Note: The job is a remote job and is open to candidates in USA. CAI is a global services firm seeking a Thermal Simulation Engineer to lead the development and implementation of complex thermal simulation models to optimize manufacturing designs and processes. The role requires expertise in Ansys Workbench and involves collaboration with cross-functional teams to enhance design optimization.
Responsibilities
- Lead the development and implementation of complex thermal simulation models to optimize manufacturing, designs, or processes (e.g., thermal simulation of current-carrying products like connectors, busbars, and cable assemblies)
- Perform calculations and simulations on temperature distribution over systems
- Conduct thermo-mechanical and structural simulations to support design optimization, material selection, and validation from concept to production
- Simplify complex CAD geometries for efficient structural and thermal simulation analyses
- Apply in-depth knowledge of mechanical design, conductive and convective heat transfer, and fluid flow mechanics
- Collaborate with design, manufacturing, and testing teams to correlate FEA results with physical testing
- Utilize DOE (Design of Experiments) and optimization techniques
- Direct cross-functional teams to address and resolve intricate design and manufacturing issues
- Analyze complex simulation results to identify areas for improvement and drive design or process changes
- Maintain and update simulation models to ensure optimal accuracy and relevance
- Validate concept designs using simulation techniques to determine design robustness and critical-to-function requirements
- Deploy FEA Techniques – implicit and explicit approach using software tools like Ansys Workbench, LS-Dyna, Hypermesh, Simufact, Digimat, and others
- Translate actual problems into Finite Element Analysis (FEA) models, interpret analysis results, and select the best solutions, including linear and non-linear analysis under different physics
- Monitor and evaluate simulation software capabilities and industry trends
- Collaborate with design and validation teams to enhance design optimization
- Understand the influence and impact of activities on financial decisions
Skills
- BE/B.Tech in Mechanical or Electrical Engineering
- Knowledge of product design processes and methodology
- Proficiency in state-of-the-art FEA tools such as Ansys Workbench, LS-Dyna, Hypermesh, Simufact, Moldex3D, Optislang, Icepak Maxwell, and Ansys HFSS
- CAD tools such as PTC Creo and Space Claim
- Programming languages like Python, Microsoft VB-script, and Power IB
- Proficiency in MS Office tools
- Knowledge of associated manufacturing processes (molding, stamping, plating, crimping, and assembly)
- Knowledge of soldering, crimping, and welding technologies
- Experience with technical paper publications and applying for patents
- 3-5 years of industry experience
- Expertise in Ansys Workbench
- Experience with connector products (plastic and sheet metal parts)
- Knowledge of material science (metals, resins, and hyperelastic materials) and its implementation for simulation
- Correlation of test and simulation data/results
- Expertise in CAE tools, optimization techniques, and testing methods
- Experience implementing LEAN/6 Sigma/Kaizen techniques on live projects
- M Tech (Mechanical/Electrical)
Benefits
- Medical, dental, and vision insurance
- 401k retirement account access
- Paid sick leave and/or other paid time off as provided by applicable law
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