Job Title: Senior CAE / FEA Engineer – Brake Systems (NVH Specialist)
Key Objective of the Job Profile
We are seeking an experienced NVH (noise, vibration, and harshness) expert specializing in disc brake caliper systems to lead the analysis, development, and optimization of brake NVH performance. The role focuses on preventing and resolving brake noise issues (squeal, groan, judder, and moan) across vehicle platforms, ensuring best-in-class acoustic comfort and regulatory compliance.
Internal / External Contacts
FEA leaders, NVH experts, testing experts, TPMs, and design leaders.
Areas of Responsibility / Main Tasks
- Lead NVH development and issue resolution for brake caliper assemblies across all project phases (concept to SOP).
- Analyze and mitigate brake noise phenomena, including squeal, creep groan, judder, and low-frequency noise.
- Define NVH targets and design guidelines for calipers, pads, shims, pistons, and mounting interfaces.
- Perform modal, dynamic, and frequency response analyses using CAE tools (e.g., FEM, complex eigenvalue analysis).
- Correlate simulation results with bench, dyno, and vehicle test data.
- Support brake system tuning through material selection, stiffness optimization, damping solutions, and geometry changes.
- Lead and support Design Verification Plan and Report activities related to brake NVH.
- Collaborate closely with design, materials, testing, manufacturing, and vehicle integration teams.
- Support customer interactions, root cause analysis, and corrective action plans for NVH concerns.
- Contribute to continuous improvement, best practices, and knowledge sharing in brake NVH engineering.
Required Experience
- Education: Bachelor’s or master’s degree in mechanical engineering, automotive engineering, or a related field.
- Professional Experience: 8-12+ years of experience in the automotive industry (OEM or Tier-1).
- Project Experience: 8+ years of relevant project experience in the automotive industry. Proven experience in 5+ NVH filed.
Required Knowledge
- Advanced: Leading complex brake noise root-cause investigations, executing and correlating advanced CAE simulations (e.g., CEA and transient dynamics), optimizing caliper design and materials for robustness, and driving system-level NVH solutions across vehicle platforms.
- Basic: Understanding brake caliper systems and common NVH issues, performing basic vibration and friction analyses, understanding dyno and vehicle test results, and applying standard NVH countermeasures.
- Tools: HyperMesh (advanced meshing skills) and Abaqus (expertise in resolving convergence issues).
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