(Fulltime or part-time consulting practice,dba Monarch Design and Analysis)Design and analysis of bearings and bearing arrangements, automated machinery, mechanisms, and precision devices. Design of machinery involving mechanisms, ball screws, roller screws, gearing and other types of power transmissions. Design of lubrication systems. Writing of control software algorithms, kinematic and dynamic analyses, stress and strain analyses, thermal and fluid dynamics analyses. Finite element analysis: ANSYS, OPERA (E-M). Failure analysis. Domestic and international clientele.Examples of projects:- Performed comprehensive computations of power losses in rolling element bearings in electrical vehicle motor and gear box combination. - Designed bearing arrangement featuring duplex hybrid spindle bearings in high- speed 30 000 RPM electric motor for use in battery powered vehicles.- Design of precision camshaft lobe grinding actuator, based on high-stiffness roller screw design, and development control algorithms for arbitrary cam lift specification. - Design of wire payout (dancer arm/pulley) device for transformer rectangular core wire winder, and constructing the associated control algorithms. - Design of centrifuge rotor system. - Analysis and design of high-temperature make/break vacuum connection to a ceramic platen in a wafer process tool. - Design of linear and rotary bearing systems for large automatic multiple-head welder for offshore oil pipeline service – pipe diameters up to 5’. - Engineering of low-friction, servoed end effector bearing arrangement, and general overall design consultancy on welding head and swivel platform structure for automated welding of 4” wall thickness spent nuclear fuel canisters. - Design of spindles and spindle bearing arrangements for high-speed optical fiber rewinders and fiber proof testers. - Failure analysis of vacuum pump bearings used in semiconductor manufacturing processing (France).

(Time-limited contractor position)Computer simulations of precision electro-mechanical actuators for semiconductor chip lithography stages; force and eddy current loss computations. Hydrostatic air bearing calculations; stiffness, capacity. air flow.

(One-year time-limited contractor position.)Mechanical design and analysis of oncology treatment systems. Design of large-diameter slewing bearing arrangement for oncology treatment machine. Writing of comprehensive bearing analysis Mathcad program for stress, deflection and life computations. Analysis of beam collimator leaf lubrication system, incl. choice of radiation-resistant lubricant and concept for lubricant application in the manufacturing environment.

Designed Linear Stage for Earth-Orbiting Telescope; Design of Core Drill and design work on Powder Drill for use on surface of planet Mars; Evaluation of design concepts for ultra-precision mirror actuators – 4 nm resolution - for the terrestrial Thirty Meter Telescope (TMT), a Caltech/JPL joint enterprise. Mentoring of young engineers - “Early Career Hires” (ECH’s).

(Plant closed Dec. 2002.)Conceived of, and designed prototype of tool frame of revolutionary construction, permitting inexpensive precision assembly of frame abroad, using low-cost modular building blocks. Analysis and computer modeling of "wafer skating" phenomenon.

(One-year contract position.)Developed novel physical control "law," based on empirical test data, for ultra-precision electromagnetic servo actuators used in lithographic stages. Developed gas squeeze film dampers for precision mechanical devices,

Provided internal consulting and troubleshooting to engineering product groups, manufacturing operations, advanced mechanical development groups, and senior management on major problems and design issues. Heavily involved with introduction of fluid film spindle bearings into disk drives, working with Japanese and European vendors on technical design and testing challenges. Performed failure analyses. Developed statistical life analysis models for subassemblies. Investigated key characteristics of water vapor diffusion phenomena. Developed ultra-precision capacitive runout test and measurement systems and diagnostics program for bearing runout and spindle vibratory signatures, using computational methods in frequency, time and amplitude domains. Developed advanced ball bearing analyses programs for stiffness and stress computations, and programs for calculation of effective axial preloading of ball bearing spindle arrangements as a function of temperature. Developed and tested acoustic treatments to disk drives, employing constrained layer dampers – up to a 13dB reduction in already low sound pressure levels were obtained. Developed programs for rotating assembly whirl frequencies and ball bearing kinematic disturbance frequencies.

Mechanical Engineer responsible for Advanced Process Tooling (wafer hi-temperature process).Advanced development of disk drives (actuator devices, spindle and actuator bearings).Fluid film bearing development, including gas and squeeze film bearing technologies.Chair of Ball Bearing Council.