Sr Structural Engineer / CAE Engineer

Jonathan Espinosa

Interests: Automotive Engineering, CAE, Product Design, Finite Element Method & Artificial

Intelligence

PROFESSIONAL EXPERIENCE:

Cosma International Group of Magna International Inc. – Senior Structural Engineer

Aug/ 2013 – Present

Gather inputs from Designers and Design Responsible Engineers (DREs)

Build Finite Element Analysis (FEA) models (meshes) from CAD solid models

Perform structural analysis using FEA methods

Use current ANSA /Hypermesh to mesh CAD models suitable for FEA

Perform linear and nonlinear FEA studies using Abaqus and MSC Nastran

Work with Product Engineer to apply appropriate constraints, loads, forces contacts and

material properties based on part function study.

Able to export data to excel sheet, write FEA technical reports, create animation views,

interpret results and communicate to Designers and DREs

Suggest design modifications to enable first-time-quality of new product designs

Details:

- Fuel Lid Static Strength Analysis using ABAQUS

- Tailgate Strong Open Swing using ABAQUS

- Luggage Hooks/BIW Strength Analysis using ABAQUS

- Sunroof Washer Dryer Analysis using ABAQUS

- Trailer Hitch Strength Analysis using ABAQUS

- Cargo Bed & Cargo Lid Plastic Assembly Strength Analysis using ABAQUS

- Modal analysis using SOL 103 Nastran

FORD Motor Company – Climate Control Systems Engineering CAE Structural Engineer

May / 2013 – May/2014

Analyze and assess the A/C Lines pattern that interacts with the powertrain engine system

Simulate the interaction of vibrating components attached with the compressor

Engine roll, vibration, deflection, pressure, modal and fatigue analysis for Climate Control

Systems and A/C Lines

Assess durability strategies and recommend design optimization for attachments and components

Investigate methods to analyze structural damage for climate control systems

Develop and support standard work for CAE durability simulations

Evaluate and recommend new software and processes

Prepare technical documents to support management meetings and CAE seminars

Provide technical leadership for advanced technology development - Communicate, coordinate,

and consult with engineering departments and customers

Stay abreast of new technology and competitive products

Correlate CAE with physical tests and visit supplier labs to meet Ford internal requirements

Details:

AC Lines Systems durability analysis:

- Pressure Linear Static analysis using MSC Nastran: This analysis considers the structural

behavior and stresses subjected to certain amount of pressure, so you can later superpose an

enforced displacement under different temperatures and evaluate engine roll motion.

- Real Eigenvalue Analysis using MSC Nastran: assess the dynamic interaction between a

component and its supporting structure in the ac lines system. Report critical Eigen shapes and

eigenvalues at low frequencies.

- Frequency Response Analysis using MSC Nastran: used to compute structural response of ac

lines system subjected to steady-state oscillatory excitation. This is a key input for design life

vibration durability analysis

- Engine Roll analysis using N Code Design Life: Use the Design Life interface to load a duty

cycle and load also the Nastran results from pressure/engine roll enforced displacement to

calculate the number of cycles that the component of ac lines can resist. Muffler, Brackets, clips,

tubes, liquid line, suction line, discharge line, Internal Heat Exchanger tubes and fins.

- Vibration analysis using N Code Design Life:

- Use the Design Life interface to load a duty cycle and load also the Nastran results from FRF

Nastran analysis and the PSD input to calculate the number of cycles that the component of ac

lines can resist under this vibration profile. Muffler, Brackets, clips, tubes, liquid line, suction

line, discharge line, Internal Heat Exchanger tubes and fins.

GENERAL MOTORS – Door Trim Body Interior CAE Structural Engineer Dec / 2012 – May/2013 (6

months)

Support the vehicle virtual development by making static and dynamic evaluations to the several

systems and subsystems for automobiles and trucks, using linear and nonlinear finite element

software.

Design proposals development to meet all the internal and international GM requirements.

Produce and evaluate solutions to improve the quality and cost of the designs, based on

specialized engineering knowledge.

Define virtual performance assessment planning that is in line with the learning analysis

development and validation plans

Work in coordination with other areas of engineering such as: design engineering, development,

validation and manufacturing to develop integral solutions using math virtual simulation.

Participate in global forums and meetings to share technical information about new procedures

and new ways of simulation

Details:

**All analysis for door trim include the full door with plastics and sheet metal material and nonlinear

properties characterization, also the attachments are analyzed.

**The mesh is done manually using Hypermesh

- Real Eigen Value analysis using MSC Nastran for Door Trim assembly: assess the dynamic

interaction between a component and its supporting structure in the door trim subsystem.

Report critical Eigen shapes and eigenvalues at low frequencies (normally the first 10 modes).

- Speaker Grille Impact using LSTC Explicit Dyna Solver: Analyze the abusive impact of a

foot kick right in the center of the speaker grille. The Dyna analysis includes nonlinearities of

materials and a dynamic behavior. The final report considers plastic strain values that are

under a certain safety factor of deformation. Analyze also how much displacement does the

honeycomb pattern has under the impact.

- Door Trim Side Impact using LSTC Explicit Dyna Solver: Analyze 12 critical points of lateral

impact to provide information about how the structure supports the impact to protect thorax,

pelvis and belt line. This is a nonlinear dynamic analysis that provides output of displacement

and reaction force of the components while being impacted. The report contains deflection of

the components to know which part of the door trim absorbs more deformation and locate a

possible penetration with the passenger.

- Insertion/exertion ergo evaluation using LSTC Explicit Dyna Solver: This analysis considers

locating a virtual Dyna transducer card to measure the reaction force of an attachment being

subjected to different loads in its vehicle position. Normally you report the attachments th at

are supporting more to know if there could be relocation or an elimination/optimization of

heat stakes, ribs etc.

- Normal/Abusive Loading analysis using MSC Nastran: The purpose of this analysis is to

provide information about stresses and strains of different door trim components under static

loading conditions.

GENERAL MOTORS – Door Trim Body Interior Design Engineer May / 2012 – Dec/2012 (7 months)

Design and failure analysis: DRBFM/FMEA

Math Data Release

Packaging Studies on design execution sections

Design of sections and 3D modeling based on manufacturing process executions

Interaction and teamwork with Design Studio

Door Trim Bolster surface design

Education

Bachelor of Science (B.S.) Mechanical Engineering, Tecnológico de Monterrey Campus Toluca,

San Antonio Buenavista, México

Master of Science in Finance (MSF), Tecnológico de Monterrey EGADE Business School, Santa

Fe, México (scheduled completion 2016)

Languages: English-Advanced (TOEFL 585)

Software

Altair HyperWorks (HyperMesh, HyperView)

Beta CAE Systems (ANSA )

Nastran / Optistruct (Linear /Nonlinear)

Abaqus

LS-DYNA

N CODE Design Life

Siemens NX 7.5 (Unigraphics)

Catia V5 (Dassault Systems)

Courses

ANSYS FLUENT INTRODUCTION: training week at ANSYS facilities in San Jose CA

MSC NASTRAN: online training week with MSC Instructors

NX7.5 Journeyman: General Motors facilities (6 months)

CATIA V5 Surface design: PD Ford Motor Company facilities (4 months)

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