that for range of load and rates considered the variation in percentage errors is 0.0037 for K and 0.007 for J-

integral. In order to study effect of initial crack length on estimation of K and J, models with varying a/W ratio subjected to same

load are analyzed. It is found that errors are minimum when a/W ranges from 0.45 to 0.55. Mesh convergence analysis is carried

out to obtain optimum element size. Criterions used are stabilization of K and J values and Contour independence of J-integral.

Element volume expressed as a percentage volume of specimen volume of 0.0041% is found to produce convergence. Geometric

form factor for CT specimen geometry is derived using 33 models of varying B and a/W ratios. ABAQUS values for

are consistently higher than ASTM E399 values by a value of 0.215.

As a step towards developing a numerical and closed form solution for Mode I + Mode III fracture toughness for brittle

materials modeling of Spiral Notch Torsion Testing (SNTT) specimen has been initiated. The finite element model of this test will

be useful in studying the parameters affecting the mixed mode fracture. Geometric model, crack definition, crack propagation

direction definition and mesh for analysis are in progress.

This successful study marks the beginnings of an array of possibilities. Numerical solutions for non-standard geometries

can be obtained. Fractures in elasto-plastic, perfect plastic modes can be simulated and studied. ABAQUS can be used to

simulate/analyze fracture for flaws in dams and levees, composites, non-metals and weldments, interfacial fracture in thermal

barrier coatings.