Emmanuel T.

Experience

• Mechanical design engineeer -Tools - KTP Associate C4 Carbides limited · Full-time Sep 2024 – Jun 2026 1 yrs 9 mos Newmarket, England, United Kingdom • Designed and executed explicit dynamic FEA models in ANSYS LS-DYNA simulating high-cycle oscillating cutting tool–workpiece interaction, capturing large plastic deformation, chip formation, material failure, and tool wear behaviour — physics directly analogous to sheet metal forming and pressing processes.
  • Applied Archard wear law within LS-DYNA to predict progressive tool wear under cyclic loading, and coupled thermal analysis to model temperature-dependent material behaviour during the cutting process.
  • Built five simulation model variants with iterative design changes, selecting two validated models for final analysis — demonstrating the ability to manage simulation campaigns systematically and draw clear design conclusions from virtual test data.
  • Conducted physical test correlation by comparing simulation-predicted blade engagement behaviour against accelerometer measurements from live cutting trials, validating model accuracy and identifying deviation drivers.
  • Executed sensitivity analysis using optiSLang to map the influence of key geometric and material parameters on simulation outputs, identifying critical design drivers and reducing physical prototype requirements.
  • Integrated parametric DOE studies within ANSYS Workbench and ANSYS Discovery, linking parametric CAD geometry directly to simulation outputs for rapid design–simulation iteration; used Minitab for statistical analysis of results.
  • Developed Python scripts to automate extraction and post-processing of LS-DYNA simulation results across multiple model runs, improving data handling efficiency and repeatability.
  • Characterised WC-Co and carbide tool materials using SEM/EDS and Vickers hardness testing to establish accurate material property inputs for simulation models and validate predicted wear behaviour against physical evidence.
  • Produced detailed simulation reports, technical specifications, and design recommendations under PRINCE2 stage control; presented findings to cross-functional stakeholders across industry and academic partners.
  • Delivered a validated cutting tool design solution contributing an estimated £30,000 R&D cost saving through simulation-led reduction of physical prototype iterations.
• CAD Design & Simulation Engineer (MSc Industrial Project) Tees Components Limited, UK · Internship Oct 2024 – Jan 2026 1 yrs 3 mos Saltburn-by-the-Sea, England, United Kingdom • Designed and optimised marine bow thruster components using Siemens NX; performed linear, nonlinear, and modal FEA alongside CFD thermal and fluid flow analysis to assess structural and thermal performance under operational loads.
  • Produced a business-ready technical report supporting manufacturability decisions and implementation recommendations for the engineering team.