Rijul Pathak

• Worked on a case study to test a plug-in for Simufact Welding™ called Welding Sequence Optimizer (WSO) • The Artificial Intelligence and Machine Learning algorithms using plug-in assisted in minimizing the inherent welding deformation by 20 %. The case study provided a starting point for further testing.

•Implemented Modified Goldak heat source in the FEA software, Simufact Welding. •Created FE geometric model using Siemens NX and discretized using MSC Apex. Modified FORTRAN user subroutine to integrate the heat input formulation. •Validated FEA results with the experimental data from Welding and Joining Institute (ISF, RWTH Aachen). •Weld pool geometry increased along the depth and width by 6.6 % and 2.3 %. Achieved realistic highest arc welding temperature value. The temperature differed by 442 ⁰C.

• Demos & example simulation models were validated and verified, comparing the old software package for quality assurance and outcomes used to develop demos for new version of Simufact Welding™. • The existing models were revised to improve and further to achieve results close to real practice. • The improvements made were incorporated in the demos and tutorial documentation.

• Developed a functional disk brake system using ANSYS with simple pin-on-disc geometry and established the functions of an actual disc-pad braking system. • Successfully performed a thermo-mechanical coupled simulation and achieved desired braking effects of temperature rise and volume loss due to wear on the pin and disc.

Project 1: Dynamic Simulation for the application of Automotive Safety •Carried out impact response and injury correlation on a human thorax using FE Human Body Model using LS-Dyna. •The simulation data was used for design modifications for the safety of the occupant. Project 2: Validated hip implant neck failures •Geometrically modelled the hip implant in Catia V5 and meshed in HyperMesh. •Studied Gait analysis to determine load cases. Simulated static analysis using ANSYS.

Project 1: Improved welding tip changing frequency of a robot spot welding station •Inspected the welding process, cleaning counter, tip geometry, and replaced tip condition. •Jobs increased from 20 to 80 resulting in an annual cost saving. Project 2: Optimization of the cycle time - robot spot welding station •Diagnosed that interference in work volume leads to additional waiting time and tact time. •Achieved a 22 % reduction in tact time increasing the production by one car after every three cycle.