STAFF SIMULATION ENGINEER

Job Overview

BU / FUNCTION DESCRIPTION

As a Staff Mechanical Simulation Engineer in the Digital Data Networks business within TE Connectivity, you will run Mechanical simulations for connectors, Terminals, Sockets, cable assembly and bus bar assembly products used in data center.

ROLE OBJECTIVE

To perform Mechanical Simulation on electro-mechanical products, predict design weakness, provide design improvement recommendation, perform hand calculations, establish correlation between simulation and test results, develop advance simulation methods, and enhance productivity or reduce lead time by suitable automation.

Responsibilities:

• Executes Complex Mechanical Simulations & develop new simulation methods.
• Create finite element model and perform Mechanical, Vibration & Dynamic simulations.
• Collaborating with cross-functional teams to identify design weakness and provide potential solutions.
• Analyzing simulation results to identify areas for improvement and propose design recommendations.
• Develop and implement complex Mechanical simulation models to optimize manufacturing, designs or processes. (Mechanical simulations of products like connectors, Terminals/contact systems, sockets, heat sink, cable assembly and bus bar assembly products)
• Perform Bending, Mating/Insertion, Un-Mating/Retention of critical to functional features.
• Perform Buckling, Fatigue & Mechanism of connector parts and assemblies
• Perform Dynamic simulations of Crimping, Seal, Drop & Impact
• Perform Vibration analysis Modal (modes, natural frequency), Harmonic (Sine), Random vibration & Transient Vibration
• Proficient in simplifying complex CAD geometries for efficient structural and Mechanical simulation analysis by utilizing software tools like Ansys Spaceclaim and Ansys Discovery
• Ensuring the maintenance and updating of simulation models to achieve optimal accuracy and relevance.
• Experience with DoE (Design of Experiments) and optimization techniques. Simulate different scenarios utilizing DoE method.
• Validate concept designs using simulation techniques and determine design robustness, critical to function requirements.
• Analyzing complex simulation results to identify areas for improvement and driving design or process changes.
• Knowledge of mechanical design. Collaborate with designer, manufacturing, and testing teams to correlate structural simulation results with physical testing.
• Translate actual problems to Mechanical model, interpret analysis results and select best solution which includes non-linear analysis under different physics.
• Conducted structural & thermo-mechanical simulations to support design optimization, material selection, and validation from concept to production
• Collaborate with design & validation teams to enhance the design optimization.

Candidate Desired Profile:

EDUCATION/KNOWLEDGE

• Good knowledge of Electro-mechanical products, design processes and methodology.
• Knowledge of relevant Mechanical, Vibration & Dynamic simulations.
• Proficiency in state-of-the-art tools such as

1. Simulation Software: ANSYS WORKBENCH & LSDYNA, Simufact & Digimat.
2. Creo10.0, ANSYS SpaceClaim / Discovery & Hypermesh

• Knowledge of Python programming language or similar & Automations.
• Proficiency in use of AI tools, MATLAB and MS Office tools.
• Proficient using MS office software (Word, Excel, PPT, Outlook, MS Teams, etc.)
• Fluent in English (both verbal and written)

CRITICAL EXPERIENCE

• Master's degree in Mech Engg with 12+ years of related industrial experience / PhD in Mech Engg with 8+ related industrial experience.
• Expertise in Ansys Workbench & Creo 10.0.
• Working knowledge of contact physics including plating systems for electrical contacts, pore blocker and contact lubricants, copper alloys used in connectors, high temp plastics.                                                                                                                         
• Working knowledge of Mechanical testing and basic knowledge of test methods for electrical connectors, cable assembly and bus bars.
• Knowledge of material science (Metals, Resins & hyper elastic material)
• Correlation of test and simulation data / results.
• Expertise in CAE tools, optimization techniques, and testing methods.
• Knowledge of associated manufacturing processes (molding, stamping, plating and crimping).
• Knowledge of Soldering, crimping & welding technologies.
• Knowledge of technical paper publications & applying for patents.

COMPETENCIES

• Data Gathering & Analysis: Knowledge of individual differences and their value; ability to recognize and respect the value of individual difference and diverse perspectives at all levels of the organization.
• Analytical Thinking: Knowledge of techniques and tools that promote effective analysis; ability to determine the root cause of organizational problems and create alternative solutions that resolve these problems.
• Communicating Complex Concepts: Knowledge of effective presentation tools and techniques to ensure clear understanding; ability to use summarization and simplification techniques to explain complex technical concepts in simple, clear language appropriate to the audience.
• Problem Solving: Knowledge of approaches, tools, techniques for recognizing, anticipating, and resolving organizational, operational or process problems; ability to apply knowledge of problem solving appropriately to diverse situations.
• Collaborate across boundaries: Knowledge of effective collaboration techniques and ability to build networks with people from different countries and cultures, think and work with them to bring positive impact and flourishing business results.
• Materials Engineering: Knowledge of materials and their properties; ability to analyze, design, and select materials for various applications.
• Simulation Modeling and Experimentation: Knowledge of simulating and experimenting with models to analyze and optimize complex systems; ability to apply different simulation methodologies to design and conduct simulation experiments to gain insights, analyze system behavior, and make informed decisions.
• Interpersonal skills: Ensure compliance with rules and processes at TE.

What your background should look like

Generally requires Bachelors degree in appropriate field with a minimum of 8 years of experience; Masters degree or higher or local equivalent may be preferred at this level

Competencies