Senior Application Engineer

CAE Engineer - Machining Assembly

• Drive the CAE process modelling requests enabling a framework for the cross functional teams to create robust machining and assembly processes. 
• Conduct PTME Machining/Assembly CAE analysis, provide interpretation, communicate, and document simulation results
• Ensure manufacturing feasibility for assembly and machining process designs, resulting in parts that can be machined or assembled by standard and best practice methods in support of new Powertrain program product launches. 
• Develop CAE methods & Applications to simulate critical machining & assembly processes involved in Electrified Powertrain & ICE Programs
• Manage & Optimize Ford Proprietary MATLAB applications developed already
• Develop new MATLAB applications required for additional virtual process models

• Provide technical support to Product Development (PD) Component Program Module Teams (CPMT's) and coordinate process design between Product Engineering, PTME – Machining and Assembly, and external machining suppliers to assure ‘design for manufacturing feasibility’ of new Powertrain Machining and Assembly Methods.
• Support the Digital Preassembly 5 (DPA5) process through the development of component Manufacturing Design Specifications (MDS) and Manufacturing Process Specifications (MPS). Complete Manufacturing Assessments.
• Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations.
• Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors.
• Conduct clamping deformation analysis and communicate results to fixture supplier, driving robust fixture design.
• Support Machining Process engineers for natural frequency vs. cutting frequency analysis, face milling analysis, cylinder bore boring roundness analysis, valve seat machining deformation, flat and cylindrical surface stiffness, dynamic stiffness analysis, face milling force and burr prediction.
• Support assembly process engineers with press in analysis requests for valve seat and guide, axle tube, gear and bearing. Conduct bolt mounting deformation analysis, contact simulation, and staking analysis for applicable components.
• Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
• Support Product Engineering in the selection and specification of component materials and test procedures.
• Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
• Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of machining and assembly methods related to productivity and quality issues of external suppliers.

Education Qualification: B. E / B.Tech in Mechanical Engineering

Preferable Qualification: M. E / MTech in CAD/CAM/Production/Manufacturing

Number of Years of Experience: 3-7 Years

Knowledge on Powertrain & Battery Manufacturing Processes, Basics of Machining & Cutting Tool Technology

CAE Tools Expertise: Hypermesh/ANSA, Nastran, Abaqus, MATLAB, Thirdwave AdvantEdge, Thirdwave PM3D