1. Surya (Senior Structural Engineer)
Mobile No: +91 9640422958
Mail Id: madduri.surya@hotmail.com
SUMMARY:
 8 years of strong professional experience in Defence, Aerospace and Rail Transportation Mechanical
Engineering design and development using Finite Element analysis and supported for mechanical vibration
testing.
 Hands-on experience with ANSYS Classic, ANSYS Workbench, Hypermesh, Optistruct, Nastran, Patran,
Hyperview, FatigueLife, Pro-e, CATIA, Unigraphics, Solidwork, AutoCAD, C, C++, Visual Basics and Microsoft
Office.
 Proficient in Structural Static-Elastic and Elastic-Plastic (Material, Geometric and contact) Analysis, Dynamic
(Modal, Spectrum, Harmonic) analysis, Fatigue Analysis, Transient Dynamic Analysis, Product optimization and
Parametric modeling. Using Submodeling and Superelement technique for the analysis of large and complex
assemblies, hand calculation for analysis of simple structures.
 Determined fastener analysis using classical theories and conducted self-locking feature audit.
 Experienced in welding standards and material selection.
 Prepared front matter for the structural analysis report based on the review of the analysis data and developed
the SAR by packaging the stress analysis data as per the standards.
 Involved in study of manufacturing feasibility, planning of raw material, processing planning, Stage drawing
preparation, Inspection and Quality controlling.
 Developed the Environmental and functional Qualification Test Procedures, Conducted a development test as per
RTCA DO-160F requirements and Generating the customer Qualification Test Report.
 Involved in Complete project life cycle processes, project documentation including requirements, design,
functional and technical specifications.
 Conducted experimental studies on Rotary milling of composite material.
 Interacted with customers to gather requirements, analyzed and identified solutions for the requirements,
prepared roadmap for Designing and Building the User Interface, Business and application layers from base.
 Commitment and conformance in delivering quality projects adhering to deadlines and hardworking, enthusiastic
and highly committed to the growth and success of the organization.
 Lead and coordinate technical project tasks as engineering responsible in complex projects, with the objective to
meet the technical requirements within the given budget and agreed schedule.
 Good communication and interpersonal skills, capability to learn fast and assume any responsibilities.
 Planned activities for the entire project and used to get it approved by the Configuration Management manager of
the Business unit.
 Experienced in working with prestigious clients including Defence Research and Development Organization
(DRDO, India), United Technology Corporation (UTC Aero, USA) and Bombardier, UK.
 Have good knowledge on industry specific Standards.
 Received Pride Award from UTC (Client) for efficient delivery of the project. Received Spot Award for delivering
the project within short deadlines.
EDUCATION
 Bachelor of Technology in Mechanical Engineering from Jawaharlal Nehru Technological University, India.
 Diploma in Mechanical Engineering from State Board of Technical Education and Training, India.

2. TECHNICAL SKILLS
CAE Software: ANSYS Classical, ANSYS workbench, Hypermesh, Nastran, Patran, Optistruct,
Hyperview, FatigueLife.
CAD Software: Pro-E, CATIA, Unigraphics, Solidworks and AutoCAD.
Aero Standards: Airworthiness Requirement-Vibration testing RTCA/DO-160F.
Rail Transportation standards: GMRT 2100, BS7608, BS118, BS12663, and BS16406.
IT Software: C, C++, Microsoft Office, Visual Basic
PROFESSIONAL EXPERIENCE
Defence Research and Development Laboratory, India: 10th Jan 2008 to 16th Dec 2010.
Designation : Junior Research Fellow
Infotech Enterprises Ltd (Client: UTC Aero, USA), India: 20th Dec 2010 to 26th Apr 2014.
Designation : Senior Structural Engineer.
Bombardier Transportation, Derby, UK: 28th Apr 2014 to 18th Apr 2015.
Designation : Senior Structural Engineer.
Infotech Enterprises Ltd (Client: Bombardier Transportation, UK), India: 20th Apr 2015 to Till Date.
Designation : Senior Structural Engineer.
Rail Transportation Project executed for Bombardier, UK.
1) Project title : Design development of CrossRail, Validated by Qualification testing and documentation.
Tools used : Hypermesh, Optistruct, Hyperview, nastran, patran and Unigraphics.
Responsibilities:
 The task involves Preparation of DFRD, Design development, Structural analysis and qualification testing and
documentation.
 Responsibility includes Review the design requirements and preparation of DFRD for mechanical package.
 Carryout Structural analysis, based upon the analysis data, suggest for improvement of design and integrity.
 Lead a team of engineers resolving all Crossrail structural issues using with working knowledge of Railway Group
Standards, BS7608 and BS8118 and FE experience.
 Managing, prioritising and delegating work to team members.
 Planning work for outsourcing including outlining scope, requirements, timescales, budgeting, providing relevant
models/geometry and reviewing the results.
 To ensure delivery of carbody and secondary structure work is within deadline.
 Sign off design/DRL’s.
 Responsibilities includes providing guidance to team members in regards to model creation, load application
(based on Railway Group Standards), and interpretation of the results (in accordance with BS 8118 and BS 7608).
 Liaising with planners and design team to plan Crossrail structures workload.
 Review of team members FE work, technical reports and supplier reports.
 Provide technical guidance and support the wider engineering team to solve complex structural issues.
 Liaising with vehicle design engineers to continually optimise the carbody design.
 Communicate effectively with mass, gauging, acoustic and dynamics engineers to understand the implication of

3. structures work within other departments.
 Creation of FE models, load application, analysing results and creating technical reports.
Aerospace United Technology Corporation (UTC), USA Projects executed from INFOTECH Enterprises Limited, India.
2) Project title : Structural analysis on A350 and Global 7000/8000 Variable frequency generator (VFG) and Altern
ate frequency generator (ASG) assemblies.
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 VFG and ASG are the power generation units for Airbus A350 program.
 Provided strength assessment and acceptance of Complex generators and its internal components.
 The major analyses carried out are: Modal analysis, Random vibration analysis, case and core pressure analysis,
Fan blade out analysis and Elastic-Plastic Analysis.
 Predicted failure modes. Recommended for design fixes.
 12 different design iterations are carried out to meet the structural integrity of the assembly with reduction in
weight and increased manufacturability.
 Provided fatigue life and durability assessment of Generators components.
 Sub-modeling technique is used to capture the results more accurately at the critical location.
 Provided analytical solutions for root-cause analyses of failure scenarios.
 Ensured compliance of parts with project requirements and all the applicable airworthiness requirements.
 Cycle time of the projects is reduced by developing the macros for FE model building.
 Integrate within the team and communicate proactively without borders.
 Supported for defining component test requirements. Follow-up on test development and results.
3) Project title: Design development of common Bus Power Control Unit (BPCU), Validated by Qualification testing
and documentation.
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 The task involves Preparation of DFRD, Design development, Structural analysis, Thermal analysis and
qualification testing and documentation.
 Responsibility includes Review the design requirements and preparation of DFRD for mechanical package.
 Carryout Structural analysis, based upon the analysis data, suggest for improvement of design and integrity as
per Air worthiness requirements.
 Prepared front matter for the structural analysis report based on the review of the analysis data and developed
the SAR by packaging the stress analysis data as per the standards.
 Developed the Environmental and functional Qualification Test Procedures for all the tests qualified by testing with
the information (e.g. Test Procedures, Success Criteria and Component Design Requirements) captured from
Acceptance Test Procedures (ATP), Environmental and Functional Requirements (Universal documents) and
prepared Test Data Sheets for the tests.
 Conducted a development test to verify readiness, conformity, test equipment calibration, test set-up, effect of
Vibration during power-up condition and to verify whether present design of the BPCU is structurally robust to
proceed to Safety of Flight and the qualification tests as per RTCA DO-160F requirements.
 Safety of Flight tests completed as per RTCA DO-160F requirements to verify air-borne readiness of the
equipment.
 Prepared the Spreadsheet and Page Tracking Sheet in order to capture the status available, missing and pending
data for each of the Test Article and Test Setup Conformities, Test Data Sheets and Test Witness Records.
 Generating the customer Qualification Test Report by writing the Front End and packaging the Appendices
applying all the Latest Lessons Learnt and checking against customer given checklist.

4. 4) Project title : Structural Analysis of 787-9 Strategic Motor Controller (SMC).
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 The major role is coordinated with the client and actively involved in all major decisions of the team.
 Work instructions and Checklists were developed for the different tasks of the project to ensure the smooth
operation of the tasks.
 Conducting technical meetings, planning, billing and estimation of the projects.
 The scope of this project is to determine the Structural integrity of the model and conducted FE analysis to
simulate the static and dynamic system behavior under normal operating conditions and extreme load cases such
as Sustained acceleration loading and Spectrum PSD analysis.
 New validated method carried out by Single point response analysis along with static Gload to determine the bolt
forces at mounting locations.
 Macro's were developed to PSD Batch run, Fasteners modeling and Bolt force extraction which makes a
reduction the cycle time.
 Detailed stress report was generated as per the AER requirements.
5) Project title : Structural Analysis of 787-9 Ram Fan Motor Controller (RFMC)
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 Provide strength assessment and acceptance of RFMC and its internal components.
 The scope of this project is to determine the Structural integrity of the model under Gravity loading, PSD analysis
and Sustained acceleration loading.
 Design changes were suggested for the component and sub-assembly levels. Multiple iterations were to be
performed to arrive at final design within the demanding schedules.
 SMV tool used for check the FE model in assembly level.
 Macro's were developed to PSD Batch run, Fasteners modeling and Bolt force extraction which makes a
reduction the cycle time.
 Provided fatigue life and durability assessment of components.
 Detailed stress report was generated as per the AER requirements.
6) Project title : C-Series RAT Dynamics
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 To modify the existing design of the RAT assembly as appropriate for weight reduction and increased
manufacturability, without affecting the fundamental design criteria.
 Structural Analysis was carried out to identify the critical stressed locations under Worst case static, Modal, Fan
Blade Out (Harmonic), High Level Short Duration (Harmonic), Single point Response Spectrum and Transient
Dynamic Analysis in a different configurations, which needs to be analyzed to justify its structural integrity against
the structural requirements.
 Provided Fatigue life and durability assessment of critical components.
 Macro's were developed to Harmonic and Spectrum Batch runs, Bolt force extraction which makes a reduction the
cycle time.
 Determined Fastener analysis using classical theories and conducted self locking feature audit.
 Writing and presenting detailed technical discussion documents.
 Provided support to, and liaising with, manufacturing engineers as required.

5. 7) Project title : C-series RAT Turbine Internal-Blade Shank Assembly Stress Analysis
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 The scope of this project is to determine the Structural integrity of the model under Rotational loading conditions
with bolt pretension.
 High quality of mesh was developed and model was checked for yield criteria and carried out Linearization for
finding MOS.
 Fatigue calculation is carried out for critical components.
 Detailed report was generated as per the AER requirements.
8) Rest of the Project titles: Vibration Analysis of Control Distribution Cabinet (CDC's), Overvoltage Protection Unit
(OPU) and Liquid pressure motor controller (LPMC)
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 The scope of this project is to determine the Structural integrity of the model under Modal, Limit, Ultimate, PSD
and Harmonic Responces.
 Superelement technique is used to capture the results more accurately at the critical bodies of large and complex
assembly with less disk space.
 Cycle time of the projects is reduced by developing the macros for FE model connections, PSD Batch run and
Bolt force extraction.
 Macro's were developed for PSD Batch run, Fasteners modeling and Bolt force extraction which makes a
reduction the cycle time.
 Determined Fastener analysis using classical theories and conducted self locking feature audit.
 Fatigue calculation is carried out for critical components.
 Ensured compliance of parts with project requirements and all the applicable airworthiness requirements.
 Detailed report was generated as per the AER requirements.
9) Project title : C-series Actuator Valve Housing Pressure Cores Stress Analysis
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:
 Structural Analysis was carried out to identify the critical locations of valve Housing, which needs to be analyzed
to justify Structural integrity against structural requirement.
 Applied plug loads to made the system into equilibrium condition from the imbalance position.
 High quality of mesh was developed and model was checked for yield criteria and carried out Linearization for
finding MOS.
 Direct Matrix Approach tool used for quick turnaround time in project execution.
 Prepare technical documentation of analysis procedure, results and conduct formal design presentations to the
customer.
Defence Projects executed for DRDL, India
10) Project title: Conceptual and Preliminary design and development of the static launcher for a missile project.
Tools used : Ansys Classic, Workbench, Hypermesh Nastran, Patran, Optistruct and Hyperview.
Responsibilities:

6.  The major role is coordinating with the Project members and actively involved in all major decisions of the team
 Conducting technical meetings and planning of the projects.
 The scope of this project is to determine the Structural integrity to elevate missile from 0 degrees to 95 degrees
and to withstand launch thrust at static loading conditions.
 Preliminary design of individual mechanical element using classical approach.
 Carryout FEA analysis to validate the results and to study the stress and deflection at worst case condition. Based
on the results design changes were suggested for the components etc.
 Prepare the list of items and material requirements for initiation the fabrication.
 Writing and presenting detailed technical discussion documents.
11) Project title: Design and development of shrink fit for a missile project mandrel of flow forming machine.
Tools used : ANSYS, Hypermesh, Pro-E
Job Profile:
 Moment transmission problem between Shaft (Mandrel) & Hub (Adaptor), when a torsion moment applied (Mt) on
adaptor & mandrel frictional moment (Mf) is generated between the contact surfaces of a joining elements.
 For transmission to be occurring between the joining elements, frictional Moment at contact surface should be
greater than the moment applied to the adaptor.
 Frictional moment generated at contact surfaces depends upon amount of contact pressure existing at contact
surface.
 Contact pressure generated between mandrel and adaptor due to min. interference should be more than min.
contact pressure required to transmit the torque generated by motor.
 During heat treatment should not form cracks on the adaptor and mandrel.
 Cost of the fabrication should be Minimum.
Responsibilities:
 Based on the above requirement suggest the most widely used method is providing interference fit. Based on the
above requirement select the minimum interference value.
 Literature survey of shrink fit analysis problem.
 By using classical approach verify the contact pressure generated between mandrel and adaptor due to min.
interference (shrink fit) is more than Contact pressure required at the shrink fit to transmit Min. torque generated
by motor. i.e. Slip doesn't occur.
 By using classical approach Calculate Max. And Min. Tangential and Radial stresses generated.
 A t same time analysis the Contact non-linear problem in FEM package.
 Compare the classical and analytical results with material properties of the mandrel and get the FOS.
12) Project title: Design and development of a Tailstock assembly of flow forming machine for a shell of a project.
Tools used : ANSYS, Hypermesh, Pro-E
Job Profile:
 Tail stock assembly is used to support the Perform while forming the shell carrying in a forward forming in flow
forming machine.
 Tail stock assembly is to be withstanding the combined torsion and compressive axial load during flow forming.
Responsibilities:
 Preliminary design of individual mechanical element like Shell, Bolts, Welded region using classical approach.
 Model the elements using Pro-E and assembled.
 Carryout FEM analysis of critical elements to study the shear stress and angle of deformation at worst case

7. condition.
 Based on FEM analysis the individual involved in the selection of suitable material for fabrication.
 Prepare the list of items and material requirements for initiation the fabrication.
13) Project title: Process planning of missile hardware for different missile projects.
Tools used: Integrated Manufacturing Information System (IMIS), Pro-E, AutoCAD.
Responsibilities:
 Study manufacturing feasibilities
 Planning of raw materials.
 Selection of process, Work center.
 Detailed operation planning and sequencing.
 Stage drawings preparation.
 Planning inspection stages.
Co- ordination with shop floor, production control, QC and designers to solve technical problems.
14) Project title: Simulation and analysis of Rear pin for a missile project using FEA technique.
Tools used : ANSYS, Hypermesh, Pro-E
Job Profile:
 The rear pin is to be arrest the motion of missile in launch tube during Transportation in bad terrain.
 Rear pin is to be welded to Rear block subjected to loading.
Responsibilities:
 In order to the above requirement select suitable configuration and material for the rear pin, numerical simulation
was carried using FEM Package.
 Classical design also carried out to verify the max. Stress obtained.
 Finally suggest the material and configuration of pin was sufficient to withstand the loading condition.
15) Project title: Experimental studies on Rotary milling of composite material.
Responsibilities:
 Conducting experiments was to compare the performance of Rotary face milling cutter with ceramic insert with
that of conventional ceramic tipped face milling cutter on a composite material (carbon-carbon).
 Literature survey of composite materials and rotary milling machining techniques.
 Conducting the experiment on three levels by varying speed, feed, depth of cut by using Rotary face and
conventional milling cutter.
 Finally concluded to lower the cutting forces and power consumption, increasing the tool life with better surface
finish by using the Rotary face milling cutter instead of conventional ceramic tipped face milling cutter
EXTRA-CURRICULAR ACTIVITES
I have participated in National Cadet Corps in India and got "A", "B" & "C" certificate.

8. PERSONAL PROFILE
Visa : H1B visa for US valid up to Dec 2016
Tier 2 ICT Visa (Work permit) for UK
Mail ID : madduri.surya@hotmail.com
Mobile No : 0091-9640422958
Date of Birth : May 05, 1986
Father's Name : Mr. Madduri Govindaraju
Gender : Male
Nationality : Indian
Marital status : Single
Languages Known : English
Temporary Address : Madduri Veera Venekata Suryanarayana,
House No: 1061, London road, Alvaston, Derby, UK, DE24 8PZ.
Declaration:
All the details above mentioned are true to best of my knowledge.
Date: May 15, 2015 Yours sincerely,
Place: India Madduri Veera Venekata Suryanarayana.