Senior CAE Analyst (Safety)

ROUSH•Livonia, MI

About The Position

At Roush, we fuse technology and engineering to provide product development solutions to customers in a diverse range of industries. Widely recognized for providing engineering, testing, prototype, and manufacturing services to the transportation industry, Roush also provides significant support to the aerospace, defense and theme park industries. With over 2,400 employees in facilities throughout the United States, Europe, Asia, and South America, our unique combination of creativity and tenacity activates big ideas on a global stage. The CAE Senior Analyst (Safety) will perform Finite Element Analysis (FEA) to solve Crash Structural Safety problems to aid engineering team in the upfront design of automotive, aerospace, entertainment, and industrial segments. This individual will build FEA models and conduct Computer-Aided Engineering (CAE) analysis supported by sound engineering explanation and hand calculations.

Requirements

Bachelor of Science in Mechanical or Aerospace Engineering with coursework in Finite Element Analysis, Strength of Materials, Mechanical behavior of metals.
Experience in non-linear explicit complex full vehicle structural FEA modeling, analysis and correlation with test data for some of the test modes.
3+ years of Safety modeling experience in building crash safety FEA models using tools such as ANSA, Hypermesh by accurately discretizing components and sub-systems.
Knowledge of mechanical systems, vehicle structure for various impact modes, safety protocols, principles for crash development for various systems.
Good attention to detail and ability to use hand calculations and free body diagrams to validate input and results. Ability to communicate verbal and written technical information. Take ownership of the problem and solutions.
Excellent problem-solving ability with minimal need for guidance. Take initiative to research solutions when dealing with new problems.
Advanced software skills in finite element pre-processors, solvers, and post-processors (Altair Hyperworks, ANSA & META, LS-DYNA).
Good verbal, written, and interpersonal communication skills and ability to train and mentor junior analysts.

Nice To Haves

Master of Science or Ph.D. in Mechanical or Aerospace Engineering with coursework in Finite Element Analysis, Strength of Materials, Mechanical behavior of metals.
Experience in writing process automation using python, or Excel VBA or C functions.
U.S. Citizen or U.S. Permanent Resident allowing for International Traffic in Arms Regulations (ITAR) compliance.
Experience working on Occupant Safety models and Development of restraint system.
Proficiency in FEA/ fatigue simulation software (Nastran, Abaqus, nCode etc.).
Experience with real-world data integration and experimental validation.
Strong understanding of some of the Safety protocols such as FMVSS, NCAP, IIHS, EuroNCAP, CFR Part 25.
Proven ability to work independently and collaborate with cross-functional teams, and present technical findings to stakeholders.

Responsibilities

Build safety models for various applications in the automotive, aerospace, and entertainment industries using commercial CAE tools such as LS-Dyna, Radioss, Abaqus Explicit.
Run Safety and strength/ durability simulations, postprocess results, and provide engineering solutions.
Should be able to work independently on strength or durability attributes using solvers such as Abaqus or Nastran.
Able to master new CAE tools quickly. Keep abreast of new capabilities in the software.
Collaborate with various groups within the CAE department to enhance predictive accuracy and reduce development cycles.
Establish and refine simulation methodologies to enhance predictive accuracy and reduce development cycles.
Independently execute projects, including direct communication with customers, and develop effective design solutions utilizing CAE tools.
Effectively handle multiple projects simultaneously, ensuring timely and high-quality deliverables.
Develop innovative techniques or processes to the advancement of the team.
Provide technical support to marketing and sales teams to enhance customer engagement and business development efforts.