Mohammad Ghalambor's Profile

Briefly!

2010-04-08T18:00:00.000-04:00

A Mechanical Engineer (Master’s Degree) with 14 years of experience in:

Designing Mechanical systems / Mechanisms / Assemblies
Automotive industry (Design / Project management)
Sheet metal design
Metal and Plastic components
Prototype fabrication
3D modeling / 2D Drafting with CAD applications (SolidWorks, Solid Edge, CATIA V5, Rhino, AutoCAD, …)
Reverse engineering
Engineering problem resolving
Air pollution control

And familiar with:

Plastic injection molding
Rapid prototyping
FEM /CFD analysis (Fluent, Ansys)
Electrical equipments / Hydraulics / Pneumatics

The Wine Chiller / Refrigerator

2010-03-08T22:16:00.008-05:00

Now I am working on a new project in Zodiac Aerospace/Monogram Systems. It is a wine chiller and Refrigerator for our customer Embraer (The third biggest aircraft manufacturing company).

I am the project engineer and the mechanical designer for all Thermal, Sheet metal, Plastic, Machined parts. It a Thermoelectric refrigerator with this major characteristics:

Manual temperature control for wine chiller (50-64 °F - 10-18 °C)
Works in -40 to 95 °F (-40 to 35 °C) ambient temperature range.
Turns to a warmer in cold ambient temperatures.
Infra Red/Ultra Violet filtered windowed door
Solid State temperature controls
1.2 cubic ft volume
Light weight
Appealing touch keypad
Air inlet and outlet on the back side
Bright white LED lights in the cavity

Here are some pictures:

The Galley Microwave Oven

2009-05-08T11:47:00.006-04:00

The main project, I’ve been working on during working for Zodiac Aerospace/Monogram systems:

Detail designing a new microwave oven for AIRBUS Co. including: Sheet metal, Plastic, Metal, and Mechanisms designs.

I work as Senior Mechanical Engineer/Designer, and created all detail drawings for production of the new microwave oven. Also served as Mechanical Eng. In fabrication of three prototypes of this oven.
In addition, I Designed new mechanisms and solved thermal / mechanical problems for other products and performed structural FEM analysis using ANSYS for the Oven.

The Telescopic Pneumatic Mast

2009-01-27T21:10:00.006-05:00

I had a chance to work in BICKFORD VEHICLES CO. for a short period. One of the projects I finished there, was reverse-engineering the telescopic pneumatic masts (used for several kinds of trucks), and designing a new mast with a new locking mechanism, to solve some problems that the of previous system had (less maintenance, smooth use and semi-automated locking).
I had to learn Solid Edge software to do the project, spending 1 and half days, I learned it and in 10 days I did the job!

The Truck for Fairfax County Public Schools

2009-01-25T22:15:00.005-05:00

One of the projects I had in Bickford Vehicles Co. was to desig mechanical parts of a truck to be made for Fairfax County Public Schools. As you see in the images there are many mechanical (mostly sheet metal, fixings, fasteners) parts designed and ready to be made in the shop. All of the parts are designed using Solid Edge.

The Side Intrusion Test Machine

2008-12-08T22:19:00.001-05:00

The system in MIRA

In (IKCO) where I had been working for 9 years, a specific test named "Side Intrusion Test" should be done on each new/modified car body (BIW).
But the company had not had the test machine!
Thus, they had sent the bodies to MIRA Co. (in England) asking Mira to do the test. Obviously the cost of the test was too high. (20000$ for each test + cost of sending the body and ...)
In order to retain the money for my company, I decided to make the test system.
I did all the researches and designed the whole system using:

The pictures taken from the MIRA's system
SOLIDWORKS
CATIA

Then, I supervised the construction, assembly and installation.

Assembling

Complete CAD assembly (Solidworks render)

Bedplate drawing

The system in IKCO

The report of the test system in company's magazine

A short film of the tests done in IKCO

The Electric Motor

2008-12-08T22:05:00.000-05:00

These are some pictures of a electric motor of a radiator fan which is used in one of the "KIA Motors" cars. These complete Assembled CAD files are generated using:

The electric motor
SOLIDWORKS software
Different measurement devices

This is done for a company to manufacture the motor using reverse engineering.

Some CAD files

2008-12-08T21:10:00.001-05:00

These images are showing some of the CAD files I prepared using
Solidworks and CATIA V5:

A New Car Front Bumper and Air intake grill

IKco. X12 Project Sound insulation (upper)

IKco. X12 Project Sound insulation (lower-right)

IKco. X12 Project floor carpet

IKco. X12 Project front windscreen wipper trim (LH)

IKco. X12 Project front windscreen wipper trim (RH)

Fuel cell bubbler

Tooth implant

Z24 Engine - Connecting rod
Z24 Engine - Crankshaft

The Right-Hand-Drive Samand

2008-12-07T20:15:00.009-05:00

There are about 2.5 billion people living in the Right-Hand-Driving countries. So IKCO started to investigate on this market. Thus we in R&D center made 2 prototypes of RHD Samand, which was a perfect experiment and in some countries such as Pakistan, Bangladesh and India they find some interests and customers.

I was the project manager of one of these prototypes which was Bi-fuel (GAS and CNG). This car was made in less than 1 month and sent for the Pakistan Exhibition.

Also preparing the FS (Feasibility study) documents and negotiating with some Chinese companies were my other roles in that project.

This is a short list of differences of LHD and RHD SAmand that had to be done in that project:

Dashboard
Glove box
Dashbord beam assembly
15 body parts (fire-wall and ...)
Steering column
Fire wall sound deadening
Carpet
Front seats
Haedliner
Door covers
Center console
Wiper blades and wiper mechanism
Gas pedal system
Clutch system

SARIR (The Limousine)

2008-12-01T23:01:00.015-05:00

The prototype and the first manufactured ones

Inside the prototype

The prototype in car exhibition

Samand is a Peugeot-based car and Sarir is the limousine version.
In 2004-2005, there were 7-8 projects in IKCo R&D Center, and one of them was the The Limousine; the best project in that period.
I was one of the most effective members of the project team, below are my responsibilities:

The project coordinator. (A-Z - from making the prototype to launching the assembly line)
The executive of "Samand assembly line adaptation to assemble Sarir" project.
The project coordinator of the "Workshop retooling" project to assemble BIW of Sarir.
An instrumental member in the research team to clarify and resolve Sarir platform weaknesses in passing "Side crash" test.

This film shows the whole process:

body pillar covers
body pillar covers welded by MIG-Brazing method

body side assembly line

The bodyshop

Sarir being assembled in assembly line

Frequency Analysis

2008-11-29T20:16:00.001-05:00

Needless to say, there are too many discussions in designing a part. This is an example in which the fixings of the Parcel shelf of X12 project in IKCo. were not in the right place, and I did a rough frequency analysis (Using CATIA), to show this issue to the other members of the design team.

The Burner Testing Furnace

2008-11-27T11:18:00.012-05:00

The Furnace

The air pollution measurement machine

Inside the furnace

Inside the furnace

One of the burners

Being a junior student, I had the opportunity to work in "IROST" in which my professor Dr. A.Dadkhahniko worked.
In a 5-person team we designed, constructed and installed a furnace to test various kinds of furnaces, (gas and diesel burners, industrial or domestic).
Changing/Modifying different components of them we measured the noise and air pollution in order to lessen them and improve the flame quality and performance.

The design and installation of the furnace cooling system was done by me myself.

This is a film which I took those days to show the process of lunching the furnace to do related tests.

The Electrostatic dust absorber

2008-11-26T23:03:00.001-05:00

shematic views

Efficency (%) vs particle size (micron)

In the I-Kashir project that you can see more about it here, This New style Electrostatic dust absorber is designed and used. In this system instead of using large panels to absorb the dust, several rotating cylinders are used to make the machine lighter, cheaper and more effective.

The Bachelor's Degree Thesis

2008-11-26T14:02:00.013-05:00

As I told before having an outstanding bachelor's degree thesis was my interest during my study. Searching for a fantastic project, my classmate and I found a knitting company called I-KASHMIR, that had had a big air pollution problem in it's workshops. That was what I seek for and like to do!

Simply the problem was a huge amount of dust and wool fuzz spreading out from the machines working in the workshops and the danger of breathing such polluted air for the workers!

This short film somehow shows what we have done:

Please notice, both of us was just senior students and it was hard to ensure the company management that the system we had designed, would solve their major problem.

We not only designed each component of the the whole system, but were involved in preparation, construction and installation!

This is me up there!

schematic view of the system

And after 4 month of hard work, the result was completely satisfactory:

They get rid of the dusts (specially the workers who were in danger of various diseases)
The effect of dust on their product (Cashmere) was eliminated.
They pay one third of what other contractors had offered.
We did our bachelor thesis

and finaly we got the ISME first price:

The "Iranian Society of mechanical Engineers (ISME) "Aalinasab first prize in mechanical engineering for "The Best B.S. Thesis" among all universities-1999.

I should thank my dear classmate and co-worker "Hossein Monfared Asl".

The Master's Degree Thesis

2008-11-25T22:37:00.004-05:00

This is a high pressure capillary viscometer to measure the viscosity of non Newtonian fluids such as drilling mud.
I used Solidworks and Ansys to design this viscometer, Constructed it and did the related tests for several fluids.
Finding and Doing a practical project was my concern during the study and both my B.S. thesis and M.S. thesis projects were useful and practical. This one was done because of the request of an oil company from Tehran University.

Cristal Molding Project

2008-11-25T20:06:00.001-05:00

These CAD files were prepared to make a complete set of a glass mold for different crystal bowls, using Solidworks.

My RESUME

2008-09-26T22:15:00.019-04:00

MOHAMMAD GHALAMBOR
mdezfuli@gmail.com

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Profile:

Mechanical Engineer (Master’s Degree) with 14 years of experience in:

- Detail Designing Mechanical systems / Mechanisms / Assemblies considering manufacturability, reliability and maintainability + FAA regulations

- 3D modeling / 2D Drafting with CAD applications (Solid Works, Solid Edge, CATIA V5 …)

- Design Metal and Plastic / Sheet metal components

- Prototype fabrication

- Reverse engineering

- Engineering problem resolving

And familiar with:

- Plastic injection molding

- Rapid prototyping

- FEM /CFD analysis (Fluent, Ansys)

- Electrical equipments / Hydraulics / Pneumatics

Work Experience:

1- ZODIAC AEROSPACE /Monogram Systems/TIA

Project Engineer / Senior Designer (Apr. 2009 – Present)

Was project & design engineer to design and manufacture:
A thermoelectric refrigerator/wine chiller for Embraer Aircraft Co.
A microwave oven “Wavejet AX” for Airbus Co.
A microwave oven “Wifi Comp. Wavejet” for Dassault Falcon Aircraft Co.
All above projects Included: Sheet-metal, Plastic, Metal, Mechanisms, and EMI filtering design, plus Building prototypes, creating mechanical/electrical drawings, and qualification test documents.
Designed new mechanisms and solved thermal / mechanical problems.

2- BICKFORD VEHICLES CO.

Mechanical Engineer / Designer (Dec. 2008 – Feb 2009.)

Designed a new pneumatic telescopic mast and improved the previous locking mechanism.
Designed mechanical parts of a truck cabin to be made for Fairfax County Schools.

3- IKCO. R&D Center

Project Manager/ Mechanical Engineer Designer (Sep. 1999 – Oct 2008.)

Providing ~%50 added value, was the project coordinator of Samand limousine (Sarir) project.
Researched and designed a complete mechanical and electromechanical car crash test system (Side intrusion test). Retaining $20000 per test. (Using Solidworks)
Directed and coordinated activities involved in fabrication, installation and operation of the "Side intrusion test system" (mentioned above).
Managed and successfully accomplished all the activities of making two prototype concept cars (Samand Limousine and Right-hand-drive Samand) within prescribed time.
Was principal engineer in the staff that prepared and presented the feasibility study documents. (F.S.) for manufacturing of two different cars (Sarir and right-hand-drive Samand).
Coordinated a BIW workshop (manufacturing 3 Sarir bodies a day).
Was Trim Dep. design engineer in "Peugeot 206 platform" group, designing and 3D model preparation /modification of interior and exterior trim parts using CATIA (e.g. bumpers, floor carpet, air intake grill, console, door panels, parcel shelf...).
Was executive of "Samand assembly line adaptation to assemble Sarir" project.
Served as design/fabrication expert in "fuel-cell" project for mechanical parts (Using Solidworks).
Was project coordinator of the "Workshop retooling" project to assemble BIW of Sarir.
Was instrumental in research team to clarify and resolve Sarir platform weaknesses in passing "Side crash" test.
Used CAD/CAE software such as CATIA and Solidworks, Rhino.
Designed and supervised the construction of two ventilation and air filtration systems in rapid prototyping and modeling workshops. (Using Solidworks)

4- IR Organization for Science & Technology

Principal technician / Mechanical designer (Fall 1995 - Summer 1997)

Served as principal technician in foundation of "Heat Transfer/Combustion" Lab.
Served as principal assistant to fabricate a burner testing furnace.
Designed and fabricated a water cooling systems for the above mentioned furnace.

5- Projects During Study,

Retaining $30000, researched, planned and designed a complete system of air pollution absorption for I-Kashmir knitting Co. (B.S. Project) (Sep. 1997 – Dec. 1997)
Was director and the principal technician of fabrication, installation and operation team of the pollution absorption system. (Mentioned above). (Sep. 1997 – Des. 1997)
Researched, designed, fabricated, installed a capillary viscometer and performed related tests for Tehran Univ (Using Solidworks). (M.S. Project) (Des. 2000 – Feb. 2001)

Education:

Master’s Degree in Mechanical Engineering, Tehran University, 2001.
B.S. Degree in Mechanical Engineering, Tehran Polytechnic (Amirkabir Univ.), 1998.

Training Courses:

TRIZ (Theory of Inventive Problem Solving.) Ruthenia Univ. Moscow

Mistake proofing & Poka-yoke

Auto Mechanics

FMEA (Failure Mode and Effect Analysis) by RWTUV/TUV Academy

Fundamentals of polymers

SOLID WORKS 3D modeling & assembly

CATIA V5- 3D modeling, assembly & analysis

ANSYS

AUTOCAD

Fundamentals of DFA (Design for assembly)

Computer Skills:

Engineering Software:

CATIA V5

(Part Design, Generative Shape Design, Assembly Design, Drafting, Structural Analysis …)

Solidworks: 3D modeling, Assembly, Drawing

Solid Edge: 3D modeling, Assembly, Drawing

Rhino 3D

Ansys, Working model, Moldflow

Application software:

Microsoft Office(Word, Excel, PowerPoint)

Adobe Photoshop /Acrobat and many other utilities and internet techniques.

Honors, Awards & other Activities:

1st prize from The “Iranian Society of mechanical Engineers (ISME)” Aalinasab in mechanical engineering for "The Best B.S. Thesis" among all universities-1999.
Managed the "Science branch" of Educational – Guild Council of Faculty of Mechanical Eng. in Tehran Polytechnic (fall 1996 - fall 1997).
Presented a paper in 4^th international ISME conference 2000.
Member of Iranian Society of Mechanical Engineers, (ISME). Since 1999

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RESUME IN PDF FORMAT