Thermal Power Staff R&D

Job Overview

Executes complex simulations to optimize design and manufacturing. Develops complex Multiphysics simulation methods.

Job Responsibilities

• Leading the development and implementation of complex Thermal simulation models to optimize manufacturing, designs or processes. (thermal simulation of current carrying products like connectors busbars, cable assemblies)
• Perform calculation & simulation on temperature distribution over system
• Conducted thermo-mechanical and structural simulations to support design optimization, material selection, and validation from concept to production
• Proficient in simplifying complex CAD geometries for efficient structural and thermal simulation analyses
• In-depth knowledge of mechanical design, conductive and convective heat transfer, and fluid flow mechanics
• Collaborate with designer, manufacturing, and testing teams to correlate FEA results with physical testing
• Experience with DOE (Design of Experiments) and optimization techniques
• Directing cross-functional teams to address and resolve intricate design and manufacturing issues.
• Analyzing complex simulation results to identify areas for improvement and driving design or process changes.
• Ensuring the maintenance and updating of simulation models to achieve optimal accuracy and relevance.
• Validate concept designs using simulation techniques and determine design robustness, critical to function requirements.
• Deploy FEA Techniques implicit and explicit approach, using Software tools like Ansys Work Bench, LSDyna, Hypermesh, Simufact, Digimat etc
• Translate actual problem to Finite Element Analysis (FEA) model, interpret analysis results and select best solution which includes linear & non-linear analysis under different physics.
• Monitor and evaluate simulation software capabilities and industry trends.
• Collaborate with design & validation teams to enhance the design optimization.
• Understanding the influence/impact activities on financial decision.

Required Skills

EDUCATION/KNOWLEDGE

• BE/ B.Tech (Mechanical/Electrical)
• M Tech (Mechanical/Electrical) (preferred)
• Knowledge of product, design processes and methodology.
• Proficiency in state-of-the-art

oFEA- ANSYS WORKBENCH, LS-DYNA, HYPERMESH, SIMUFACT, MOLDEX3D, OPTISLANG, ICEPAK MAXWELL, Ansys HFSS System simulations such as MATLAB & SIMULINK.

oCAD tools- PTC Creo, Space Claim.

oProgramming language - Python, Microsoft VB-script, Power IB.

• Proficiency in use of MS Office tools.
• Knowledge of associated manufacturing processes (molding, stamping, plating, crimping & assy).
• Knowledge about the Soldering, crimping & welding technologies.
• Knowledge on technical paper publications & applying for patents.

CRITICAL EXPERIENCE

• 14-18 years of industry experience.
• Expertise in Ansys Workbench.
• Experience on connector products (Plastic and Sheet Metal parts).
• Knowledge on material science (Metals, Resins & hyper elastic material) and implement for simulation.
• Correlation of Test and simulation data / results.
• Expertise on CAE tools, Optimization techniques, and testing methods.
• Implementing of LEAN / 6 Sigma / Kaizen techniques to live projects.

COMPETENCIES

• System and Product knowledge: Thorough understanding of customer requirements, product and application needs, required for creating effective designs
• Market intelligence: A thorough understanding of market trends and technologies.
• Conceptual thinking: Being able to see a broad picture, understand problems by putting the pieces together and simplify complex issues.
• Concern for order, quality, and accuracy: An underlying drive to reduce uncertainty by continuous risk assessments, taking accurate decisions, and continuously improve processes.
• Communication skills: Fluent communication skills to be able to articulate well with customers and teams across different functions & locations.
• Internal stakeholder management: Manage requests, address customer requirements and work effectively with different cross functional teams.
• Interpersonal skills and people management: Supervise and manage a team by ensuring compliance with rules and processes at TE and keep them motivated.