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Staff Engineer, Finite Element Analysis

bw_wordkay_placeNoblesville - Indiana - USA

bw_wordkay_timeJul 08, 2019

bw_wordkay_optionFull time


BorgWarner is a global product leader in clean and efficient technology solutions for combustion, hybrid and electric vehicles. Our facilities are located across the globe to provide local support for our diverse customer base.

We operate in two groups: The Engine Group develops air management strategies and products to optimize engines for fuel efficiency, reduced emissions and enhanced performance. BorgWarner’s expertise includes engine timing systems, boosting systems, ignition systems, air and noise management, cooling and controls. The Drivetrain Group harnesses a legacy of more than 100 years as an industry innovator in transmission and all-wheel drive technology. The group leverages this understanding of powertrain clutching technology to develop interactive control systems and strategies for all types of torque management.

BorgWarner PowerDrive Systems is currently looking for a “dynamic, results driven” individual to join as a Staff Engineer, Finite Element Analysis (FEA) at our Noblesville Technical Center (NTC) in Noblesville, Indiana.

In this role, Staff Engineer, Finite Element Analysis will be primarily responsible for providing mechanical computer-aided engineering (CAE) analysis support for new product development and improvement of component products. Can be counted on to complete advanced, complex assignments requiring full use and application of engineering tools, processes, and methods.

Key Accountabilities:

  • Create finite element models of parts and assemblies
  • Perform structural, vibration, explicit dynamic, thermal, & acoustics finite element analysis (FEA)
  • Perform fatigue analysis for structural durability
  • Verify that FEA results are reasonable using hand calculations
  • Provide Computational Fluid Dynamics (CFD) simulations
  • Propose design modifications to meet requirements
  • Coordinate outside test and analysis resources, when needed
  • Write test plans and coordinate tests for input data collection, model calibration, and correlation studies
  • Provide mechanical and electrical component/system analyses, using various analytical methods and engineering tools (e.g., MathCAD, MATLAB, Excel, etc.)
  • Develop new design tools to improve predictive engineering capabilities
  • Document best practice analysis techniques in Engineering Standards
  • Write reports to summarize CAE projects
  • Give presentations to internal and external customers
  • Solve complex problems using ingenuity and creativity
  • Coach, mentor, and train entry level & new hire CAE Engineers

Requirements & Qualifications:

  • BSME, BSEE or Materials Engineering degree required; MS or PhD degree preferred
  • Minimum 8 years engineering experience in related field required. Will consider less years of experience with advanced degree, but preference will be given to those with 8 years industry experience
  • Automotive or rotating electric machine experience required
  • Proficiency in CAD required
  • Proficiency in finite element analysis (FEA) required with ANSYS preferred
  • Familiarity with CFD (Computational Fluid Dynamics) required
  • Working experience in statics, dynamics, thermal, and Multiphysics simulation preferred
  • Electromagnetic noise (acoustic) simulation experience preferred
  • Solid understanding in fatigue theories, strain-based and stress-based required
  • Knowledge of material modeling for different materials, metals, plastics, rubbers, composites required
  • Experience in writing test plans and coordinating tests required
  • Experience in performance testing mechanical products Experience in manufacturing environment for mechanical components/systems preferred
  • Working knowledge of rotating electrical machines preferred
  • Experience working in global teams for international customers preferred
  • Proficiency in Matlab/Simulink preferred
  • Excellent people skills and history of teamwork required
  • Excellent oral and written communication skills required

BorgWarner Competencies:

  • Learning on the Fly
  • Problem Solving
  • Decision Quality
  • Interpersonal Savvy
  • Working in Teams
  • Action Oriented
  • Driving for Results
  • Functional/Technical Skills
  • Ethics & Values


This position will adhere to Global Star Safety Program, including safety rules, practices and training as outlined in the BorgWarner NTC/WHQ Safety Policy Manual, which includes the use of equipment, protective devices, or clothing that the employer requires.  This individual will work in manners that stress the importance of preventing accidents and illnesses.  He/she must take every precaution reasonable in the given circumstance for the protection of themselves and co-workers.  In addition, he/she is responsible for reporting all injuries and/or possible dangerous situations, incidents, or occurrences to the immediate supervisor.

Equal Employer Opportunity Statement

BorgWarner is an equal employment opportunity employer such that all qualified applicants will receive consideration for employment without regard to race, color, age, religion, sex, sexual orientation, gender identity, national origin, disability or protected veteran status.

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