Karthik Prakash Sivakumar
Mechanical Design Engineer @Consolidated Metco
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WORK HISTORY
Mechanical Design Engineer @Consolidated Metco
Vancouver, WA, US
Job Scope: Own mechanical design & release of seals, bearings, spacers, rotor assemblies in drive axle hardware. Partner with suppliers, test engineers to ensure part designs are robust & perform reliably from launch to field use.• Solved tight-fit retentions via targeted GD & T refinements at metal rubber interfaces.• Resolved removal-induced stamped part separation via unbend force calcs; optimized OD fits & retainer curl stiffness increase.• Streamlined ECN process, Y14.5 drawing checks to reduce dwg release timelines by ~ 40%.• Built Abaqus FEA models for elastomer parts to simulate install force / contact-pressures. Achieved >70% correlation to real world installations. Used it to optimize parts for low deflection & better life. • Accelerated launches by ~3 months via preplanned supplier visits to assess plant capability. Defined fits, dim constraints, and test criteria; reviewed concepts & prototype samples. Onboarded via design reviews.• Led R&D to develop unique pressure vents, advancing ideas from concept builds through pressure/leak tests to production readiness & patent activity. • Released drawings & documented design iteration history: feature geometry/tolerance changes, feature-wise friction impacts, bench test hrs & wear trends. Benchmarked competitor designs via CMM.• Did tradeoff studies on design change impacts Ex. shaft roughness vs part retention.• Identified root causes on field returns for wear, part spin (bore issues), axial overload (impact wrench) or low preload (tool/torque error). Debunked supplier process changes to decrease field issues to <10%. • Resolved bench test failures via tolerance stack on test setups; identified fixture-induced space-outs causing dirt ingress.• Organized DVPR efforts (bench life, torque, field testing) & produced Weibull to compare design robustness. • Applied Six Sigma methods for MSA in bore gage readings & DFMEA development, ensuring production readiness via stage gate reviews.
EDUCATION
Anna University
Bachelor of Engineering (BE), Mechanical Engineering
University of Illinois Chicago
Master of Science (MSc), Mechanical Engineering
SKILLS
ABOUT KARTHIK PRAKASH SIVAKUMAR
Mechanical Design Engineer improving seals, rotating system components, besides designing sheet metals, frame structures, integrating motors, drive systems and fluid systems.Experience applying CAD, GD & T, tolerancing, FEA & validation testing to optimize part retention, wear performance, and durability.Background in electric drive integration, like sizing and testing motors, gearbox reducers, belt drives, couplings to drive rotating machinery, mounted via sheet-metal brackets & welded frames.Worked in elastomer component design, material evaluation & failure analysis, supported by testing and failure mode investigations to evaluate real-world performance.Added background in fluid systems: sizing & assembling pumps, valves, tubing, piping, flanged nozzles, flow/pressure testing, leak troubleshooting.Focus areas: Sealing • Elastomers • Bearings • Rotating Machinery Components • Electric Drive • Power Transmission • Fluid Systems • GD & T • FEA • Reliability • Sheet Metals-Side Profile - Hobby Aviation : Building unmanned electric-powered, radio-controlled airplanes with a specific mission via collegiate and personal hobby projects. This includes aircrafts, quadcopters, Prandtl flying wings- Sending capstone design papers for space challenges : Electric Propulsion aircrafts, Microgravity toilet flush -Contact : email : s••••••••@yahoo.com Mobile : 31••••••65
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