CAE & CFD Engineer, Drive Systems

The Role

The Drive System Engineering team is looking for an exceptional CAE (CFD, Thermal & FEA) engineer to work on drive unit simulation analysis to assist drive unit development. The work is aimed to predict hydraulic and thermal performance, and to guide design through accurate and timely simulation. This role will be primarily focusing on but not limited to simulation/modeling of cooling fluid flow and drive unit system thermal behavior and initiating validation testing.

During product development, CAE is playing an important role to facilitate/guide initial component or system design. CAE is heavily used to predict the cooling and lubrication efficacy and to generate all the required inputs for prototyping system level reduced order modeling and to help achieving desired system efficiency. As design matures, CAE simulation/prediction and prototype testing are used together interactively to evaluate design changes and to look for best design with lowest system cost.

Our world-class engineering team operates with a non-conventional automotive product development philosophy of high inter-disciplinary collaboration, flat organizational structure, technical contribution at all levels, and self-motivated innovation. You will be expected to challenge and to be challenged, to create, to innovate. You will work alongside with accomplished, world-renowned engineers on perhaps the most exciting automotive programs in existence today, and in a fast-paced, disruptive, collaborative and fun working environment.

Responsibilities

• Full-phase drive unit CAE and analytical modeling for design optimization
• Detailed multiphase cooling fluid simulation to determine flow distribution in various drive unit components in the whole fluid circuit
• Conjugate heat transfer to determine max power within operation thermal limit
• Actively solve sustaining issues that is affecting drive unit durability or reliability through simulation and trace root cause and proactive troubleshooting
• Explore Innovative cooling strategy and continue improving cooling performance
• Initiate and lead the validation test with prototype/test bench and improve the simulation accuracy, and correlating simulation results with empirical data
• Component level structural analysis and multi-physics simulation
• Develop pre and post-processing automation
• Reduced-order model development, model parametrization and increase optimization capability
• Assist cooling and lubrication team for iterative design and product development, and also from time-to-time support teams cross the whole vehicle component function teams

Requirements

• Master's Degree in Mechanical Engineering, or equivalent
• Strong skills with finite volume method CFD simulation and have solid background in turbulent thermal fluid domain.
• Experienced with multiphase CFD model creation, simulation strategy selection, post-processing and data analysis.
• Experienced with one or more of Ansys, Star-CCM or Altair etc. flow simulation software
• Experienced with creating and executing design validation plan for validating the lubrication simulation models
• Working knowledge of motor and gearbox cooling and lubrication strategy
• Working knowledge of gearbox/motor design and thermal management
• Experience with MATLAB, Python, or 1D modeling is a plus.
• Automotive industry experience is a plus

Compensation and Benefits

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Aetna PPO and HSA plans > 2 medical plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• LGBTQ+ care concierge services
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D, short-term and long-term disability insurance
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program
Expected Compensation

$80,000 - $300,000/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.