In industries like oil & gas, water supply, and sewage systems, pipeline inspections are crucial for detecting defects, cracks, and internal erosion. Our team developed an In-Pipe Inspection Robot designed for 500 mm to 600 mm diameter pipelines, integrating hybrid locomotion for navigation in varying pipe orientations.

Key Features & Innovations:

Hybrid Locomotion Mechanism - A combination of wall-pressed movement and track wheels allows the robot to traverse both horizontal and vertical pipelines.

Non-Destructive Testing (NDT) - Equipped with ultrasonic sensors, the robot detects flaws such as cracks, corrosion, and deposit build-ups.

Wireless Communication & Control - Controlled via Bluetooth & Arduino, allowing remote operation using a mobile app.

SolidWorks & FEA Simulations - Comprehensive CAD modeling and stress analysis ensured optimal design performance.

Spring-Piston Mechanism - Enables automatic adjustment to varying pipe diameters, ensuring stability and efficiency.

Outcome & Impact:

Successfully climbs vertical pipes and adapts to different diameters.

Provides real-time defect detection and location mapping for maintenance.

Enhances efficiency, safety, and cost-effectiveness over traditional inspection methods.

This project helped me apply my mechanical design, CAD, FEA knowledge to a real-world problem. It was an good experience working on multidisciplinary aspects, from structural mechanics to robotics and automation.

Looking forward to exploring more such projects in engineering! 

Composite materials are revolutionizing industries like aerospace, automotive, and wind energy, but their anisotropic nature presents significant machining challenge especially delamination during drilling. My literature review in Advanced Composite Manufacturing focused on analyzing delamination mechanisms and optimizing drilling techniques to improve the structural integrity of composite components.

Highlights:

Delamination Mechanisms - Investigated factors affecting delamination, including fiber orientation, matrix properties, and tool geometry.

Advanced Drilling Techniques - Explored ultrasonic-assisted and vibration-assisted drilling, which lower thrust forces and enhance chip evacuation.

Innovative Tooling - Studied the impact of step drills, multi-faceted tips, and hybrid machining on reducing entry and exit delamination.

FEA & Experimental Validation - Explored Finite Element Analysis (FEA) to predict delamination onset, non-destructive testing (NDT) and thrust force measurements.

Future Perspectives - Highlighted the need for real-time sensor feedback, adaptive control systems, and multi-physics predictive models to refine drilling methods further.

Impact & Learnings:

Enhanced understanding of delamination mechanics and its impact on composite performance.

Studied the need of FEA-based predictive models to optimize drilling parameters and reduce defects.

Strengthened knowledge in composite machining, structural analysis, and advanced manufacturing techniques.

This literature review reinforced my passion for composites and manufacturing optimization. Looking forward to exploring cutting-edge solutions that push the boundaries of precision machining and material science! 

Tools Used: SOLIDWORKS
Skills Demonstrated: CAD Modeling, Assembly Design, Mechanical Linkage Understanding

Project Overview:
This project involved the design and modeling of a double wishbone suspension system, a key component in automotive suspension architecture known for offering superior handling and wheel alignment capabilities. The objective was to recreate a functional and mechanically accurate 3D model using SOLIDWORKS, showcasing both part modeling and assembly proficiency.

Key Contributions:

Modeled a total of 43 unique mechanical parts, each reflecting realistic proportions and geometry.

Created 11 subassemblies, each representing major functional sections of the suspension system (e.g., upper & lower control arms, axel, shock absorber assembly).

Applied precise assembly mates in SOLIDWORKS to position components in alignment with design intent and motion constraints, ensuring realistic articulation of the suspension mechanism.

Gained strong hands-on experience in part creation, hierarchy-based subassembly design, and kinematic constraints within CAD environments.

Outcome:

Developed a comprehensive understanding of the mechanics of independent suspension systems, including camber control and load distribution.

Polished proficiency in SOLIDWORKS by working with large assemblies and complex mating conditions.

Demonstrated an ability to replicate real-world mechanical systems in 3D, improving my spatial awareness and mechanical design intuition.

Tools Used:

AutoCAD (2D Drafting)
ISO/ANSI Drawing Standards

Project Overview:
The project involved the creation of a complete 2D drafting package for a Bush Type Flexible Coupling, commonly used in power transmission systems to accommodate misalignment and vibration between connected shafts. The goal was to demonstrate proficiency in technical drafting and mechanical component detailing using AutoCAD.

Key Contributions:

Designed individual component drawings including flanges, bushes, bolts, and rubber bushings with dimensional accuracy.
Assembled a fully-dimensioned general assembly drawing using appropriate orthographic projections, centerlines, and sectional views.
Developed a detailed drawing sheet layout incorporating title blocks, BOM, tolerances, surface finish symbols, and geometric dimensioning where applicable.
Ensured all drawings adhered to engineering drawing standards for clarity and manufacturability.

Outcome:
Successfully created a professional-quality technical drawing set representing a real-world mechanical assembly. This project highlights my command over AutoCAD for mechanical drafting, attention to detail, and understanding of design documentation required in manufacturing environments.

In mechanical assemblies across automotive, aerospace, manufacturing, and structural applications, bolted joints are critical load-bearing elements. Accurate evaluation of bolt pretension, contact behavior, and load transfer is essential to ensure joint reliability and safety.

In this project, I performed a detailed finite element analysis (FEA) of a bolted joint subjected to bolt pretension and shear loading using ANSYS Mechanical. 

Key Features & Analysis Highlights:

Bolt Pretension Modeling - A realistic bolt pretension of 5 kN was applied in the first load step to simulate tightening, followed by shear loading while maintaining preload.

Contact & Frictional Interaction - Frictional contacts were defined between the bolt, plate interfaces, and hole surfaces to accurately capture clamping behavior and load transfer.

Shear Load Application - A lateral shear force of 1 kN was applied to the top plate to simulate service loading, inducing combined shear and bearing effects in the joint.

Stress & Deformation Evaluation - Von Mises stress, total deformation, and contact pressure were analyzed for both the bolt and plates to identify critical regions and verify elastic behavior.

Mesh Refinement Strategy - Local mesh refinement was applied near the bolt shank, hole perimeter, and contact regions to improve stress accuracy while maintaining computational efficiency.

Hand Calculation Validation - FEA results were validated using analytical calculations for bolt shear stress, plate bearing stress, bolt elongation, and factor of safety.

Outcome & Engineering Insights:

Maximum bolt stress remained well below yield, achieving a FOS ≈ 4, confirming safe elastic operation.
Plate stresses and bearing stresses were within allowable limits, preventing local crushing or permanent deformation.
Contact pressure results confirmed that the joint remained fully clamped with no separation under shear load.
Reaction forces verified static equilibrium and correct boundary condition implementation.
Strong correlation was observed between FEA predictions and hand calculations, validating the model accuracy.

Learning & Impact :

This project strengthened my understanding of bolted joint behavior, including pretension effects, contact mechanics, and realistic load sequencing. It allowed me to apply finite element modeling, stress analysis, and design verification techniques commonly used in real-world mechanical and manufacturing engineering problems.

I gained hands-on experience with -   

1. Bolt pretension modeling

2. Contact convergence strategies

3. Engineering validation through hand calculations

4. Interpreting FEA results from a design-decision perspective
   
   

Looking forward to applying these analysis skills to more complex mechanical systems and real-world engineering challenges!