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Knuckle Joint
Knuckle joints are mechanical connectors that allow two rods to transmit tensile or compressive forces and are commonly used in linkages, steering systems, and suspension assemblies.
In this knuckle joint assembly project, I aimed to design a reliable and durable connection that could effectively transmit force. A knuckle joint, often used in mechanical linkages, is essential for connections that need slight angular adjustments.
In this project, I worked through the stages of design, material selection, and tolerance analysis. I began by analyzing various materials to ensure strength and longevity under high stress, selecting alloys that balance durability with machinability. I modeled the assembly using CAD software, taking particular care to maintain alignment and ensure compatibility between components.
This project highlights my ability to bring together theoretical knowledge and practical skills in mechanical design.
Cotter Joint Assembly
A cotter joint is a fastening device used to connect two rods end-to-end for transmitting axial tensile or compressive forces.
For the cotter joint assembly project, my focus was on creating a secure and easily maintainable connection suitable for transmitting axial force.
I designed the joint to allow quick assembly and disassembly, selecting materials that withstand shear stress effectively. Using CAD modeling and stress analysis, I verified the joint’s performance under axial loads, ensuring reliability in variable load conditions. This project demonstrates my ability to optimize mechanical linkages for strength and efficiency.
Coupling Assembly
A coupling assembly connects two shafts to transmit torque while accommodating slight misalignments.
In the coupling assembly project, I worked on creating a robust connection between rotating shafts to transmit torque smoothly while minimizing misalignment. I analyzed different coupling types to select one that balanced flexibility and strength. Through CAD modeling and dynamic simulation, I ensured the coupling's efficiency and durability under high-torque scenarios, showcasing my skill in designing components for rotational mechanics.
Screw Jack Mechanism
A screw jack is a mechanical device used to lift heavy loads by converting rotational motion into linear motion through a threaded screw.
For the screw jack project, I designed a mechanical lifting device capable of supporting heavy loads with minimal manual effort. I selected materials with high compressive strength and optimized the screw pitch to balance load-bearing capacity and ease of rotation. Using CAD and load testing, I refined the design to ensure stability and safety during lifting operations. This project reflects my expertise in designing mechanisms that combine practicality with structural integrity.
Thermo-mechanical analysis
Performed a thermo-mechanical analysis on a metallic rod to understand how materials respond to combined thermal and mechanical loading. A temperature gradient was applied to simulate real-world conditions such as those experienced in aerospace or automotive environments. Using FEA tools, I observed the resulting thermal expansion, induced stresses, and overall deformation. This exercise provided insight into how temperature changes can affect structural integrity, especially in constrained systems, and highlighted the importance of material selection in thermally dynamic applications
FEA Analysis of Chassis
Conducted Finite Element Analysis (FEA) on a vehicle chassis to evaluate its structural performance under dynamic conditions, including acceleration, cornering forces, and crash impact scenarios. Simulated realistic load cases to assess stress distribution, deformation patterns, and potential failure points. The analysis helped identify critical areas requiring reinforcement and guided design optimization for safety. This project enhanced my understanding of how high-performance structures behave under multi-directional forces and the importance of crashworthiness in automotive design.
FEA analysis to compare the aerodynamic behavior of an SUV and a sports car.
The simulation focused on evaluating pressure drag and shear drag (skin friction) under identical flow conditions. Results showed that the SUV generates significantly higher pressure drag due to its upright, boxy geometry, which causes increased flow separation and turbulent wake regions. The sports car, with its low-profile and streamlined contours, exhibited reduced pressure drag and smoother flow reattachment. Although shear drag (caused by surface friction) was present in both models, it contributed less to total drag compared to pressure drag—especially in the SUV. The sports car’s optimized surface profile helped minimize boundary layer disruption, further reducing overall drag. This analysis highlighted the critical role of shape optimization in aerodynamic efficiency and the effectiveness of FEA in visualizing complex flow behavior.
Mode and Natural frequency
Conducted a modal analysis on a bar with a square cross-section to determine its natural frequencies and mode shapes. Using FEA tools, the study identified how the structure vibrates at specific frequencies without external damping. This analysis is essential for predicting potential resonance conditions, ensuring the design avoids operational frequencies that could lead to vibration-induced failure. Results provided insights into dynamic behavior critical for structural and mechanical system design.
Stress-Strain Analysis of Different Geometries
Stress-Strain Analysis of Different Geometries
Conducted a stress-strain analysis on components with varied geometric profiles to evaluate their response under varied loading. The study focused on how changes in shape affect stress distribution, deformation behavior, and structural efficiency. Using FEA simulations, it was possible to compare performance and identify which geometries offer better mechanical advantage for different loading scenarios as well as different material and multiple material in same problem. This analysis supported more informed decisions in design and optimization.
CRANKSHAFT
A precision-engineered 3D model of a multi-throw crankshaft created using [CAD software name]. The design focuses on realistic geometry, optimized for strength and balance, considering manufacturing feasibility and dynamic loading conditions. The model reflects core mechanical principles and is suitable for engine simulation or prototyping.
TOY AIR PLANE MODEL
A concept design of a toy airplane modeled in SolidWorks, focusing on aesthetic form, symmetry, and ease of manufacturing. The model includes main components such as fuselage, wings, and landing gear, demonstrating foundational skills in surface modeling and part assembly.
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