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resume-6

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  ASHRAF A. FARAG 4031Juneberry Rd Naperville, IL 60564 (716) 704-9972 (Cell) [email protected] OBJECTIVE ENGINEERING MANAGEMENT I have over 20 years of success driving the design and rollout of the next-generation of complex systems and products for the automotive industries. Dynamic, results-driven Engineering Manager centered on product design, development and validation. Offering a full range of proven technical and management skills to build/grow product design development and validation organization and produce results. PROFESSIONAL STRENGTHS and ABILITIES: • Department & Engineering Mgmt • Project Engineering/Management • Technical Leadership • Business and Customer Related Skills EXPERIENCE 7/2011 – present Navistar Inc. (Engine & Truck group), Lisle IL Product Development Engineering Manager • Manages group of 17 engineers responsible for guiding the design and development of Engine Cooling System, HVAC System, After Treatment Systems, External Aerodynamics, and Under-hood Thermal Management of Navistar’s medium (up to 250hp) and heavy-duty (up to 500hp) trucks. • Establish standard test/analysis validation procedures for Vehicle Thermal Management Systems. Validate analysis procedures through experimental testing. • Work across different functional teams to ensure a quality release of Engine Cooling/HVAC systems that conform to the Navistar standard product development procedure. • Ensure compliance with the performance integration and validation department work flow processes. • Support programs and manage staff allocation to different programs. • Develop aero-acoustic and vibro-acoustic capabilities to manufacture the best acoustically insulated cabin in the trucking industry. • Support analysis-led integrated product development by initiating and developing cross-group or cross- department work processes and training within the company. • Optimize the use of the test, simulation or other IT tools such that redundancies are eliminated, cost is reduced, and the use of the state-of-the-art technologies is ensured. • Participate in product development engineering budget forecast for engine and vehicle programs. 7/99 – 6/2011 Delphi Automotive Inc., Lockport, New York Staff Product Engineer • Product Development Engineer (2 yrs), promoted to Sr. Product Engineer (3yrs), promoted to Staff Product Engineer (7yrs) • Led HVAC CFD group for the Thermal Division:- • Establish standard CFD procedures for HVAC module developments. Validate CFD procedures through experimental testing. • CFD technologies follow up to maintain technical edge over competition. • CFD support for different HVAC programs Using Fluent, T-Grid, ICEM CFD, and Gambit software. • Global Responsibilities (Shanghai and Luxemburg) for Fan & scroll subassembly design across all programs:- Ashraf Farag Page 1
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  • Lead math-basedfan development team to develop different families of fans developed for HVAC and Electronic Cooling business units. • Developed a virtual Fan & scroll development process. This process helped Delphi to develop and patent the best in class fan and scroll in the auto industry. The patented design helped Delphi to win more than $5M worth of new business in Asia Pacific region between 2007 and 2010. • Implement the best designs to stay ahead of competition in different markets • Coordinate with different technical teams to share technologies and implement lessons learned globally. • Developed liquid cooling system for PC applications. • Developed math based analysis procedures for predicting noise levels of the HVAC module and understanding flow induced noise sources in the HVAC system. Testing different turbulent models like LES and DES for more accurate noise prediction. • Developed de-icing model for the vehicle windshield and side window using solidification and melting model in Fluent software. The model monitors the deicing pattern overtime as specified by SAE standards. The model was validated through wind tunnel testing with great success. • Developed condensate carryover model using Discrete Phase Model in Fluent. One of the main functions of the evaporator core in the HVAC module is to extract the moisture from the incoming air and drain it out. The CFD model was validated through experimental testing. • Developed Battery pack cooling system for hybrid Vehicle. This system was essential to improve our energy saving capabilities for new programs. • Developed and executed validation plans according to customer specifications on schedule and within budget. 10/98 – 7/99 Caterpillar Inc., Process Tool Development (Contract through AXIS, Inc.), Peoria IL CFD Analyst. • Conducted CFD Analysis for the “under-hood” cooling systems for large size earth moving vehicles using Fluent, Computational Fluid Dynamic Package. • Used Fluent, T-gird, and ICEM-CFD to conduct airflow analysis for different HVAC system modules and components. • Conducted system thermal analysis to size the “under-hood” cooling system and HVAC systems using in-house developed two-dimensional code (COOL-1). • Conducted Aero-Acoustics analysis for different cooling system fans. 12/97 – 10/98 Visteon Automotive Systems, Climate Control System Division, Detroit MI Product Development Engineer (Contract through Livernoise Engineering Staffing Company). • Responsible for developing computer models verified through laboratory experiments for HVAC blowers, Scrolls, and motors for current products and advanced development for luxury vehicles and medium duty trucks. • Coordinated the airflow and NVH of the blower subassemblies for different vehicles. • Conducted computer simulation for different HVAC blower subassemblies using Computational Fluid Dynamics (CFD): • Provided the CAD designer with the design parameters that define the parts within the available packaging space. • Used SDRC I-DEAS to clean up the CAD files by eliminating unnecessary features for the CFD analysis. • Used SDRC I-DEAS or HyperMesh as pre-processors to create the surface mesh on the part then T-GRID to build the volume mesh. • Performed the CFD solution using FLUENT UNS solver to investigate the flow field in different components of the HVAC system. • Presented the simulation results to product and development engineers for final evaluation and recommendations. • Used laser Doppler equipped with Rotary Machinery Resolver to validate the CFD solutions especially in the blade passages. • Used Labview to create the virtual instruments for data acquisition for different experiments. 8/94 - 1/98 University of Toledo, Toledo, OH Ashraf Farag Page 2
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  Research & TeachingAssistant • Studied the local heat transfer coefficients and temperature distributions on a gas turbine cascade. • Conducted tests to study the fluid mechanics in bifurcating pipe models typical to the human airways using Laser Doppler Velocimetry (LDV) and Particle Image Velocimetry (PIV). • Designed and manufactured different types of heat exchangers (Tube and Shell, Concentric, and Tube Bank in Cross Flow). • Conducted wind tunnel tests to reduce the drag over a cylindrical fuel tank using heating surface principle. • Improved the frictional drag by using the concepts of smart material actuators and large eddy break up devices (LEBUs) to create an active device, a smart LEBU, for turbulent boundary layer manipulation. • Set up and instructed thermo/fluid experiments for undergraduate and graduate laboratories. • Utilized LabView, a data acquisition package, to create different Virtual Instruments for different applications. • Utilized CFX4.1 Flow Solver to study different fluid and heat transfer problems. • Taught Heat Transfer, Fluid Mechanics, and Thermodynamics courses. • Published several research papers in International Conferences and world class Journals. 11/93 - 8/94 Cleveland State University, Cleveland, OH Research Scholar • Developed a new numerical technique applicable to various fluid and heat transfer problems. • Solved several Non-Newtonian fluid problems using similarity solutions. 2/89 - 11/93 National Research Center, Cairo, Egypt Research Assistant • Developed a numerical code to study the aerodynamic performance of the wind turbine blades. • Developed the aerodynamic characteristics of the wind turbine blades through wind tunnel tests. • Participated in the design and manufacturing of multi-bladed wind turbine. • Benchmarking different centrifugal pumps to match optimally different applications of wind turbine systems. • Tested and developed different hydraulic products (pumps, fans, and valves) based on the British Standards. • Taught thermodynamics and Heat Transfer for two years. • Conducted field tests to measure noise and pollution levels as part of a national program to improve the environment. Citizenship: US citizen EDUCATION 5/2009 Canisius College, Business School, MBA with International Business Concentration 5/1998 University of Toledo, Toledo, OH, Ph.D. in Mechanical Engineering. 5/1992 Cairo University, Cairo, Egypt, MS in Mechanical Engineering. 5/1987 Mounofia University, Egypt BS in Mechanical Engineering. Publications & Patents • Published eleven research papers in International Conferences and world class Journals. • Recipient of eleven US Patents and trade secrets. References: Available upon request Ashraf Farag Page 3