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Briefly

Published on 04/08/2010 by in CAD

 

Mechanical Engineer (Master’s Degree) with 15+ years of experience in:

-        Detail Designing Mechanical systems / Mechanisms / Large Assemblies,

         considering manufacturability, reliability & maintainability + FAA regulations

-        Project Management

-        3D / 2D applications: Solid Works, Solid Edge, CATIA V5 …

-        Design Metal & Plastic / Sheet metal components

-        Cost Effective Design

-        Assessment & Design Improvement

-        Innovative Design & Product Development

-        Efficiency Improvement

-        Multi-Project Coordination

-        Root Cause Analysis & problem resolving

-        Prototype fabrication

-        Reverse engineering

-        FAR 25 Certification

And familiar with

-        GD&T

-        Plastic injection molding

-        Rapid prototyping

-        FEM / CFD analysis (Fluent, Ansys)

-        Electrical Design & Wiring.

 
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The Wine Chiller / Refrigerator

Published on 03/09/2010 by in CAD, DESIGN
Now I am working on a new project in Zodiac Aerospace/Monogram Systems. It is a wine chiller and Refrigerator for our customer Embraer (The third biggest aircraft manufacturing company).
I am the project engineer and the mechanical designer for all Thermal, Sheet metal, Plastic, Machined parts. It a Thermoelectric refrigerator with this major characteristics:

  • Manual temperature control for wine chiller (50-64 °F – 10-18 °C)
  • Works in -40 to 95 °F (-40 to 35 °C) ambient temperature range.
  • Turns to a warmer in cold ambient temperatures.
  • Infra Red/Ultra Violet filtered windowed door
  • Solid State temperature controls
  • 1.2 cubic ft volume
  • Light weight
  • Appealing touch keypad
  • Air inlet and outlet on the back side
  • Bright white LED lights in the cavity
Here are some pictures:

 
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The Galley Microwave Oven

Published on 05/08/2009 by in CAD, CONSTRUCTION, DESIGN

 

 


The main project, I’ve been working on during working for Zodiac Aerospace/Monogram systems:

Detail designing a new microwave oven for AIRBUS Co. including: Sheet metal, Plastic, Metal, and Mechanisms designs.

I work as Senior Mechanical Engineer/Designer, and created all detail drawings for production of the new microwave oven. Also served as Mechanical Eng. In fabrication of three prototypes of this oven.
In addition, I Designed new mechanisms and solved thermal / mechanical problems for other products and performed structural FEM analysis using ANSYS for the Oven.


 
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The Telescopic Pneumatic Mast

Published on 01/28/2009 by in CAD, DESIGN



I had a chance to work in BICKFORD VEHICLES CO. for a short period. One of the projects I finished there, was reverse-engineering the telescopic pneumatic masts (used for several kinds of trucks), and designing a new mast with a new locking mechanism, to solve some problems that the of previous system had (less maintenance, smooth use and semi-automated locking).
I had to learn Solid Edge software to do the project, spending 1 and half days, I learned it and in 10 days I did the job!

 
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The Truck for Fairfax County Public Schools

Published on 01/26/2009 by in CAD, DESIGN


One of the projects I had in Bickford Vehicles Co. was to desig mechanical parts of a truck to be made for Fairfax County Public Schools. As you see in the images there are many mechanical (mostly sheet metal, fixings, fasteners) parts designed and ready to be made in the shop. All of the parts are designed using Solid Edge.

 
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The Side Intrusion Test Machine

The system in MIRA

In (IKCO) where I had been working for 9 years, a specific test named “Side Intrusion Test” should be done on each new/modified car body (BIW).
But the company had not had the test machine!
Thus, they had sent the bodies to MIRA Co. (in England) asking Mira to do the test. Obviously the cost of the test was too high. (20000$ for each test + cost of sending the body and …)
In order to retain the money for my company, I decided to make the test system.
I did all the researches and designed the whole system using:

  • The pictures taken from the MIRA’s system
  • SOLIDWORKS
  • CATIA

Then, I supervised the construction, assembly and installation.

Assembling
Complete CAD assembly (Solidworks render)
Bedplate drawing


The system in IKCO

The report of the test system in company’s magazine

A short film of the tests done in IKCO
 
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The Electric Motor

Published on 12/09/2008 by in CAD



These are some pictures of a electric motor of a radiator fan which is used in one of the “KIA Motors” cars. These complete Assembled CAD files are generated using:

  • The electric motor
  • SOLIDWORKS software
  • Different measurement devices

This is done for a company to manufacture the motor using reverse engineering.

 
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Some CAD files

Published on 12/09/2008 by in CAD
These images are showing some of the CAD files I prepared using
Solidworks and CATIA V5:

A New Car Front Bumper and Air intake grill

IKco. X12 Project Sound insulation (upper)

IKco. X12 Project Sound insulation (lower-right)
IKco. X12 Project floor carpet

IKco. X12 Project front windscreen wipper trim (LH)

IKco. X12 Project front windscreen wipper trim (RH)

Fuel cell bubbler
Tooth implant
Z24 Engine – Connecting rod
Z24 Engine – Crankshaft
 
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The Right-Hand-Drive Samand

Published on 12/08/2008 by in CAD, CONSTRUCTION, DESIGN




There are about 2.5 billion people living in the Right-Hand-Driving countries. So IKCO started to investigate on this market. Thus we in R&D center made 2 prototypes of RHD Samand, which was a perfect experiment and in some countries such as Pakistan, Bangladesh and India they find some interests and customers.

I was the project manager of one of these prototypes which was Bi-fuel (GAS and CNG). This car was made in less than 1 month and sent for the Pakistan Exhibition.

Also preparing the FS (Feasibility study) documents and negotiating with some Chinese companies were my other roles in that project.

This is a short list of differences of LHD and RHD SAmand that had to be done in that project:

  • Dashboard
  • Glove box
  • Dashbord beam assembly
  • 15 body parts (fire-wall and …)
  • Steering column
  • Fire wall sound deadening
  • Carpet
  • Front seats
  • Haedliner
  • Door covers
  • Center console
  • Wiper blades and wiper mechanism
  • Gas pedal system
  • Clutch system
 
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SARIR (The Limousine)

The prototype and the first manufactured ones

Inside the prototype

Inside the prototype


The prototype in car exhibition

Samand is a Peugeot-based car and Sarir is the limousine version.
In 2004-2005, there were 7-8 projects in IKCo R&D Center, and one of them was the The Limousine; the best project in that period.
I was one of the most effective
members of the project team, below are my responsibilities:

  • The project coordinator. (A-Z – from making the prototype to launching the assembly line)
  • The executive of “Samand assembly line adaptation to assemble Sarir” project.
  • The project coordinator of the “Workshop retooling” project to assemble BIW of Sarir.
  • An instrumental member in the research team to clarify and resolve Sarir platform weaknesses in passing “Side crash” test.

This film shows the whole process:

body pillar covers
body pillar covers welded by MIG-Brazing method

body side assembly line
The bodyshop
Sarir being assembled in assembly line

 
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Frequency Analysis

Published on 11/30/2008 by in CAD, DESIGN

Needless to say, there are too many discussions in designing a part. This is an example in which the fixings of the Parcel shelf of X12 project in IKCo. were not in the right place, and I did a rough frequency analysis (Using CATIA), to show this issue to the other members of the design team.

 
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The Burner Testing Furnace

The Furnace

The air pollution measurement machine


Inside the furnace

Inside the furnace

One of the burners

Being a junior student, I had the opportunity to work in “IROST” in which my professor Dr. A.Dadkhahniko worked.
In a 5-person team we designed, constructed and installed a furnace to test various kinds of furnaces, (gas and diesel burners, industrial or domestic).
Changing/Modifying different components of them we measured the noise and air pollution in order to lessen them and improve the flame quality and performance.

The design and installation of the furnace cooling system was done by me myself.

This is a film which I took those days to show the process of lunching the furnace to do related tests.

 
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The Electrostatic dust absorber

Published on 11/27/2008 by in DESIGN

shematic views
Efficency (%) vs particle size (micron)


In the I-Kashir project that you can see more about it here, This New style Electrostatic dust absorber is designed and used. In this system instead of using large panels to absorb the dust, several rotating cylinders are used to make the machine lighter, cheaper and more effective.

 
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The Bachelor’s Degree Thesis


As I told before having an outstanding bachelor’s degree thesis was my interest during my study. Searching for a fantastic project, my classmate and I found a knitting company called I-KASHMIR, that had had a big air pollution problem in it’s workshops. That was what I seek for and like to do!

Simply the problem was a huge amount of dust and wool fuzz spreading out from the machines working in the workshops and the danger of breathing such polluted air for the workers!


This short film somehow shows what we have done:

Please notice, both of us was just senior students and it was hard to ensure the company management that the system we had designed, would solve their major problem.

We not only designed each component of the the whole system, but were involved in preparation, construction and installation!

This is me up there!

schematic view of the system

And after 4 month of hard work, the result was completely satisfactory:

  • They get rid of the dusts (specially the workers who were in danger of various diseases)
  • The effect of dust on their product (Cashmere) was eliminated.
  • They pay one third of what other contractors had offered.
  • We did our bachelor thesis
  • and finaly we got the ISME first price:

The “Iranian Society of mechanical Engineers (ISME) “Aalinasab first prize in mechanical engineering for “The Best B.S. Thesis” among all universities-1999.

I should thank my dear classmate and co-worker “Hossein Monfared Asl”.

 
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The Master’s Degree Thesis

Published on 11/26/2008 by in CAD, DESIGN



This is a high pressure capillary viscometer to measure the viscosity of non Newtonian fluids such as drilling mud.
I used Solidworks and Ansys to design this viscometer, Constructed it and did the related tests for several fluids.
Finding and Doing a practical project was my concern during the study and both my B.S. thesis and M.S. thesis projects were useful and practical. This one was done because of the request of an oil company from Tehran University.

 
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Cristal Molding Project

Published on 11/26/2008 by in CAD, DESIGN



These CAD files were prepared to make a complete set of a glass mold for different crystal bowls, using Solidworks.

 
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My RESUME

Published on 09/27/2008 by in CAD


MOHAMMAD GHALAMBOR
mdezfuli@gmail.com
==========================================
Profile:

Mechanical Engineer (Master’s Degree) with 14 years of experience in:
-          Detail Designing Mechanical systems / Mechanisms / Assemblies considering manufacturability, reliability and maintainability + FAA regulations
-          3D modeling / 2D Drafting with CAD applications (Solid Works, Solid Edge, CATIA V5 …)
-          Design Metal and Plastic / Sheet metal components
-          Prototype fabrication
-          Reverse engineering
-          Engineering problem resolving
And familiar with:
-          Plastic injection molding
-          Rapid prototyping
-          FEM /CFD analysis (Fluent, Ansys)
       -          Electrical equipments / Hydraulics / Pneumatics



Work Experience:

Project Engineer / Senior Designer (Apr. 2009 – Present)
    • Was project & design engineer to design and manufacture:
    • A thermoelectric refrigerator/wine chiller for Embraer Aircraft Co.
    • A microwave oven “Wavejet AX” for Airbus Co.
    • A microwave oven “Wifi Comp. Wavejet” for Dassault Falcon Aircraft Co.
    • All above projects Included: Sheet-metal, Plastic, Metal, Mechanisms, and EMI filtering design, plus Building prototypes, creating mechanical/electrical drawings, and qualification test documents.
    • Designed new mechanisms and solved thermal / mechanical problems.

      Mechanical Engineer / Designer (Dec. 2008 – Feb 2009.)
      • Designed a new pneumatic telescopic mast and improved the previous locking mechanism.
      • Designed mechanical parts of a truck cabin to be made for Fairfax County Schools.

      Project Manager/ Mechanical Engineer Designer (Sep. 1999 – Oct 2008.)
      • Providing ~%50 added value, was the project coordinator of Samand limousine (Sarir) project.
      • Researched and designed a complete mechanical and electromechanical car crash test system (Side intrusion test). Retaining $20000 per test. (Using Solidworks)
      • Directed and coordinated activities involved in fabrication, installation and operation of the “Side intrusion test system” (mentioned above).
      • Managed and successfully accomplished all the activities of making two prototype concept cars (Samand Limousine and Right-hand-drive Samand) within prescribed time.
      • Was principal engineer in the staff that prepared and presented the feasibility study documents. (F.S.) for manufacturing of two different cars (Sarir and right-hand-drive Samand).
      • Coordinated a BIW workshop (manufacturing 3 Sarir bodies a day).
      • Was Trim Dep. design engineer in “Peugeot 206 platform” group, designing and 3D model preparation /modification of interior and exterior trim parts using CATIA (e.g. bumpers, floor carpet, air intake grill, console, door panels, parcel shelf…).
      • Was executive of “Samand assembly line adaptation to assemble Sarir” project.
      • Served as design/fabrication expert in “fuel-cell” project for mechanical parts (Using Solidworks).
      • Was project coordinator of the “Workshop retooling” project to assemble BIW of Sarir.
      • Was instrumental in research team to clarify and resolve Sarir platform weaknesses in passing “Side crash” test.
      • Used CAD/CAE software such as CATIA and Solidworks, Rhino.
      • Designed and supervised the construction of two ventilation and air filtration systems in rapid prototyping and modeling workshops. (Using Solidworks)
      Principal technician / Mechanical designer (Fall 1995 – Summer 1997)
      • Served as principal technician in foundation of “Heat Transfer/Combustion” Lab.
      • Served as principal assistant to fabricate a burner testing furnace.
      • Designed and fabricated a water cooling systems for the above mentioned furnace.
      5- Projects During Study,
      • Retaining $30000, researched, planned and designed a complete system of air pollution absorption for I-Kashmir knitting Co. (B.S. Project) (Sep. 1997 – Dec. 1997)
      • Was director and the principal technician of fabrication, installation and operation team of the pollution absorption system. (Mentioned above). (Sep. 1997 – Des. 1997)
      • Researched, designed, fabricated, installed a capillary viscometer and performed related tests for Tehran Univ (Using Solidworks). (M.S. Project) (Des. 2000 – Feb. 2001)
      Education:
      Training Courses:
      TRIZ (Theory of Inventive Problem Solving.) Ruthenia Univ. Moscow
      Mistake proofing & Poka-yoke
      Auto Mechanics
      FMEA (Failure Mode and Effect Analysis) by RWTUV/TUV Academy
      Fundamentals of polymers
      SOLID WORKS 3D modeling & assembly
      CATIA V5- 3D modeling, assembly & analysis
      ANSYS
      AUTOCAD
      Fundamentals of DFA (Design for assembly)
      Computer Skills:
      Engineering Software:
      CATIA V5
      (Part Design, Generative Shape Design, Assembly Design, Drafting, Structural Analysis …)
      Solidworks: 3D modeling, Assembly, Drawing
      Solid Edge: 3D modeling, Assembly, Drawing
      Rhino 3D
      Ansys, Working model, Moldflow
      Application software:
      Microsoft Office(Word, Excel, PowerPoint)
      Adobe Photoshop /Acrobat and many other utilities and internet techniques.
      Honors, Awards & other Activities:
      • 1st prize from The “Iranian Society of mechanical Engineers (ISME)” Aalinasab in mechanical engineering for “The Best B.S. Thesis” among all universities-1999.
      • Managed the “Science branch” of Educational – Guild Council of Faculty of Mechanical Eng. in Tehran Polytechnic (fall 1996 – fall 1997).
      • Presented a paper in 4th international ISME conference 2000.
      • Member of Iranian Society of Mechanical Engineers, (ISME). Since 1999


      =====================================
       
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