Bilal Khan

Product development: Apparel collection for kids with a theme

A product development concern providing engineering, design and product dev services.

Business development in Germany: Demonstrating company's design and analysis capabilities to new and existing clients.

Training and management of resources in simulation department.

Project execution for R&D oriented work.

Brainstorming, Design and analysis for the development of a bearing testing machine according to unique requirements from the client. Dynamic and static analyses considering forced friction and dynamic friction for designing various components and frame of the machine.

Team management: time-sheet management, progress reporting, scheduling of resources, project planning and making processes more efficient to meet tight deadlines.

Team management: time-sheet management, progress reporting, scheduling of resources, project planning and making processes more efficient to meet tight deadlines.

Material non linearity Analysis: Non linear Rubber seal analysis for the purpose of selection of best material for the seal as per system requirement.

Design of experiments DOE/ response surface/statistics tools implementation for Optimization analyses. Recommendation of new designs using optimization techniques for weight reduction and constant deformation and stress concentrations.

Project coordinator/ Lead: Simulation
Automotive simulation pre-processing

Simulation Engineer for Active testing platform: Conducting and managing simulation related tasks for active testing platform being developed in house.

Fatigue Analyses
Simulation driven product development

Solar Dish design: Design and acquisition of harnessing system for solar dish assembly procedures.
Develop efficient Assembly procedures for the Solar dish, conducting FMEA analysis for the assembly procedures.
Conduct Ray-trace analyses for solar concentration on focal point and engine receiver.

Excavator ROPS (Roll over Protective structure) Analysis ISO 12117-2
Making Analysis and design recommendations for ROPS structure for a client. Presenting effective results resulting to successful first run prototyping tests. The analysis results had close comparison to the actual results.
The project made use of non linear material model, hysteresis and storage of deformation for the each step for this three step ISO standard.

Fatigue analysis of hydraulic manifold: Analysis and design recommendations for increased life of hydraulic manifold used for actuation in dump trucks.

Investigative analyses: Analysis conducted for finding cause of failure and presenting plausible reasoning with remedies and value addition for the product.

Drop-test Analysis: Design recommendation for PET bottles after extensive impact analyses.

Casting simulations: Design and casting simulations for magnesium based sun roof panels based in order to reduce the weight while keeping steady stiffness and stress concentrations under control.

Metal forming simulation.

Skills:

Solid Meshing & Shell Meshing
Automotive Pre-Processing
Extensive work on structural analysis and optimization.

Analysis and Simulation Of an automated AVLB for structural integrity: component and assembly level analysis and design of an AVLB vehicle. Reaction forces from Assembly level analysis used for design and analysis of individual components.
Selection of material and best possible selection of grade off the shelf.

Chassis design for a single seat sport vehicle: Managed research and analysis conducted for torsion and impact FOPS analysis for the vehicle.

Casting simulations: casting simulations and design recommendations for metals using industry standard software.

Inventor part and assembly modelling: Modelling and assembly of a 250 component assembly of a mobile conveyor system.

Solid Meshing& Shell Meshing

Responsible for Design and Fabrication of a light weight vehicle. The project included a complete design of a three wheel
light weight public transport. This included dynamics, manoeuvrability, usability, ergonomics, aerodynamics, chassis design,
drive train, transmission and suspension of the vehicle. This project was completed with the help of following simulation
software i.e. Msc Adams, Shark, 3Ds Max, Pro E and Matlab.

Completed 4 week internship at the Land Rover service center. I had the opportunity to work with a team of engineers and
technicians working on the maintenance and modification of Land Rover vehicles.