Systems simulation & Crash simulation (TT17ST RM 3905)

Position: Systems simulation & Crash simulation (TT17ST RM 3905)

Role Overview
We are seeking a highly skilled and versatile Systems & Crash Simulation Engineer / Analyst to join our advanced engineering team in Pune. This critical role involves applying cutting-edge simulation methodologies to predict and optimize the performance, safety, and dynamic behaviour of our products. You will be responsible for conducting both detailed crashworthiness simulations to ensure occupant safety and regulatory compliance, as well as complex multi-body dynamics (MBD) and system-level simulations to evaluate overall vehicle/product performance, handling, and interaction between subsystems. This role demands a strong understanding of physics, numerical methods, and a passion for leveraging simulation to drive design excellence.

Key Responsibilities
As a Systems & Crash Simulation Engineer / Analyst, your responsibilities will include:

• Crashworthiness Simulation:
  o Perform advanced Explicit Finite Element Analysis (FEA) for various crash scenarios (e.g., frontal, side, rear impact, pedestrian protection) using industry-standard software.
  o Analyse results for energy absorption, structural deformation, occupant kinematics, and injury criteria to ensure compliance with global safety regulations (e.g., FMVSS, UNECE, GNCAP, Euro NCAP) and consumer ratings.
  o Develop and validate highly detailed crash models, including material models, connection definitions, and boundary conditions.
  o Propose design improvements to enhance vehicle crash performance and occupant safety.
• Systems (MBD) Simulation:
  o Develop and execute Multi-Body Dynamics (MBD) models of complex systems or full vehicles to analyse kinematics, dynamics, vibration, and interaction between components.
  o Evaluate system performance attributes such as handling, ride comfort, stability, and control system integration (e.g., suspension, steering, braking systems).
  o Integrate detailed component models into system-level simulations to predict performance under various operating conditions.
  o Collaborate with controls engineers to implement and test control algorithms within the MBD environment.
• Pre-processing & Post-processing:
  o Build, modify, and manage complex FE/MBD models from CAD data, including meshing, material property assignment, contact definitions, and load case setup.
  o Effectively post-process large simulation data sets, visualize results, and extract key performance indicators.
• Correlation & Validation:
  o Correlate simulation results with physical test data to continuously improve model fidelity, prediction accuracy, and simulation methodologies.
• Design Optimization & Problem Solving:
  o Collaborate with design and testing teams to identify potential performance and safety issues early in the design process and propose data-driven solutions and design optimizations.
  o Conduct root cause analysis for performance or safety-related issues using simulation.
• Technical Reporting & Communication:
  o Prepare comprehensive technical reports, present simulation findings, and provide clear design recommendations to cross-functional teams and management.
• Methodology Development:
  o Contribute to the development and standardization of simulation methodologies, best practices, and automation scripts.

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or a related field.
• 3 to 8 years of experience in performing both Crash Simulation and Systems (MBD) Simulation within the automotive or related industries.
• Proficiency in Crash Simulation software: Hands-on experience with explicit FEA solvers such as LS-Dyna, Abaqus/Explicit, or Radioss.
• Proficiency in Systems (MBD) Simulation software: Hands-on experience with MBD tools such as MSC Adams, Altair MotionSolve, or Simcenter Amesim.
• Strong understanding of continuum mechanics, structural dynamics, material behaviour under high strain rates, and occupant kinematics.
• Familiarity with global automotive safety regulations and consumer rating protocols.
• Experience with pre-processing tools (e.g., Ansa, HyperMesh, Oasys PRIMER, LS-PrePost) and post-processing tools (e.g., HyperView, MetaPost, LS-PrePost).
• Ability to interpret engineering drawings, CAD models, and technical specifications.
• Excellent analytical, problem-solving, and critical thinking skills.
• Strong communication and collaboration skills to effectively work with multi-disciplinary teams.

Desired Skills & Experience

• Experience with occupant restraint system design and simulation.
• Familiarity with functional safety standards (e.g., ISO 26262).
• Experience with scripting languages (e.g., Python, Tcl/Tk) for automation and customization of CAE workflows.
• Knowledge of CAD software (e.g., CATIA, Creo, NX).
• Exposure to vehicle dynamics testing and data acquisition.
• Experience in advanced driver-assistance systems (ADAS) or autonomous driving (AD) simulation.
• Familiarity with electric vehicle (EV) specific crash and system dynamics considerations.

*******************************************************************************************************************************************