Senior Officer Analysis

Sr. Engineer - Analysis

 Job Description

Mission       

Simulation of the durability of conceptual solutions for piston assemblies, presentation of results and proposal for improvements. Simulation of piston solidification for aluminum gravity die casting.

Main tasks

•            Independent execution of finite element analysis (FEA) and durability of conceptual solutions for pistons, piston assemblies and possibly adjacent components

•            Recommendation of improvements for piston design (geometry, pin bore and skirt profiles) and cooling options

•            Participation in the development team (application engineering, design, test bench) and communication of simulation results

•            Simulation of piston solidification for aluminum gravity die casting to assess die cooling parameter, solidification time and porosity risk.

•            Determination of the loads and boundary conditions based on the customers statement of requirements (SOR) and the product functional specification sheet (PFS) together with application engineering (AE)

•            Extraction of the relevant load cases from a set of pressure curves if provided by the customer

•            Creation of the FEA model based on a CAD design: mesh generation, definition of sets and surfaces, contact definitions, loads and boundary conditions for the following components: piston, ring carrier, cooling gallery, pin, bushing, connecting rod, connecting rod bushing, cylinder, piston rings, cooling jet

•            Definition of the profiles for pin bore, skirt and lands

•            Morphing of FE meshes for independent geometry modification

•            Calculation of the temperature field of the piston assembly and the heat flow over the system boundaries

•            Calculation of the stresses and deformations of the piston assembly for different load cases

•            Calculation of the durability of the piston assembly based on the stresses and temperatures

•            Independent improvement of piston assemblies by profile optimization and minor geometry modifications by morphing

•            Creation of simulation reports with detailed investigation of all relevant locations of the piston assembly. Submission of these reports into an internal approval process.

•            Creation of the piston solidification simulation model including the die parts, fluid volume and temperature, cooling channels and parameter.

•            Communication with AE and foundry to get the data and check the plausibility.

•            Simulation of piston solidification including solidification time and porosity.

•            Definition of improvement measures like variation of cooling parameter, insulation areas, ingate and riser modifications.

•            Cooperation with design team to improve the die geometry

•            Creation of simulation reports for piston solidification including proposals for improvement.

•            Investigation of production problems like porosities and adaption of the simulation model to match these problems as basis for a solution

•            Presentation of the simulation reports to application engineering, foundry engineers and customers

•            Participation in customer meetings if required

•            Comparison of the simulation results with the engine test results

•            Carrying out the assigned project simulations in compliance with specified target deadlines

•            Carrying out priority planning for several project tasks assigned in parallel in accordance with Request for Engineering Services (RES) orders under consideration of specified deadlines

•            Further development of the simulation methodology to increase the speed of the process and the accuracy of the simulation results

Work and operating resources           

•            Piston casting analysis (e.g. Magma)

•            FEA software (e.g. Abaqus)

•            Durability software (e.g. Femfat)

•            Pre- and post-processors (e.g. Hypermesh, SimLab, Abaqus/Viewer)

•            Macro programming (e.g. Python)

•            PLM systems (e.g. Windchill)

•            Queueing systems for HPC clusters (e.g. LSF)

•            MS-Office applications

•            Windows operating systems

Working documents, regulations and information     

•            Workplace safety

•            Directive: Workplace Ordinance

•            Plans, lists, statistics, drawings, etc.

•            Knowledge of environmental requirements

•            Knowledge of accident prevention regulations

•            DIN standards

Qualifications required.

Education : Master of Engineering (Mechanical Engineering or comparable)

 Additional Knowledge    

•            Advanced fundamentals of thermodynamics, strength and structural mechanics, engine dynamics, finite element analysis, numerical solution methods

•            Advanced knowledge of combustion engines and simulation

•            Business fluent in written and spoken English

Specific Knowledge 

•            Hypermesh

•            Abaqus

•            Femfat

•            Piston casting analysis (e.g. Magma)

Professional experience      

•            Minimum 5 years as Analysis Engineer

•            Preferably in the automotive industry

•            Working experience with global automotive OEM or tier 1 supplier

Other requirements

•            Very good technical understanding, innovative, strategic thinking

•            Goal- and result-oriented, very independent, and organized working style

•            Team player, flexible, confident demeanor, adaptable, customer-oriented