Manager

The position of Sheet Metal Forming Engineer is to

(1) Drive development of manufacturing solutions for sheet metal forming such as deep-drawing, bending and stamping of FRP products.

(2) Build and validate models and simulation techniques for metal forming processes,

(3) Support tooling development at customers for springback & defects

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

Process Development:

• Lead the design, development, and implementation of sheet metal forming solutions tailored to flat rolled products, emphasizing processes like deep-drawing, bending, and stamping.
• Identify and develop innovative methods for optimizing quality and cycle time in forming processes.
• Collaborate with product design and manufacturing teams to integrate metal forming solutions into product designs.

Modeling and Simulation

• Build, validate, and improve simulation models for sheet metal forming processes, applying techniques like finite element analysis (FEA) to predict and optimize material behavior.
• Develop and implement advanced modeling techniques to analyze strain distribution, springback, material flow, and other critical factors impacting flat rolled product forming.
• Continuously improve simulation tools to enhance accuracy, speed, and predictive capability, supporting iterative process development and decision-making.

Technical Support

• Provide expert support to customer teams in design and development of tools, addressing issues in forming processes, such as springback, cracking, and wrinkling.
• Conduct assessments and assist customers in refining tooling parameters to improve defect rates and forming accuracy.
• Troubleshoot and resolve process-related challenges, fostering strong customer relationships and ensuring satisfaction with technical support.
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Project management and execution

• Work with stakeholders to scope the project appropriately
• Plan and execute project activities as per project timelines
• Work closely with the project team during execution phase to meet project milestones and deliverables
• Perform hazop analysis while working on developments, develop SOPs for routine activities and follow the standard safety norms while working
• Work closely with external project partners and vendor management
• Keep track of budgeted resources versus resource utilization during the project execution
• Follow and strengthen HIC way of project management and execution e.g. charters, milestone planning, stage gate, QBR etc

Technical development of self and others

• Attend technical conferences, review technical and academic literature, attend supplier webinars, interact with experts, visit plants etc to stay abreast of technological advancements in the field of forming and manufacturing technologies and equipment.
• Provide trainings on forming processes and material properties related to forming
• Present research findings at internal forums like Manthan, downstream summits etc.

External and internal customer insight generation

• Develop keen understanding of the key functionality of product/technology to be developed
• Develop understanding of testing requirements and if desired develop new methods
• Visit fabricators/vendors and customers for developing understanding of the processes and applications

Capability enhancement and development

• Maintenance and enhancement of existing fabrication lab and pilot capabilities along with the lab-in-charge
• Identify needs for in-house capability development
• Identify equipment, specifications and vendors for capability development and coordinate for commissioning

Knowledge creation and dissemination

• Document and maintain results for various developments and convert into high quality tech-memos
• Document and record inventions in Invention Record and work with legal team for patent filing where applicable
• Present non-sensitive research findings in international journals, conferences to more widely disseminate knowledge and showcase Hindalco R&D capabilities

Qualifications:

Doctor Of Philosophy (Phd),Post Graduate

Minimum Experience Level:

3-8 Years

Report to:

• Vice President