Simulation Engineer

Job Title: Simulation Engineer – Sheet Metal (Skin Parts Focus) Department: CAE / Vehicle Engineering / Tooling & Simulation Reports To: Simulation Lead / CAE Manager Experience Required: 3–8 years in Sheet Metal Forming Simulations Industry: Automotive / Engineering Services / Manufacturing Job Purpose: To lead and execute sheet metal simulation activities focused on skin panels and associated tooling systems. Ensure high correlation between virtual and physical outcomes, contribute to die design processes, and collaborate across cross-functional teams for optimized formability, quality, and efficiency in the press-shop and tooling lifecycle. Key Responsibilities:1. Simulation Execution & Deliverables Carry out formability, spring back, skin evaluation, compensation, and quality analysis specifically for skin parts. Deliver final simulation results to SE (Simultaneous Engineering) teams for Die Layout (DL) creation. 2. Virtual vs Actual Correlation Perform virtual-to-physical correlation of simulation results. Continuously improve simulation accuracy by analyzing discrepancies and enhancing material and process models. 3. Correlation Enhancement & Standards Develop and update simulation standards: Acceptance Criteria, AFR (Area Feasibility Ratio), Material Models, and Reporting formats. Benchmark and apply lessons learned to enhance simulation fidelity and standardization. 4. Tooling & Automation Simulation Simulate and validate pallets, trolleys, die automation systems, and FTGs (Forming Tool Gauges). Ensure design feasibility and functional performance via upfront simulation inputs. 5. CAE Integration Sync simulation activities with vehicle CAE teams for accurate input mapping and integration with overall vehicle simulation data. 6. Issue Management & Documentation Generate and manage PCRs (Problem/Change Reports) related to simulation issues in the Concern Management System. Contribute to knowledge management by maintaining What Went Right/Wrong documents and incorporating lessons learned into process improvements. 7. Optimization & Efficiency Drive reduction in simulation hours, iterations, and license usage through process streamlining and automation. Provide early feedback based on clay model and initial surface data, enabling faster design cycles. 8. Cross-functional Collaboration Coordinate with SE teams to align on die number targets and material yield goals. Participate in joint project reviews and contribute to achieving SE and simulation KPIs. Required Skills & Competencies: Proficiency in simulation tools such as AutoForm, PamStamp, LS-Dyna, etc. In-depth understanding of sheet metal forming, especially skin panel characteristics and challenges. Knowledge of material properties, tribology, and spring back behavior in forming processes. Strong analytical mindset with focus on virtual vs physical data correlation. Good documentation, communication, and project management skills. Experience in CAE-process integration and concern management systems. Qualifications: B.E./B.Tech or M.E./M.Tech in Mechanical / Automotive / Production Engineering or related field. Industry certifications or training in Sheet Metal Forming Simulation preferred.