Senior Finite Element Analysis Engineer (FEA)

Job description

We are seeking experienced **Mechanical Integrity Engineers** with strong expertise in **Stress Analysis** and **Finite Element Analysis (FEA)** to ensure the structural integrity and reliability of aerospace components. This role involves detailed mechanical analysis across a wide range of engine commodities and supports the full lifecycle of product development—from concept to in-service support and disposal. **Key Responsibilities:** - Perform **stress analysis** and **FEA simulations** to validate mechanical integrity of components such as fans, compressors, casings, combustors, turbines, and structures. - Apply **FEA tools** (e.g., Abaqus, Ansys, LS-Dyna) to predict mechanical behavior under various loading conditions including fatigue (low & high cycle), creep, vibration, thermal loads, and extreme operating scenarios (blade-out, over-speed, burst duct). - Conduct **mechanical integrity assessments** to ensure product robustness and compliance with design requirements. - Support **in-service engine safety** through stress analysis and mechanical evaluations. - Lead **Design of Experiments (DoE)** and mechanical testing to validate stress predictions and improve design reliability. - Collaborate with multi-disciplinary teams to ensure designs meet performance, manufacturability, cost, and weight targets. - Define and execute analysis plans aligned with project milestones, cost, and quality goals. - Recommend design optimizations using **Robust Engineering** principles and stress analysis insights. - Drive continuous improvement in **FEA methods** , stress analysis processes, and mechanical integrity tools. - Act as a subject matter expert in **stress analysis** and **FEA** , sharing knowledge across engineering functions. **Technical Skills Required:** - Strong experience in **Finite Element Analysis (FEA)** using tools such as **Abaqus, Ansys, LS-Dyna** . - Proficiency in **stress analysis** , mechanical behavior prediction, and failure mechanism evaluation. - Familiarity with meshing tools (e.g., Hypermesh, Unigraphics) and data management systems (e.g., Teamcenter). - Understanding of material science, crack propagation, contact mechanics, and thermo-mechanical fatigue. - Ability to communicate complex **FEA and stress analysis** results to internal and external stakeholders. - Knowledge of aerospace product integrity, liability, and certification frameworks. **Qualifications:** - Degree in Mechanical, Aerospace, or Structural Engineering (BE/BTech/MSc/MEng). - 1 to 10 years of hands-on experience in **FEA** , **stress analysis** , and **mechanical integrity** in aerospace or related industries.