Sathvik Reddy Dudipala

Manufacturing & Supplier Quality Engineer Intern at Hydraforce - a bosch rexroth company

Designed & developed the heat exchanger for formula student combustion vehicle. The primary design is based on forced convection concepts i.e., Dittus Boelter equation in the cooling circuit. And the thermal boundary on a flat plate is considered to get convective heat transfer coefficient between air & heat exchanger.

o Determined fins with insulated tips, where the length of the insulated portion is half the total length of the fin when it is placed between two identical temperatures.

o After successful static analysis, the radiator is built & the primary goal of a heat exchanger is to maintain the engine at its optimal operating temperature, as engines tend to operate inefficiently when cold. To achieve this, a thermostat is incorporated to block the flow of water from the engine to the radiator until the engine reaches its peak efficiency temperature of 85°C. Once this temperature is reached, the thermostat enables the coolant (water) to enter the radiator for cooling purposes. 

o Apart from this, I introduced the radiator fan which is activated when the engine temperature reaches 95°C to facilitate swift cooling of the engine.

 • I extensively utilized advanced analysis software such as Ansys Workbench, Fusion 360, PTC Creo, Minitab to facilitate a continuous drive for design & manufacturing enhancements. The complexity of this endeavor lay in identifying potential improvements within the models and striving to achieve efficient solutions. Notable design enhancement includes: 

o Replacing overweight stainless-steel fuel tank with aluminum one reduced 10lbs weight in overall vehicle, which increased performance. As we know heavier automobiles need high power to accelerate & high brake power to rest. 

o I utilized Computational fluid dynamics module analysis to introduce optimized air intake & exhaust system for reduction of vibration & noise which should be less than 103 decibels. o Awarded with 2nd runner up prize for the complete business plan presentation of formula student FSAE vehicle building in 200 teams at formula FMAE competition.

 • As a manufacturing Engineer intern at hydra force, a Bosch Rexroth company, I played a pivotal role in streamlining the documentation process at my workplace, from the component assembly stage to the validation stage. These include: 

o Performed Capability Analysis & Root Cause Analysis for various multi-functional hydraulic valves to validate actuator tubes and test process. 

o Linked all part and assembly models to centralized master document, enabling easy & efficient editing of designs for the new production house of various hydraulic valves. 

o Defined comprehensive notes for the components & drawing for the tools which helps machining processes, finish processes, and production stages. 

o Introduced standard & modified tools for the assembly process, and defined standard reports for product validation, BOM, METR and other Material requisition forms. 

o Conducted correlation studies for various test stands, emphasizing the importance of data-driven decision-making and optimization efforts during the company relay-out process. 

o Completed a Breakaway Study Leading to the Elimination of Spool Wash Process in Assembly. 

o Executed 7S activity aimed at eliminating extraneous materials from the manufacturing area. 

o Working in Supplier Quality domain to ensure the highest standards of product quality & drive continuous improvement to meet the organization's quality goals and requirements

Masters in Industrial Engineering