Gilberto Morales Phd Email & Phone Number

Fort Worth, Texas

-IPT Lead of two $1 million Future Advanced Rotorcraft Drive System (FARDS) research projects. Lead the technical team responsible for the design, manufacture and test of a composite-steel helicopter mast and a composite-steel sprag clutch. Coordinated the development and test activities with multiple departments and external subcontractors. Developed and tracked the project schedules. Supported all briefings with the Army customer and prepare monthly technical and project reports. -Performed static and fatigue FEA analysis on transmission cases, gears, drive shafts, masts and clutches for the drive systems group at Bell Helicopter. -Created a non linear model of the planetary system for the FARDS transmission. Iterated the model to obtain a geometry that minimized the fatigue and static stresses while decreasing the weight of the assembly.-Created a model of the FARDS transmission case. Analysis was used by the designed to determine low stress areas where material could be removed and high stress areas that required modifications. Worked with the designer to iterate the design/analysis to minimize the transmission’s weight.-Designed and analyzed a composite-steel mast. Iterated the FEA model of to design a geometry that reduced the mast’s weight and the stress levels.-Designed and analyzed the fatigue test fixture for the composite-steel mast.-Designed and analyzed a composite-steel sprag clutch. Performed the FEA analysis of the clutch to determine a geometry that reduced weight the stress levels.-Performed static and fatigue analysis of transmission cases to determine damage limits. Analysis required nonlinear models with plasticity to correctly describe the load paths.-Performed a transient heat transfer analysis of the FARDS transmission to determine different configurations that decreased the temperatures in the transmission.-Conducted training sessions for less experience engineers on ANSYS and engineering topics.

Perform stress, vibration, thermal, fluid, magnetic and electrical finite element analysis for multiple Honeywell facilities in Texas, Illinois, Rhode Island, Columbus and Germany. Manage pressure and flow testing laboratory. Troubleshoot testers and send components out for maintenance and calibration. Coordinate with outside subcontractor to assemble components and perform pressure and flow measurements on these assemblies. Modify testers and LabView software to measure burst pressure and drift of the pressure sensors.Coordinate the phase gate process at the Richardson facility. Monitor projects to ensure completion as planned. Coordinate phase gate review with managers, project engineers and senior management.Designed various mechanical components using ProE. Created technical drawings for components purchased from outside suppliers.Performed extensive electrical/thermal/stress analysis on a thermal sensor to determine the root cause of a failure observed by our customers. Modified the sensor eliminating customer returns. Conducted thermal/stress analysis of a testing system and determined that the measured error was due to the assembly process and not the pressure die. Designed thirty-four pressure sensors using design of experiments. Modeling minimized the number of actual prototypes built, which saved over $2 million.Analyzed the stresses caused by airflow on a shroud component. Modeled the airflow around a shroud and the pressure created by this airflow using ANSYS/CFX. Analysis proved that design was robust and saved a $1 million project from being canceled. Modeled the drift on a pressure sensor created by transient heat transfer and thermal stress. Model explained the mechanism behind the drift and allowed Honeywell to design a new isolation structure that minimized the drift by 400%. Modeling saved at least six months of testing and $0.5 million in prototyping.

Designed isolation structures and diaphragms for various pressure sensors.Developed a technique for modeling the Hall Effect in ANSYS. The model was used to design various Hall sensors.Decreased the design time of pressure sensors from months to weeks by developing computer prototypes.

Designed and obtained prototypes for the interconnect RF joint and the 80K liner.Analyzed the stresses on the cooling tubes and supports for the 80K liner.Interacted with industry to obtain designs, prototypes and cost estimates.

Ph.D, Mechanical Engineering

Ms, Mechanical Engineering

Bs, Mechanical Engineering