FEA Simulation Engineer

Team: System Engineering team within the Power Solutions division

The simulation engineer works within the system engineering group, helping our internal product development teams to derive requirements for current and future power-related components and subsystems, and to support the engineering groups with detailed analysis of the component behavior under realistic engine and vehicle scenarios, helping them understanding underlaying physics and cause-effect relationships.

Based on a profound expertise in Finite Element Method simulation, thermodynamics, internal combustion, heat transfer, data science and powertrain components, develop the mobility of the future, by managing and following up activities for development of new projects, to accomplish internal and external customer requirements, according to their specifications.

The FEA simulation engineer is responsible for developing Finite Element models to perform numerical simulations for multiple components to analyze different phenomena of interest, in order to provide insights for product development, innovation and problem-solving tasks. The FEA simulation engineer is responsible of providing deep analysis of simulation results and correlation to physical tests, being able to validate the FE models developed. The FEA simulation engineer is capable of communicating simulation results to all relevant stakeholders in a professional manner, with the correct technical content balance, supporting project on-time and on-spec execution.

Job Responsibilities

• Responsible for performing FEA simulation projects, for different components and subsystems using state of the art computer-based simulation software, processes, methods and standards in PS.
• Generate discrete physical models using Finite Element methods.
• Proficiency using FEM simulation software for the specific simulation task.
• Execution of linear/nonlinear, single/multi-phase, implicit/explicit simulations as required.
• Translate physical conditions and technical specifications into initial and boundary conditions, contacts and constraints definitions.
• Understand product and simulation specific requirements, related to topic under investigation.
• Successful execution, and eventual debugging, of simulation model.
• Analysis and interpretation of simulation results, providing insightful recommendations to design/product engineering team.
• Reporting simulation results, in a professional manner (e.g. clear, concise and complete), according to quality standards.
• Support project development, satisfying specific requirements and deadlines, providing design improvements and recommendations.
• Be an active part of our international team, focusing on FEA and data-driven development activities.
• Promote compliance with safety regulations and identify and report unsafe conditions. Promote safety health and environment protection according to IS0 14001/OHSAS 18001.

Topics

• Finite Element Methods & Analyses.
• Static-structural analysis.
• Dynamic analysis, e.g. modal, harmonic, random.
• Linear & nonlinear analysis.
• Implicit & explicit analysis
• Materials characterization, e.g. isotropic, anisotropic, composite, etc.
• Heat transfer, i.e. convection, conduction, radiation.
• Fatigue and damage tolerance analysis.
• Durability & lifetime analysis.
• Physical testing correlation.
• Manufacturing process.
• Data Science: programming/scripting in Python, data-driven development, graphical user interfaces, automation workflows, etc.

Required Qualifications:

• Related Engineering degree, e.g. Mechanical Engineering, Mechatronics Engineering, Aeronautical Engineering, Electromechanical Engineering, Physics, etc. (Desirable Master or PhD).
• Language: Advanced (technical & conversational) English (written and oral). (Desirable: German)
• Min. 3 years professional experience (demonstrable with references).
• International experience (Desirable).

Required Technical Skills:

• Mechanics solid knowledge.
• Deep knowledge in the theory of Finite Element Methods.
• Proficiency with specialized CAE software, solvers and models for FEM simulation, e.g. Abaqus, Ansys Mechanical, Nastran, etc.
• Meshing skills (model discretization) & proficiency using specialized Meshing software, e.g. Ansys Meshing, Hypermesh, GMSH, etc.
• Experience with CAD tools (e.g. NX, Catia, SolidWorks, SpaceClaim, Design Modeler, etc.).
• Mathematical and analytical skills (hand calculation) for basic mechanical problems, e.g. cause-effect relationship, physics of failure, product reliability and durability.
• Perform static & dynamic analysis.
• Materials modeling and characterization.
• Post-processing simulation data, simulation results analysis and interpretation.
• Requirements engineering, to translate customer requirements into CAE model and simulation results requirements.

Desirable Technical Skills:

• Fatigue analysis & Lifetime estimation.
• Plastic injection & plastic modling.
• Experience in Data Science and Data Analysis for Engineering.
• Experience with Optimization methods, theory & tools, e.g. Ansys Optislang, GNU Octave, SciLab, OptiStruct, etc.
• Proficiency with Data Visualization & Data Analytics apps (i.e. Power BI, Power Automate, Azure DevOps, etc.).
• Knowledge of manufacturing processes.
• Knowledge of physical testing and validation techniques.
• Knowledge on Linux systems and shell/batch job scripting.

Required Soft Skills:

• Professional presentation & communication skills (in English & Spanish).
• Communication and presentation skills (advanced, technical, in English & Spanish).
• Excellent reporting skills (e.g. clear, concise, adequate technical content).
• Ability to work effectively in a technical team, in an international environment.
• Proactive and self-driven mindset.
• Responsible and innovative.
• Methodical and diligent.
• Analytical thinking and problem solving oriented.

In the Systems Engineering group we work as a diverse and multidisciplinary team, results oriented, driven by the technical challenges for present and future mobility problems. We work with hybrid working model and flexible hours, allowing a good balance between our professional and personal goals. We embrace diversity and promote the international cultural exchange through constant exchange with colleagues from other parts of the world.

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