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
