Senior Analytical Engineer

AAM - American Axle & Manufacturing • Detroit, MI

1d

About The Position

Develops and executes thermal, oil flow and drive cycle efficiency simulation models for conventional and electrified driveline system/component optimization and relevant virtual gate release. Job Description: Performs detailed computational fluid dynamics (CFD) analysis including both multiphase thermal and oil flow of conventional and electrified drive systems (eAxles etc) and individual components (pumps, heat exchangers, clutches etc.) to predict lubrication and thermal performance using STAR-CCM+, Simerics or similar 3D software. Performs system level thermal and drive cycle efficiency analysis of the above using Amesim/GT or similar 1D tools. Develops new and works on improving existing integrated workflows specific to the above subject area. Generates scripts for complex geometry/meshing and supplemental physics modeling (rotating component interaction, aeration, cavitation etc.) implementation with minimal supervision. Works with external engineering teams (System/Test/Pursuit) on ensuring drive system adherence to targeted lubrication, thermal and efficiency performance goals. Participates in external and internal customer presentation. Analyzes simulation and relevant test data for model validation and tuning. Participates and contributes to program peer reviews, maintains modeling best practices and lessons learned documentation.

Requirements

• Position requires Master’s degree (PhD preferred) in mechanical engineering or related field, or foreign equivalent education and 5-10 years of experience working in CFD field.
• At least 3 years of experience is required in each of the following: 3D CFD modeling including Multiphase thermal and internal lubrication related to automotive.
• STAR-CCM+, Simerics or similar tools.
• Rotating component implementation, understanding of VOF and similar modeling methods.
• Understanding of and hands on experience with comprehensive 3D and 1D Thermal management simulation workflows related to eDrive system and component design and optimization.
• STAR-CCM+, Simerics, Amesim, Masta, Motor-CAD and/or similar tools.
• Thorough understanding of theoretical concepts related to heat transfer, adequate meshing resolution, solution accuracy and convergence, boundary condition setup, transient modeling, turbulence modeling and CFD code development for flows involving complex physics.
• Strong theoretical understanding of efficiency concepts in electrified drive unit applications. Demonstrated ability to apply and develop corresponding methods on vehicle and component level.
• Record of cross-functional teamwork including interacting with CAE, test and manufacturing/product engineers.
• Experience may be obtained concurrently.

Responsibilities

• Performs detailed computational fluid dynamics (CFD) analysis including both multiphase thermal and oil flow of conventional and electrified drive systems (eAxles etc) and individual components (pumps, heat exchangers, clutches etc.) to predict lubrication and thermal performance using STAR-CCM+, Simerics or similar 3D software.
• Performs system level thermal and drive cycle efficiency analysis of the above using Amesim/GT or similar 1D tools.
• Develops new and works on improving existing integrated workflows specific to the above subject area.
• Generates scripts for complex geometry/meshing and supplemental physics modeling (rotating component interaction, aeration, cavitation etc.) implementation with minimal supervision.
• Works with external engineering teams (System/Test/Pursuit) on ensuring drive system adherence to targeted lubrication, thermal and efficiency performance goals.
• Participates in external and internal customer presentation.
• Analyzes simulation and relevant test data for model validation and tuning.
• Participates and contributes to program peer reviews, maintains modeling best practices and lessons learned documentation.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees