Ashish Kumar

• Implementation, Testing and Validation of different Inherent Strain based approaches for the distortion/ residual stress calculation in in laser powder bed fusion (LPBF). • Additively manufactured test samples and prototypes using LPBF. • Developed in-house tool for finite element (FE) mesh generation and distortion calculation for additively manufactured metal components.

• Structural assessment (FEM based) of weaving machine components designed with carbon fiber composite material. • Computational fuild dynamics (CFD) assessment of 3D turbulent flow for new coagulation bath design. • Fluid flow simulation for multi jet wash bath concept for wet spinning process.

• FE based sensitivity study of pore sizes and its distribution on stiffness of thermoplastics using Representative Volume Element (RVE) approach. • Automation of the Pre- and Post-processing of FEM simulation with Python. Resulted in 70% reduction in effort.

• Requirements gathering and coordination with multidisciplinary teams. • FEM evaluation of turbine, automative and aviation mechanical components. • Assessment included stiffness calculation, stress evaluation, thermal calculations, bolted joint evaluation, modal evaluation, seal tightness, creep strain assessment, and fatigue life evaluation (LCF & HCF). • Documentation of FEM evaluations and project results in technical reports. • Development of a Python-based tool for preliminary design evaluation.

• Feasibility study for application of thermal barrier coating (TBC) on valve casings to enhance the fatigue life. • Development and implementation of a new seismic evaluation method for turbine valves.

Production Systems Engineering (PSE)