CAE Engineer

Thomas A. Buchler Email: ***********@*******.***

**** ****** **** **********@*****.***

Grand Blanc, MI 48439 Cell: 248-***-****

U.S. Citizen Home: 810-***-****

OBJECTIVE

I wish to earn a position where I can utilize my skills in CAE, CAD, and product development as

well as my knowledge in mechanical engineering to their fullest potential.

1 SYNOPSIS OF QUALIFICATIONS

• 15+ years experience in Structural Engineering and FEA with an emphasis in the automobile

industry. Experienced in Durability (Fatigue), NVH, Impact (Crash/Safety), and Optimization

Analysis.

• Capable of evaluating BIW, Closures, Interiors, Exteriors, and Chassis systems.

• Very proficient in using Hypermesh, NASTRAN, LSDYNA, ABAQUS and Optistruct.

• Expert in many Federal Motor Vehicle Safety Standards and OEM Structural Criteria.

• Involved with the Product Developmental Process on numerous projects in that I provided

structural enhancing, weight and cost effective solutions to design problems.

• Capable Team Player and Leader in determining customer expectations, developing analysis

plans, coordinating model construction and analysis, and presenting design countermeasures.

2 WORK EXPERIENCE

July 2012 to Senior CAE Engineer, Magna Vehma International

Present Troy, MI

Experience and Skills

• Magna Steyr merged with Magna Vehma in July of 2012.

• Performed block cycle durability, static stiffness, abuse loads analyses (Nastran, Abaqus,

and nCode Solvers) on chassis components that Magna supplies for major OEMs.

• Coordinated and built computer models of full vehicles as well as subsytems.

• Performed linear static full vehicle global and local suspension attachment point stiffness,

modal, and durability analysis on a multi-material lightweight C/D segment vehicle study and

Sports Utility Truck for two different OEM’s.

• Performed modal analysis on full vehicle structures.

• Performed and set up Modal Transient Response Durability analyses (Nastran and nCode

solvers) on sheet metal and spotwelds for the same lightweight C/D segment and Sports Utility

Truck. Also learned how to perform root cause analysis to determine the reason why a spotweld

might be below target.

• Performed and set up Linear Static Durability (Nastran) and Non-Linear Abuse Cases

(Abaqus) for an Integrated Trailer Hitch on the Sports Utility Truck.

• Wrote and proposed several CAE procedures based off of physical testing specifications for

the tailgate for the Sports Utility Truck.

• Gave design direction and structural solutions so the designs met customer engineering

targets.

Oct 2010 to Senior CAE Engineer, MagnaSteyr LLC

July 2012 Troy, MI

Experience and Skills

• Under the guidance of a lead engineer, I helped to set up and run crash analysis for Front,

Side, Rear, Roof Crush load cases using LSDYNA on a high end sports car for a major OEM.

• Ran and performed linear static Global and Modal Analysis on the above mentioned sports

car.

• Ran Modal Transient Response for spotweld durability (Nastran and nCode) on large CUV

for a major OEM.

• On-Site experience at OEM: Ran Modal Transient Response on sheet metal and seam weld

durability (Nastran and nCode) on front subframe, rear twist axles, and engine component

frame subsystems on an Electric Vehicle program for a major OEM. Also performed linear

static stiffness, stress, and modal analysis on engine component frame subsystems. Ran bolt

slippage analysis (Abaqus) on critical joints on the front subframe. Presented engineering

solutions to potential design issues that are in production today.

Nov 2007 to Senior Project Engineer, Engineering Technology Associates, Inc.

October 2010 Troy, MI

Experience and Skills

• On-Site experience at OEM: Worked on site at customer facility in the Research and

Development Group from March to October 2010. Performed drum drop, payload, mounting

hook, oil can dentability analysis on a pick up boxes subsystems. Also performed linear static,

fatigue, and some optimization analyses on BIW, chassis subsystems for an alternative material

and ground breaking design on a full size truck.

• On-Site experience at customer facility: Worked on-site at MagnaSteyr from October 2009

to March 2010. Under guidance of a Lead Engineer, performed crash simulation (front, side,

rear and roof crush analyses) using LSDYNA. My main focus was to perform BIW static and

modal analysis using LSDYNA-Explicit software on a light weight vehicle study for a

European steel supplier. Customer has used the results from the project to promote their

products.

• While in-house at ETA, I was a lead/senior durability CAE engineer on non-automotive

projects for two School Bus Manufacturers. Set up linear static loading and analysis (Nastran)

techniques for less experienced engineers.

• Gave design direction to CAD designers for a redesign of a davenport / rear structure for

the school bus project and shock mount area for a Chinese OEM.

• Performed shape optimization on front longitudinal rail using Optistruct software for a

leading Steel Association. Also developed new methodology of performing topology

optimization using Inertia Relief on a full vehicle taking into consideration several different

engineering load cases such as Global Bending & Torsion, Front, Side, Rear Impact analysis

using Genesis Optimization Software.

• Worked to establish organizational & analysis procedures to improve overall efficiency of

Engineering Services Group.

May 2006 to Senior Design Analyst, Benteler Automotive

Nov 2007 Auburn Hills, MI

Experience and Skills

• Worked on Front and Rear Cradle subsystems. Performed Fatigue (nCode), Stress, Static

Stiffness and NVH Analysis (Nastran) on various smaller chassis components that Benteler

supplies for various OEM’s.

• Performed weight, shape, and weld optimization using Optistruct on Front Cradle system.

Took the results from the optimization and gave design direction to product development team

to improve product performance. This subsequently reduced start-up costs by $1 Million for the

front cradle.

November 2005 Structural Engineer Consultant

to July 2006 Independent Consultant

Grand Blanc, MI

Experience and Skills

• Worked for the CARLAB, Inc. located in Orange County, CA. Telecommuted over the

Internet to perform job responsibilities.

• Performed global bending & torsional stiffness and modal analysis on a space frame for a

low production street legal race car. Gave design direction and performed design studies to

achieve optimum performance.

• Established vehicle structural targets for CARLAB group.

• Created BOM for CARLAB group.

June 2004 to Senior Project Engineer, MSX International, Inc.

November 2005 Auburn Hills, Michigan

Experience and Skills

• Performed Front NCAP and ODB, Side, and Rear Impact Analysis on various vehicles.

• On-site experience at OEM: Went on site at a major OEM from Oct 2004 to Dec 2004 to

work on a high performance sports car hood. Saved $0.66 and 1kg of mass per hood because

the original design was over designed.

• From Jan 2005 to Sept 2005, I performed durability; seat safety analysis; mine blast, and

roof crush (SAE J2422) analysis on a military utility vehicle for a non-automotive

manufacturer.

• From Sept 2005 to Nov 2005 went on-site at MagnaSteyr. Did Front End Durability and

Closure analysis on a Brazilian Sports Utility Truck for an OEM.

Oct 2002 to Senior Project Engineer, Hartwick Professionals, Inc.

June 2003 Troy, Michigan

Experience and Skills

• 1 of 2 engineers that supported the Closure Program for a small sports utility vehicle for a

major OEM. The closure program included Front and Rear Doors, Liftgates, and Hoods.

Became proficient at running FMVSS214 Side Impact Door Analysis. I developed an FE

methodology to do door slam fatigue analysis using LSDYNA

• Did structural analyses on Joint and Vehicle Stiffness and Shipping Slot (Semi Tie Down)

Areas. Provided cost and weight effective solution to potential design issue in Shipping Slot

Analysis.

• Expanded knowledge of injection molding, part stamping, welding and vehicle assembly

process.

Feb. 1996 to Project Engineer, Engineering Technology Associates, Inc.

Jan. 2002 Flint, Michigan

Experience and Skills

• From 1996 to 1999, I was stationed at the ETA branch office in Flint, MI. I started to learn

my CAE craft here. I learned proper FEA modeling and vehicle assembly techniques and

analysis software like NASTRAN and LSDYNA. Was a quick learner and began to train new

employees in model and vehicle assembly techniques. I also guided employees in setting up

various analyses and troubleshooting models.

• Coordinated full BIW FEA model creation and assembly for various vehicle programs.

• While in-house at the ETA office, I supported a major OEM by working in the following

projects:

1. Closures- Hoods; Decklids, Decklid Drain Stiffness and Slam analysis; Front and

Rear Doors; Fenders.

2. Body- Chassis to Body Mount Interfaces; Modal Analysis on full BIW and

Various Components; Front and Rear Shock Mounts (Max Pothole Analysis);

Shipping Slots; Car Jacking.

3. Crash- Full BIW Frontal Crash Analysis (NCAPS and 5 to 15 Degree Offsets)

• Later in my stint at this office, I assumed some of the office management responsibilities

and roles. I went over to the customer’s facility (GM) to bid on and receive projects for other

employees when there was a slowdown in project production. I also was in contact with GM

engineers to make sure customer satisfaction was always met.

• On-site experience at OEM: From Early 2000 to Jan 2002, I was placed on site at an OEM

in Flint. Supported the Exterior and Interior Analysis Group. I gained a great deal of experience

by working on the following automotive subsystems such as IP’s, Consoles, Assist Handles,

Coat Hooks, Electronic Modules, Grilles and Fascias, Headlamps and Turn Signals.

• Gave structural enhancing improvements that have been implemented into several vehicles.

• Correlated CAE simulation with real life physical testing. Worked on developing CAE

procedures for the major OEM.

3

4 COMPUTER EXPERIENCE

• Engineering Software- FEMB, VPG, Hyperworks Suite, ANSA, LSPost, NASTRAN, LSDYNA,

ABAQUS, Optistruct, nCode and Ford Fatigue Software

• CAD Software- Basic Skills in Unigraphics (UG), ProE, and CATIA V5.

• Operating Systems- Windows, MAC-OS, DOS, UNIX, LINUX

• PC Programs- MS OfficeSuite

5 EDUCATION

1990 – 1995 Lawrence Technological University

Bachelor of Science in Mechanical Engineering

GPA: 3.22/4.00 Scale

1 References are Available Upon Request

Contact this candidate