Mechanical Design Intern – CAE & Simulation

Selected intern's day-to-day responsibilities include: A. Product design: 1. Assisting in designing components and systems for mechanical products, focusing on performance, durability, and cost-effectiveness. 2. Creating detailed 3D models and technical drawings using CAD software (SolidWorks, AutoCAD). 3. Applying design for machining, design for analysis, and design for manufacturing principles to ensure robust and practical designs. 4. Collaborating with the team to refine and optimize designs based on feedback and testing. B.Analysis & Simulation: 1. FEA & structural simulation: Performing structural, stress, deformation, thermal, vibration, and modal simulations using CAE tools such as Altair HyperMesh/OptiStruct to evaluate component and assembly performance under real operating conditions. 2. Simulation setup: Preparing CAD geometry, meshing components, assigning appropriate material properties, contacts, loads, constraints, and boundary conditions for accurate analysis. 3. Design validation & optimization: Interpreting simulation results to identify high-stress regions, excessive deformation, resonance, or potential failure points and recommending design improvements. 4. Correlation with physical testing: Comparing simulation results with prototype or physical test results to validate assumptions and improve the accuracy and reliability of future simulations. C. Product development: 1. Supporting the development of prototypes for new products, ensuring designs meet functional and aesthetic requirements. 2. Conducting mechanical analysis (stress, thermal, vibration) to validate designs. 3. Integrating mechanical subsystems with electrical and embedded systems. D. Technical drafting & CAD: 1. 2D drawing creation: Generating detailed manufacturing drawings from 3D models, including orthographic views, sections, and dimensions. 2. Annotation & GD&T: Applying tolerance standards to ensure parts manufactured by vendors will actually fit the vehicle frame. 3. CAD optimization: Modifying existing 3D models to fix interferences or to simplify the assembly process. 4. BOM maintenance: Keeping the Bill of Materials updated so that every nut, bolt, and bracket is tracked and ordered. E. Physical vehicle integration: 1. Trial fitment: Taking prototype parts to the vehicle to check clearances, hole alignments, and ease of installation. 2. Interference detection: Identifying 'clashes' where components might rub, vibrate against each other, or block access to other parts. 3. Tooling & hardware selection: Determining which fasteners (bolts, rivets, adhesives) and tools are best suited for the specific mounting location. F. Verification & testing: 1. Physical measurement: Using calipers, micrometers, or measuring tapes to verify that the 'as-built' vehicle matches the 'as-designed' CAD model. G. Communication: 1. Vendor coordination: Communicating with fabrication shops to explain drawing requirements or clarify manufacturing queries.