My Portfolio !
Overview: My Education & work Experience
I did my four years Bachelors of Sciences degree in Mechanical Engineering from University of Engineering & Technology (UET), Lahore . UET is the oldest institution of the country founded in 1921 as an engineering college. UET is offering a wide range of undergraduate, postgraduate & PhD's through its 17 engineering departments. UET has been placed at 592 among the top ranked Universities of the world in World Ranking Universities 2008 .
The language of instruction was only English during my 4 years of bachelors studies at this university . The course of contents being taught at this university is well versed with the same advanced courses being taught at other universities of the world. I studied mathematics, engineering mechanics (statics & dynamics), engineering drawings & graphics, machine design & CAD, machine tools and machining, IC engines, mechanics of materials, finite element analysis, quality assurance & quality control, production management, numerical methods for engineering etc. I have attached copy of detailed marks certificate on which there is a complete list of courses, I studied.
Strength of materials & Machine design & CAD was my favorite course; I was assigned two assignments in this course, first one was to elaborate design aspects & 3D modeling of any mechanical machine. I selected a car lifter cruise machine to design its mechanisms, loading capacity, its front booms strength analysis. I used Solid edge for solid modeling. It was an individual assignment. My assignment was prominent & I got an appreciation letter too. See fig-1 at bottom this portfolio.
Second assignment under this course but in 5 th term was to design mechanisms & 3D modeling of a lathe machine . It was an individual assignment. I did this assignment again using Solid Edge & got a score of 50 out of 50 . See fig-2 at bottom of this portfolio
Final Year B.Sc Thesis Work
At the start of final year, it was the time to get ready for final year thesis work comprising of 200 marks out of 200 marks for 8 th & final term. After discussing my interests with my advisor, who was Chairman of my department i.e. Mechanical Engineering Department. He already knew about my work & attachment to Design, CAD & CAM. He got agreed and I selected the thesis with title “ Designing, 3D Modeling, Static & Dynamic Analysis & Machining of Connecting Rod die on CNC machine ” .
(E-copy of my thesis can be accessed online at http://www.ihtsham.com/ihtsham_thesis.pdf )
I got lucky to have connecting rod design notes & lectures from Automotive Engineering Department, Cranfield University , UK . So whole of the design work for connecting rod was done using these lectures & notes. Then I calculated all the forces (reciprocating & rotational), stiffness, bending stresses, bending moments at small & bigger end of connecting rod . I was having maximum allowable stresses & working stresses for the connecting rod material & its geometry. For future easiness of design calculations, I programmed all the above numerical calculations in a stand-alone program using MATLAB® .
For analytical & FEA based analysis, I did static structural analysis of connecting rod by exporting its 3D geometry from Pro/Engineer to ANSYS® 8.0. Analysis in ANSYS was not that easy, I was lucky to get help for structural analysis from Madam Sara of AEDesign. I put my 3 weeks with her for analysis training. I then compared the results of ANSYS analysis with the already done numerical analysis values, which were exactly the same. Some results were misguided because of some incorrect boundary conditions applied to connecting rod geometry during analysis.
As connecting rod is under fluctuating stresses during its strokes, its dynamic analysis was necessary to do. It was the reason I made 3D model of all the components, needed for dynamic analysis. I exported the connecting rod & its piston assembly to MSC® visualNastran, performed & validated its results.
Then I personally practiced connecting rod die manufacturing in university 3-axis milling CNC machine . I worked extensively in Pro/MOLD & Pro/NC module of Pro/Engineer® where I got expertise with moulds creation, machining sequences, tools geometries, feed rates etc.
During my industrious work even with the limited resources at my department & frequent visits and trainings from industries, I was not known about the results of my thesis, finally, at one end I got professional skills and at the other end my thesis was awarded ‘thesis of the year' and It scored 200 marks out of 200 marks .
I would like to conclude my technical skills other than theory, what I got during the completion of my bachelors final year thesis.
Engineering & conceptual design, 3D solid modeling & assembly, mechanism & motion analysis, structural & dynamic analysis, numerical & analytical problem solving skills, basic programming using MATLAB & C++, computer aided manufacturing, manufacturing using different plastics by injection molding.
Computer skills I got; Pro/Engineer Wildfire for solid modeling, interactive & free form surface modeling using Pro/SURFACE, Pro/MECHANISM, Pro/MOLD for plastic & metallic moulds, ANSYS® multiphysics, ANSYS® Workbench, MSC® visualNastran, Primavera® project planner, AutoCAD®, Microsoft® Office & Windows VISTA.
For graphics & web design, Adobe® Photoshop, Macromedia® Flash, Macromedia® Fireworks, Macromedia® Dreamweaver.
My Experience:
First Job:
AWC is an engineering R&D organization, which fulfill the engineering related needs of Pakistan Air Force with a more than 5000 engineers & technicians.
What I used to dream, I got in form of AWC where I can perform engineering design activities.
It was quiet fascinating for me to play with the engineering tools and materials. The problem identification & defining the methodology for design, numerical calculations, then for a required strength against a specified set of working loads, the selection of material which will qualify & will sustain for a desired time period, fatigue life calculations, finite element analysis both numerically & analytically was really cool & solid base for my firm grip over engineering design & latterly on my profession.
I got a firm grip over strength of materials, mechanics of materials, before going to finalize the design, having the constraints of only available materials in mind, their strengths i.e. modulus of elasticity, modulus of rigidity, poison ratios, section modulus, bending moments etc, all these things made you in challenge.
We (design team) were given assignments on component design for which the available resources like materials in the inventory & our machine shop capabilities are set as a challenge. So designing in such a tight environment was really a challenge where you have to design very carefully, specially by having clear concept of Design for Manufacturing (DFM) & Design for Manufacturing & Assembly (DFMA) techniques.
I got proficient with free form surface modeling, using state of art CAE software, Pro/Engineer by PTC . I worked extensively in it specially in surfacing module. I love to play with datum features like, datum planes, points, curves, surfaces, axis & complex contours being developed with the help of these datum features. It was the difficult enough in solid modeling to get handy with surface modeling after which you can design & model whatever you think actually.
During my stay at Air Weapons Complex, I also got skills in finite element based analysis using ANSYS® Workbench . Also worked in advanced mechanism design using Pro/MECHANISM & MSC® visualNastran.
I would like to conclude my work 2 ½ years experience at AWC, after which I got sharpened in the following fields:
Strength & metallurgy of materials, engineering design, numerical & analytical problem solving skills, 3D modeling & assembly, surface modeling, mechanism design & motion analysis, mould design, graphics work using adobe products, photorealistic rendering, FEA, 2D/3D drawings & drafting using AutoCAD®, 3D scanning using scanners & CMM (coordinate measuring machine) machine.
My 2nd Job
I availed a chance to work abroad in Saudi Arabia in project management field. As I got hands on experience engineering design, so I wished to sharpen my skills in project management. I worked for six month as project engineer, my job responsibilities are listed below;
Project planning using Primavera® 5.0, planning and scheduling of all engineering and/or construction projects activities, like WBS, roles & resources, cost flow charts, CPM & PERT, S-Curves, project execution & reporting etc.
Defining the scope of work from available engineering data pack, mobilization of the manpower, monitoring and reporting the completed work to the project manager.
Construction supervision at site to make sure that costs, schedules and safety are maintained.
Technical assistance to surveyors in interpreting specifications & plans and estimating quantities of materials, manpower and equipment requirements.
Managing the site staff for efficient running and functioning of the project.
My Work: Visual Material
My first assignment at University:
Problem statement:
To elaborate design aspects & 3D modeling of any mechanical device/machine. I selected a car lifter cruise machine to design its mechanisms, loading capacity, its front booms strength analysis. I used Solid edge for solid modeling. It was an individual assignment. My assignment was prominent & I got an appreciation letter too. I am representing that ‘cruiser' down.
Fig-1 Conceptual Design of car lifter
My 2nd assignment at University:
Problem Statement:
Second assignment under this course but in 5 th term was to design mechanisms & 3D modeling of a lathe machine. It was an individual assignment. I did this assignment again using Solid Edge & got a score of 50 out of 50 . 3D conceptual model is as under:
Fig-2 Lathe Machine
My 3rd assignment at University:
Problem statement:
We were two students assigned this small project of designing, analysis of a wheel, trim & there assembly. We also have to suggest the material & manufacturing method for both wheel & trim. We did this assignment efficiently.
Here are some 3D modeling visuals of wheel & trim.
Fig-3 Wheel & trim with bolts
Fig-3a Conceptual Design of wheel & trim
Fig-4 Conceptual Design wheel & trim assembly
My Thesis Work: Visual Material
As I told earlier, my thesis (Designing, 3D Modeling, Static & Dynamic Analysis & Machining of its Die on CNC Machine) was a complete Computer Aided Engineering (CAE) project. As I have given details on previous pages, I will put some visuals here to show how I started my work from scrap, designing and then finally developed an engineering component.
3D Modeling & FEA Work:
Down you will find some of the 3D modeling work, which was done using Pro/Engineer Wildfire 2.0, and Analysis work using ANSYS®.
Fig-5 Conceptual Design of connecting rod
Fig-6 Piston with rings & gudgen pin
Fig-7 Piston connecting rod assembly
Fig-8 Piston connecting rod assembly
Photorealistic rendering work using MSC® visualNastran.
Fig-9 Rendering of connecting rod cavity
Fig-10 Complete Connecting rod die rendering
Here it is the final die of connecting rod which I machined at CNC machine, with a number of machining sequences & tool geometries. I have had submitted this at my faculty at the time of completion of my thesis.
Fig-11 Practiced & final connecting rod
Fig-11a Machined connecting rod die
My Personal Work
I worked on many self-motivated projects, just to make my grip over conceptual design skills. Here you will find some of that work.
Fig-12 Concept air craft
Fig-13 Concept air craft-2
Fig-14 Concept head phone
High resolution pictures of above work:
Click on files to open in new window.
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