Dennis Chen Interview

Presentation
 Key Points of the Presentation
• Present the brief summary of a mathematical model for
the mechanism of a mechanical system I have created,
with the intent to
• Demonstrate Key technical capabilities and Project
Management Skills associated with a Mechanical Design
Engineer
• Showcase the thought process involved in the creation
of the model
Common Design & Problem Solving Process
Why Mathematical Model
As a Design Engineer…
How is the Model Created…
Examples of Spatial Constraints
Examples of Spatial Constraints
Examples of Spatial Constraints
 Examples of FEA based DOEs
• Running FEA based DOEs to establish key sub-system functional
outputs based upon loading condition of the system.
• Construct Component and System level models in NX from scratch
• Manipulate constraints and design features to establish the
location and orientation of the model.
• Modify individual features to establish low and high
• Use Abaqus CAE to run large scale system level simulations to
establish transfer functions
• Both Factorial and Response Surface based DOE based upon
estimated level of main effects.
• Responses of the DOEs are based upon Nodal translations of
critical features
Examples of FEA based DOEs
Transfer Functions from FEAs
𝑌𝐶ℎ𝑎𝑛𝑛𝑒𝑙𝐷𝑖𝑝 = 𝐶 + 𝐶1 ∗ 𝑋1 + 𝐶2 ∗ 𝑋2 + 𝐶3 ∗ 𝑋3 + 𝐶4 ∗ 𝑋4 + 𝐶5 ∗ 𝑋5 + 𝐶6 ∗ 𝑋6 + 𝐶7 ∗ 𝑋7 + 𝐶8 ∗ 𝑋1 ∗ 𝑋2 + 𝐶9 ∗
𝑋1 ∗ 𝑋5 + 𝐶10 ∗ 𝑋1 ∗ 𝑋7 + 𝐶11 ∗ 𝑋5 ∗ 𝑋6 + 𝐶12 ∗ 𝑋5 ∗ 𝑋7 + 𝐶13 ∗ 𝑋1 ∗ 𝑋5 ∗ 𝑋7 + Cp

Where
𝑌𝐶ℎ𝑎𝑛𝑛𝑒𝑙𝐷𝑖𝑝 is the Amount the lockout pocket dips down Channel Dip Coefficient Summary
in the Y-direction from its initial perfectly horizontal Variable Coefficients
position C -5.9603525054
C1 239.4869086046
X1 is the thickness of Art Link
C2 26.1627118182

X2 is the Length of Art Link C3 -0.2716021875

C4 0.1966615625
X3 is the Closure Ring partial OD
C5 4.2441611354
X4 is the Closure Tube partial OD C6 0.3921803815
C7 35.6815443317
X5 is the Over-Translation C8 -1042.6863636365
C9 -211.6244011809
X6 is the Link/Ring Boss Hole Clearance
C10 -1461.3114763597
X7 is the Articulation Stack Clearance C11 -25.0407619102
C12 -2159.6340704841
CP is the center point C13 87303.7204149276
CP 0.0012310000
 List of Transfer Functions that define the model
𝑉1 − 𝑉2 𝑉 − 𝑉2 − 𝑉3
S I N −1 − S I N −1 ( 1 )
𝐿 𝑘 𝑛 𝑖 𝑓 𝑒 − 0 . 1 − 𝑉4 𝐿 𝑘𝑛𝑖𝑓𝑒 − 0 . 1
𝒀 𝒕 𝒊 𝒍 𝒕 = 𝐷 𝐿 𝑜 𝑐 𝑘 𝑜 𝑢 𝑡 − V6 + S I N ∗ 𝐿 𝑘 𝑛 𝑖 𝑓 𝑒 − 0 . 1 ∗ 2 + 𝑉5 ∗ 𝑉𝟒 / ( 𝐿 𝑘 𝑛 𝑖 𝑓 𝑒 − 𝑉4 )
2

𝐷 2 − 𝐷1 − 𝑆 𝑖 𝑛 1 4 0 − 9 0 + 𝑋 ∗ 𝐿 2𝑥 1 + 𝐿 2𝑥 2
𝒀 _ 𝒔 𝒕 𝒓 𝒐 𝒌 𝒆 𝑨𝒑𝒆𝒙 = C O S S I N −1 ∗ 𝐿 2 − 𝐷4 − 𝐷5 + S I N 4 0 − 𝑋 ∗ 𝐿 2𝑥 1 + 𝐿 2𝑥 2 − 𝐷 3 . 1 + 𝐷 3 . 2 − 0 . 1 5
𝐿2

𝒀 𝑺 𝒕 𝒓𝒐𝒌 𝒆 𝑨 𝒎 𝒑
𝐷1 − 𝐷 2 .1 − 𝐷 2 .2 + 𝑆 𝑖 𝑛 14 + 𝑋 ∗ 𝐿 1
= 𝐷 3 − 𝐷 4 .1 + 𝐷 4 .2 − 𝐷 ℎ𝑜𝑚 𝑒 1 − 𝐷 ℎ𝑜𝑚 𝑒 2 + COS S IN − 1 ∗ 𝐿 2 + COS 14 + 𝑋 ∗ 𝐿 1
𝐿2

𝒀 𝑪𝒉𝒂𝒏𝒏𝒆𝒍𝑫𝒊𝒑 = 𝐶 + 𝐶1 ∗ 𝑋1 + 𝐶2 ∗ 𝑋 2 + 𝐶3 ∗ 𝑋 3 + 𝐶4 ∗ 𝑋 4 + 𝐶5 ∗ 𝑋 5 + 𝐶6 ∗ 𝑋 6 + 𝐶7 ∗ 𝑋 7 + 𝐶8 ∗
𝑋1 ∗ 𝑋 2 + 𝐶9 ∗ 𝑋1 ∗ 𝑋 5 + 𝐶10 ∗ 𝑋1 ∗ 𝑋 7 + 𝐶11 ∗ 𝑋 5 ∗ 𝑋 6 + 𝐶12 ∗ 𝑋 5 ∗ 𝑋 7 + 𝐶13 ∗ 𝑋1 ∗ 𝑋 5 ∗ 𝑋 7 + C P

𝒀 𝑲𝑮 𝑫𝑰𝒔𝒕𝒂𝒍
= 𝐶 + 𝐶1 ∗ 𝑋1 + 𝐶 2 ∗ 𝑋 5 + 𝐶 3 ∗ 𝑋 6 + 𝐶 4 ∗ 𝑋 7 + 𝐶 5 ∗ 𝑋1 ∗ 𝑋 5 + 𝐶 6 ∗ 𝑋1 ∗ 𝑋 7 + 𝐶 7 ∗ 𝑋 5 ∗ 𝑋 6 + 𝐶 8 ∗ 𝑋 5 ∗ 𝑋 7 + 𝐶 9 ∗ 𝑋1 ∗ 𝑋 5 ∗ 𝑋 7 + 𝐶 𝑝

𝒀 𝑷𝒓𝒐𝒙𝒊 𝒎𝒂 𝒍 𝑲𝑮
= 𝐶 + 𝐶1 ∗ 𝑋 1 + 𝐶 2 ∗ 𝑋 4 + 𝐶 3 ∗ 𝑋 5 + 𝐶 4 ∗ 𝑋 6 + 𝐶 5 ∗ 𝑋 7 + 𝐶 6 ∗ 𝑋 1 ∗ 𝑋 6 + 𝐶 7 ∗ 𝑋 4 ∗ 𝑋 7 + 𝐶 8 ∗ 𝑋 5 ∗ 𝑋 7 + 𝐶 𝑝

𝒀𝒔𝒑𝒓𝒊𝒏𝒈_𝒃𝒆𝒏𝒅
= 𝐶 + 𝐶1 ∗ 𝑋1 + 𝐶2 ∗ 𝑋2 + 𝐶3 ∗ 𝑋3 + 𝐶4 ∗ 𝑋4 + 𝐶5 ∗ 𝑋5 + 𝐶6 ∗ 𝑋1 ∗ 𝑋2 + 𝐶7 ∗ 𝑋1 ∗ 𝑋3 + 𝐶8 ∗ 𝑋1 ∗ 𝑋4 + 𝐶9 ∗ 𝑋1 ∗ 𝑋5 + 𝐶10 ∗ 𝑋2 ∗ 𝑋3 + 𝐶11 ∗ 𝑋2 ∗ 𝑋4
+ 𝐶12 ∗ 𝑋3 ∗ 𝑋4 + 𝐶13 ∗ 𝑋3 ∗ 𝑋5 + 𝐶14 ∗ 𝑋4 ∗ 𝑋5 + 𝐶15 ∗ 𝑋1 ∗ 𝑋2 ∗ 𝑋3 + 𝐶16 ∗ 𝑋1 ∗ 𝑋3 ∗ 𝑋4 + 𝐶17 ∗ 𝑋1 ∗ 𝑋4 ∗ 𝑋5 + 𝐶18 ∗ 𝑋3 ∗ 𝑋4 ∗ 𝑋5 + 𝐶 𝑝
Final Model Demonstration
 Technical Skills Summary

1) Tolerance Stackups in 1D, 2D and 3D

2) Finite Element Analysis using Abaqus CAE
3) Proficient in CAD (Solidworks and NX10) – Able to design both components, fixtures and construct large
scale assemblies
4) Highly proficient in GD&Ts, component level design and drawing development
5) Highly Proficient in most Minitab Statistical Analysis Functions (T, ANOVA, Chi-square, Power Analysis,
Distribution Fitting, DOEs – Factorial, Fractional Factorial and Response Surface, Gage R&R, Gage Linearity
and Bias, Process Capability, Monte Carlo Simulations, etc)
As a Side Note, I am also
1) Very familiar with Design Verification activities, test method developments, and general mechanical
testing.
2) Fully trained with DMADVV process (Design Excellence) or FDA Design Control Process, including all
associated techniques such as FMEAs
Project Management Skill Summary