Job Description
3.1 Mission
Simulation of the durability of conceptual solutions for piston assemblies, presentation of results and proposal for improvements
3.2 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
3.3 Subtasks
- 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.
- Presentation of the simulation reports to application engineering 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
3.4 Customer contact
- Contact person for customers for technical questions related to durability
3.5 Monitoring function
- Consideration of safety guidelines and standards
3.6 Cooperation
- Tenneco‘s global application, design and analysis teams
- Customers
5. Material conditions
5.1 Work and operating resources
- 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
5.2 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
6. Qualifications required
6.1 Education
Master of Engineering (Mechanical Engineering or comparable)
6.2 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
6.3 Specific Knowledge
6.4 Professional experience
- Minimum 3 years as Analysis Engineer
- Preferably in the automotive industry
- Working experience with global automotive OEM or tier 1 supplier
6.5 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
