Product Development Engineer- HV Battery Structural CAE Engineer

Job Title

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In this position, we are looking for an experienced structures CAE engineer to lead High Voltage battery internals and related system structural design using CAE tools. You will work with battery design & release engineers on cutting-edge battery technologies for managing the battery functional environment to be within specified operating conditions. With your creative and analytical mind, you will use key insights to frame new opportunity spaces and guide the experience vision for our future global customers.

You will relentlessly advocate a human centric perspective through all stages of the design process. As a team player, you will create impact by collaborating across the Electrified Powertrain Engineering organization and with key stakeholders of the battery business. The Ford Global Electrified Powertrain Engineering Team is a growing team committed to envisioning and creating simple, thoughtful, enjoyable and compelling product experiences that continually inspire our teams and customers to go further.

Our diverse Global Electrified Powertrain Engineering Team collaborates closely together as well as with the global suppliers to bring efficiency and value into the battery architecture. Together our team works to understand our changing world, identify new opportunities, and take action to design and innovate for the future of mobility – Ford's vehicles and surrounding experiences.

What you'll do...

• Build 3D battery internal structural analysis CAE models from CAD designs.
• Capable of debugging complicated FE models independently.
• Perform 3D structural analysis simulations on system, subsystem and component level high voltage battery packs in support of battery internals design development using commercial CAE codes such as ABAQUS, Ansys, Optistruct Non-linear or similar non-linear structural FEA.
• Evaluate 3D structural analysis results and provide feedback and design direction to vehicle program and battery pack design teams.
• Interact with vehicle-level teams to obtain boundary conditions for battery pack structural level simulations.
• Interact with battery lab and vehicle-level testing teams; specify instrumentation for data collection; process physical structural test results and use the data to correlate CAE models.
• Interact with extended CAE teams overseas for CAE meshing and geometric clean up tasks.

You'll have...

• Bachelor's Degree in Mechanical or Structural Engineering or equivalent degree.
• 4+ years of experience working with structural components and designs.

Even better, you may have...

• Master of Science, Mechanical Engineering or equivalent degree. Structural Mechanics, focus on finite element analysis (FEA)
• 5 years or more experience in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent, including experience selecting appropriate solution procedure for complex non-linear problems, proficiency in ABAQUS scripting (Python) for automation and advanced post-processing techniques.
• Working knowledge of ABAQUS, Opti Struct non-linear, Hypermesh, Hyperview, ABAQUS Viewer, Teamcenter, 3DX, CATIA or equivalent (Ansys, etc)
• Working knowledge of CAE tools for durability assessments such as Femfat, nCode, fe-safe or equivalent
• Strong experience in correlating complex non-linear CAE models with physical test data, including sensitivity analysis and model tuning for improved accuracy
• Extensive knowledge of various structural materials with high strength, energy flow theory and analysis methods, fracture mechanics, crack initiation/propagation.
• Working knowledge and experience using CAE preprocessing codes such as Hypermesh equivalent for geometry cleanup and meshing, ABAQUS, Nastran, or equivalent for CAE model solving and post-processing.
• Familiarity with sheet metal related design specs, sealing design, structural testing setup and data collection experience.
• Familiarity with thermal-mechanical coupled analysis that considers temperature dependent material properties, thermal expansion and effects on structural integrity.
• Proven record of innovative applications and capability of introducing new…