Mechanical Product Validation Engineer II

Role Overview

• Manage and coordinate failure analysis documentation in collaboration with cross-functional teams and global counterparts to accurately identify the root causes of early bench test failures for Class 8 Heavy-Duty Truck
• non-driven front, conventional, and electric driven rear axles
• Commission and certify heavy-duty class 8 truck fatigue test rigs, ensuring compliance with Daimler standards
• Employ advanced signal processing techniques for accurate strain and load measurements and fatigue analysis
• Design and develop structural durability test rigs replicating real-world road load-measured strain for Class 8 heavy-duty trucks, ensuring precise correlation between measured strain gauge data and NX Nastran simulation models
• Conduct comprehensive statistical analysis and fatigue life estimations to validate the durability and reliability of Class 8 Heavy-Duty Truck
• non-driven front, conventional, and electric driven rear axles using nCode software and Reliasoft Weibull++ under real-world loading conditions through global collaboration
• Leverage expertise in front and rear axle suspension interfaces and subsystem-level knowledge to validate test rig setups
• Ensure compliance with durability calculations by applying industry-standard fatigue life prediction methodologies, including rain flow counting, critical plane analysis, and multi-axial fatigue models
• Utilize road load or MBS data to correlate with test rig results, predict damage progression, and optimize test rig configurations for accurate lifespan assessments of driveline, chassis, and structural components
• Determine fatigue damage for Heavy-Duty Truck
• non-driven front, conventional, and electric-driven rear axles by correlating test results with NX Nastran simulation models and nCode
• Leverage advanced signal processing techniques to correlate road load signals from Class 8 heavy duty trucks with MBS model outputs, real-world testing data, and virtual simulations for test rig validation
• Enhance strain measurement accuracy, fatigue life prediction, and structural performance optimization using DSP in durability testing
• Lead and mentor support engineers and analysts, guiding them in the systematic process steps, following standard Detroit Axle Engineering processes and methods for CAE
• Provide knowledge transfer of standard methods and processes of CAD assembly setups, advanced meshing techniques (FEM/FEA), and boundary conditions to ensure simulation accuracy and quality
• Manage test rig commissioning, test rig design, and CAE correlation studies, ensuring adherence to timelines, milestones, technical specifications, and Daimler truck durability standards
• Identify and assess potential risks, delays, or technical issues, communicating them to middle management and collaborating with cross-functional teams to implement corrective actions and mitigate project disruptions
• Drive innovative design solutions by collaborating with Product Design, Validation Engineering to enhance the structural integrity and durability of Heavy-Duty Truck – nondriven front, conventional, and electric-driven rear axles
• Collaborate with international FEA and durability testing teams to streamline the simulation and testing processes and ensure the timely delivery of results
• Support validation and design decisions with accurate simulation data, strain gauge instrumentation, and real-world road load correlation
• Foster cross-team collaboration to enhance project efficiency and effectiveness in commercial vehicle durability assessment

Requirements

• Bachelor’s degree in Mechanical Engineering
• 2 years of relevant experience in the automotive industry
• Must have experience with each of the following:
• Using the following CAE tools for automotive structural durability analysis: nCode Glyphworks & DesignLife , Siemens NX Nastran Suite 2312 or later (NX Modeling, Pre/Post, 401/402 Multistep, Simcenter Motion), MathCAD 10.0, and VDI 2230 (Bolt preload calculations)
• Correlating road load data with simulation models to verify and validate structural performance
• Performing Non-Linear analysis (SOL 401) with Bolt preloaded joints
• Using CAD tools for the design of test rigs and setup validation
• Using nCode v25 solid weld fatigue analysis methods/processes
• Performing fatigue analysis and FEA calculations for conventional front axle and rear axles on Class 8 heavy-duty trucks
• Performing on-site evaluations, ensuring test setups meet technical specifications, and resolving issues through real-time guidance and corrective recommendations
• Executing virtual strain gauge correlation, strain-life fatigue analysis, fatigue editing, and time series generation to match test load setups and road load data
• Utilizing PDM/CAD/CAE systems such as Engineering Client, SMARAGD, ZG DokClient , and ViewCA
• Managing projects, training and mentoring junior engineers, and managing professional services or other external resources.

Tech Stack

• Assembly

Benefits

• annual bonus program
• 401k company contribution with company match up to 6% as well as non-elective company contribution of 3
• 7% depending on age
• starting at 4 weeks paid vacation
• 13+ calendar holidays
• 8 weeks paid parental leave
• employee assistance program
• comprehensive healthcare plans and wellness programs
• onsite fitness (at some locations)
• tuition assistance and volunteer paid time off
• short-term and long-term disability plans