Sr Engineer Systems - Thermal/CFD

Auto req ID: 57720
Title: Sr Engineer Systems - Thermal/CFD
Job Function: Engineering
Location: PDC
Workplace Category: Onsite
Company: Harley-Davidson Motor Company
Full or Part-Time: Full Time
Shift: SHIFT1

In 1903, out of a small shed in Milwaukee, Wisconsin, four young men lit a cultural wildfire that would grow and spread across geographies and generations. Their innovation and imagination for what was possible on two wheels sparked a transportation revolution that would make Harley-Davidson the most recognizable motorcycle brand in the world. Today, we continue to define motorcycle culture, evoking soul-stirring emotion reflected in every product and experience we deliver - like we have for well over a century and will for generations to come. Are you ready to ride with us?

The Harley-Davidson Motor Company Product Development Center (PDC) located in Wauwatosa, WI is home to the mantra – You dream it. We build it. Join our team as a Sr Engineer Systems - Thermal/CFD.

Job Summary

The Senior Systems Engineer – Thermal/CFD is a full-time onsite position reporting to the System/Component Simulation Engineering Manager. This individual is expected to provide 3-D CFD simulation and analysis to support vehicle aerodynamics, thermal comfort and powertrain (ICE/EV) development to ensure the delivery of world class Harley-Davidson motorcycles. This work must align with cross-functional stakeholders and strategies within product development. The role must collaborate with motorcycle project teams, design studio, test labs, and other internal and external partners to develop innovative solutions for all future product plan projects as well as current production issues.

Job Responsibilities

The Senior Systems Engineer is responsible for the following:

• Retrieving, preparing and cleanup of CAD parts for CFD volume meshing
• Work with internal customers to ensure proper boundary conditions are applied
• Work with Powertrain, Electrical, Mechanical, and Reliability engineers to develop simulation cases and physical tests in parallel to validate and refine 3-D/1-D models
• Develop 3-D/1-D CFD/CAE models to analyze problems related to thermodynamics, fluid flow and heat transfer (lubrication, cooling, air and other means).
• Develop 3-D/1-D thermal models of heat conduction, convection and radiation to enable thermal design decisions and their impact on vehicle components (rider/passenger). Examples include power train
• components, battery cases, motors, components including metals, non-metals, gap fillers, conduction interfaces, coatings, battery cells (jelly roll), etc.
• Develop 3-D/1-D thermal models for power electronics and motor cooling, including motor windings, and rotor interior.
• Develop 3-D/1-D thermal convection models for understanding ICE/EV energy balance
• The ability to analyze 3-D/1-D models to identify incremental opportunities for overall vehicle / system improvements via reduction in engineering scalars (pressure loss, heat transfer, energy balance, flow and drag)
• The ability to communicate across multiple software tools to quantify or optimize performance of vehicle/sub-systems (Star-CCM+, GT-Power, Sculptor, ModeFrontier, Simulink)
• Interpret analysis results with respect to results obtained by lab testing procedures, and converting these results into practical design suggestions
• Proactively validate/correlate results with real world data and make model improvements to drive methods development and continuous model improvement
• Generates high level engineering reports and presents CFD/CAE results/conclusions to the motorcycle project teams

Education Requirements

Bachelor's Degree Required

Education Specifications

Position requires a bachelor’s degree in one of the following disciplines:

• Mechanical Engineering (Fluids, Heat transfer, or Combustion emphasis), Aerospace/Aeronautical Engineering or Applied Physics. Master of Science or PhD degree with specialization in CFD preferred.

Experience Requirements

The successful candidate will have a minimum of 5 years or more of demonstrated performance related to the following:

• Demonstrated history of 3D CFD simulations in battery enclosure heat transfer, ICE heat transfer, powertrain applications, vehicle aerodynamics, and thermal comfort
• Strong understanding of fundamental physics – thermodynamics, fluid flow, heat transfer and combustion
• Demonstrated use with engineering analysis tools for CFD Modeling and simulation (e.g., Star-CCM+, Converge, GT-Power, modeFrontier, Sculptor, TaiTherm, Simulink, Optistruct, etc.)
• Experience with data sets and CFD correlation (Powertrain, Dyno, Vehicle, Wind tunnel)
• Experience in parallel computations, parametric modeling, and design optimization
• Proficient at programming with commercial software (Matlab, EES, Java, Python)
• Demonstrated familiarity with Creo and CFD mesh repair techniques
• Excellent communication skills, both verbal and written
• Outstanding interpersonal and problem-solving skills
• Demonstrated technical problem solving

The pay range shown represents the national average pay range for this role. Your pay may be more or less than the stated range and is dependent on your geographic location and level of experience.

We offer an inclusive compensation package for all full-time salaried employees including, but not limited to, annual bonus programs, health insurance benefits, a 401k program, onsite fitness centers and employee stores, employee discounts on products and accessories, and more. Learn more about Harley-Davidson here.

Applicants must be currently authorized to work in the United States.

Direct Reports: Yes
Travel Required: 0 - 10%
Pay Range: $93,400 - $145,000
Visa Sponsorship: This position is not eligible for visa sponsorship or visa transfer
Relocation: This position is eligible for domestic relocation assistance (within posted country)