Vibration Simulation & FEA Engineer II

Job Description: Vibration Simulation / FEA Engineer – Advanced Battery Simulation We are seeking a Vibration Simulation / FEA Engineer to support the development and virtual validation of structures, mechanisms, and components for batteries. This role will focus on using finite element analysis (FEA), vibration simulation, modal analysis, and dynamic analysis to predict structural behavior, identify potential vibration and durability issues, wear, thermal fatigue, optimize designs, and improve product reliability. The engineer will work closely with design, test, reliability, and product development teams throughout the product development cycle. The successful candidate will translate product requirements and real-world operating conditions into appropriate simulation models and loading criteria, correlate simulation results with physical test data, and provide actionable recommendations to improve product performance, durability, reliability, and cost. You’ll also be DISRUPTIVE through these duties and responsibilities • Develop and execute FEA simulations for structural and vibration performance of components, assemblies, and complete systems. • Perform modal analysis , including prediction and evaluation of natural frequencies, mode shapes, and structural resonance. • Conduct dynamic simulations such as frequency response, harmonic response, random vibration, transient response, and shock analysis as applicable to product requirements. • Evaluate structural response to operational vibration environments and identify potential resonance, amplification, fatigue, and durability concerns. • Perform linear and nonlinear FEA to evaluate structural behavior under static and dynamic loading conditions. • Develop appropriate finite element models, including mesh generation, material properties, boundary conditions, contacts, joints, and loading conditions. • Define and apply vibration and structural loading criteria based on product requirements, customer usage, field data, and physical testing. • Analyze vibration test data, including time-domain and frequency-domain data , to develop representative simulation inputs and validate analytical predictions. • Support random vibration analysis , including interpretation and application of PSD-based loading where appropriate. • Evaluate vibration-induced stresses and responses and perform fatigue and durability assessments using simulation results and measured operating data. • Correlate simulation results with modal testing, shaker testing, field testing, and other physical validation data . • Work closely with the test team to develop appropriate test methods, instrumentation strategies, excitation profiles, and performance criteria. • Investigate discrepancies between simulation and physical test results and improve FEA models and assumptions to achieve meaningful correlation. • Support troubleshooting of vibration, noise, structural, and durability issues identified during development and validation testing. • Perform design optimization to improve structural stiffness, mass, natural frequency separation, durability, and overall product performance. • Continuously improve simulation methods, modeling practices, and FEA/test correlation processes. • Partner with design engineers to refine structural concepts and develop robust designs that meet performance, reliability, cost, and timing objectives. • Develop, maintain, and release FEA models, vibration analysis reports, loading criteria, simulation methodologies, and technical documentation . • Support product development teams in resolving structural and vibration issues while maintaining program development schedules. • Assist with processing and interpretation of laboratory and field vibration data to establish realistic durability and loading criteria. • Work closely with NPD (New Product Development), Test & Validation Engineering, Reliability & Durability Engineering, and Marketing. • Communicate simulation results and engineering recommendations clearly to design and test teams. • Work effectively in a fast-paced, cross-functional product development environment. What TOOLS you’ll bring with you: • Bachelor of Science Degree in Mechanical Engineering • 3+ years of Finite Element Analysis (FEA) experience • 3+ years of prior work experience in design or product validation environment. • doing mechanical design or validation, proficient in a CAD software package • 3+ years of prior work experience in nonlinear FEA and fatigue analysis • 3+ years of prior work experience with the following: Ansys, Abaqus and Abaqus Explicit FEA software, Hypermesh, and Optistruct software, Fatigue Software such as nCode, Mechanical principles, kinematics, structural materials, and standard machine and mechanism components. • Knowledgeable in CAD – NX, Solidworks, or similar Milwaukee Tool is an equal opportunity employer.