AProfessional
Vehicle Integration
Working-student role in vehicle integration, on virtual full-vehicle assemblies. Scope and method are on the project page.
Open the vehicle-integration project pageMihir Raj Rathore
Mechanical Engineer working across CAD, virtual manufacturing and validation.
Virtual CNC/CAM planning in Siemens NX and a vibration condition-monitoring prototype for a CNC machine.
- Target roles
- Mechanical design (CAD) · product development · integration · CNC/CAM · condition monitoring (entry level)
- Contact
rathore.mihirraj@gmail.com- CV (PDF)
- CV — DeutschCV — English
PortfolioUpdated Oct 2026
Schematic / illustrative
Signal path: CNC condition-monitoring prototype (Master's thesis)
- 01CNC machineSpinner VC850
- 02Vibration sensorIFM VSA004
- 03IFM VSE100Diagnostic module
- 04OPC UAIFM VOS050 server
- 05PythonClient and queue
- 06Signal processingFilter, Z-score
- 07FFT / featuresRMS, kurtosis, FFT
- 08Trend analysisBaselines, thresholds
- 09DashboardStreamlit
Select a block to jump to its stage. On touch screens, tap a block.
Near-real-time acquisition cycle. The block highlighting order is illustrative, not per-stage timing. Timing is not stated.
About
Mechanical engineer: design, virtual manufacturing and validation.
I am a mechanical engineer based in Rosenheim, Bavaria, with an M.Eng. in Engineering Sciences from Technische Hochschule Rosenheim (exam passed 20 November 2025).
As a working student in vehicle integration at BMW AG (04/2024–04/2025) I ran virtual contact-point and clash analyses on full-vehicle assemblies in CATIA V5. In my Master's work I planned a virtual CNC machining process in Siemens NX CAM and built a vibration condition-monitoring prototype for a CNC machine.
I am looking for engineering roles in Germany and Austria and am willing to relocate.
- Education
- M.Eng. Engineering Sciences, TH Rosenheim
- Experience
- BMW AG, working student, vehicle integration (04/2024–04/2025)
- Focus
- CAD · virtual manufacturing · validation · condition monitoring
- Based in
- Rosenheim, Bavaria · open to Germany & Austria · willing to relocate
- Languages
- German B2 (working proficiency) · English fluent · Hindi native
Three engineering domains
Vehicle integration, CNC and CAM, condition monitoring.
Full scope statements (what I did, what was virtual, what was not done) sit on each project page.
- Vehicle integrationDesign interfaces
- CNC & CAMVirtual process planning
- Condition monitoringMachine in operation
BAcademic · individual
CNC & CAM
SchematicVirtual only
I developed the virtual CNC machining process and simulation in Siemens NX CAM. Physical machining trials were not conducted.
Open the CNC & CAM project pageCAcademic · independent
Condition monitoring
SchematicRecorded resultsHealthy machine only
A sensor-to-dashboard prototype that acquires raw vibration data from a CNC machine, processes it in Python and applies rule-based alert logic against baselines.
Open the thesis project pageIndependent project
Geometric Clearance Inspector
An independent Python prototype for screening geometric relationships in synthetic geometry and generating structured inspection records.
Explore the prototype
Experience & education
What I have worked on.
Professional and academic work are kept apart. Each entry states its scope.
-
04/2024 – 04/2025Professional
Working student, vehicle integration
BMW AG · Munich
Virtual contact-point and clash analyses on full-vehicle assemblies in CATIA V5.
Vehicle-integration project page -
2025Academic · independent
Master's thesis: condition monitoring
TH Rosenheim · Spinner VC850
A sensor-to-dashboard prototype that acquires raw vibration data from a CNC machine, processes it in Python and applies rule-based alert logic against baselines.
Thesis project page -
2024Academic · individual
Master's project: virtual CNC process planning
TH Rosenheim · Siemens NX CAM
Developed the virtual CNC machining process and simulation in Siemens NX CAM. Physical machining trials were not conducted.
CNC & CAM project page -
SoSe 2024Academic · team
Teach-in station design project
TH Rosenheim · industry partner TGW
Coordinated a five-person student team; developed concepts for several assemblies; CAD in CATIA V5.
-
2022Academic · two-person
Bachelor thesis: viscoelastic sandwich panels
Vellore Institute of Technology
“Nonlinear Transient Response of Viscoelastic Sandwich Panels with Composite Laminate Face Sheets.” Contributed to model formulation, debugged the MATLAB code, evaluated and interpreted results.
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2020 – 2021Internships
Three engineering internships
ELEATION · DANISH Private Ltd. · JK Lakshmi Cement & Power Plant
ELEATION (CAE intern, 03–05/2021): structured ANSYS Mechanical FEA training with a static-structural analysis of a rack-and-pinion steering assembly. DANISH Private Ltd. (mechanical design intern, 10–12/2020): supported mechanical assemblies and technical/fabrication drawings. JK Lakshmi Cement & Power Plant (intern, 01–03/2021): exposure to plant operations, maintenance and troubleshooting.
M.Eng. Engineering Sciences
Specialist field: Mechanical Engineering and Plastics Engineering. Exam passed 20 November 2025.
B.Tech. Mechanical Engineering
Interactive project exploration
Domain C → Master's thesis, 2025
From spindle vibration to dashboard in nine stages
Academic · independentSchematicRecorded resultNot tested
Stage 1 / 9
CNC machine
The machine under test is a Spinner VC850 vertical machining centre with a Heidenhain TNC 640 control, in the university lab. The signal of interest is vibration at the spindle housing.
The prototype was built around this one machine. No claim is made about other machines or machine types.
Vibration sensor
An IFM VSA004 piezo accelerometer is stud-mounted on the spindle housing. It is one sensor at one measuring point.
IFM VSE100
The IFM VSE100 diagnostic module processes the sensor signal at the edge and records raw data when commanded.
OPC UA
An IFM VOS050 OPC UA server, with a VOD001 device licence, connects the VSE100 to the Python client. A passive subscription did not deliver the raw data. A command-and-retrieve routine did:
- StartRecording
- wait until the recording is finished
- Open
- Read
- Close
UaExpert was used to explore the server before the client was written.
Python
A Python 3.9 client runs the command sequence and passes records through a thread-safe queue (producer–consumer), so acquisition and processing run in separate threads.
Recording, transfer and analysis repeat as a near-real-time acquisition cycle.
Signal processing
Each record is detrended, band-pass filtered with a 4th-order Butterworth filter and normalised with a Z-score.
FFT and features
Time-domain features are RMS, peak, crest factor and kurtosis. The FFT gives the spectrum.
Baselines were recorded with the machine running without load, thermally stabilised, at discrete spindle speeds.
Trend analysis
Alert and alarm thresholds were defined in the thesis from baseline statistics using μ+2σ and μ+3σ. Rule-based diagnostic logic is applied to the features, and values are trended in persistent CSV files.
Recorded result
| Test | Result |
|---|---|
| Artificial impact applied to the sensor | In a healthy-machine test, an artificial impact applied to the sensor produced a kurtosis excursion from about −0.1 to above 230, and the alert logic responded. |
| 2000 RPM, aluminium 6061: no load versus light facing cut | Raw RMS 0.03 g in both. Normalised kurtosis 26.29 versus 26.13. Kurtosis values were similar between the two states and are not interpreted here; one machine, one light cut, one spindle speed. |
Dashboard
A Streamlit dashboard shows current feature values, alert state and trend history.
Not tested
- Real fault conditions. All data are from a healthy machine.
- Prognostics (remaining-life prediction).
- More than one sensor.
- Spindle speeds other than the discrete speeds used for the baselines.
The full statement of what I did and did not do for this project is on its project page.
Skills
Tools and methods, with where I used them.
CAD and design
- CATIA V5 Used for virtual full-vehicle assemblies at BMW and for the TGW teach-in station project.
- SolidWorks
- Structured design method
Virtual manufacturing
- Siemens NX CAM Used for virtual CNC process planning and simulation in the Master's project.
- Virtual CNC/CAM process planning
- LBM post-processing virtual only
Analysis and validation
- Virtual validation Contact-point analysis in vehicle integration.
- ANSYS Mechanical Training, with a static-structural analysis of a steering assembly.
- MATLAB Working knowledge.
Programming and monitoring
- Python NumPy, Pandas, SciPy, Matplotlib, Streamlit.
- OPC UA Used to retrieve raw sensor data in the thesis prototype.
- FFT, RMS, kurtosis, crest factor Used for vibration features in the thesis prototype.
- Condition monitoring
CV and contact
Emailrathore.mihirraj@gmail.com