Design Engineer - HD eAxle Gears, PS Rbhp

Job Description

Job Summary

Design engineer for HD eAxle Gears.

Roles and Responsibilities

• Conceptual and Detailed Design:

• Design and develop new gear systems (spur, helical, bevel, planetary) from concept through to production-ready detailed drawings.
• Perform gear geometry calculations, tooth profile optimization, and strength analysis to meet performance, life, and reliability targets.
• Create 3D models and 2D manufacturing drawings with full GD&T (Geometric Dimensioning and Tolerancing) specifications.

• Analysis and Validation:

• Conduct gear design calculations for bending strength (Lewis equation, AGMA standards), surface durability (pitting resistance), scuffing, and efficiency.
• Perform tolerance stack-up analysis for gear assemblies.
• Support prototype testing, analyze test results, and implement design modifications based on findings.
• Perform root cause analysis for gear failures (e.g., pitting, spalling, tooth breakage) and propose corrective design actions.

• Collaboration and Support:

• Work closely with cross-functional teams including Systems Engineering, Manufacturing, Quality, and Procurement.
• Provide technical support to manufacturing teams during production, troubleshooting gear-related issues.
• Collaborate with suppliers on gear manufacturing processes (hobbing, shaping, grinding, shaving) and material selection.
• Create and maintain design documentation, including design reports, calculations, and Bill of Materials (BOM).

• Standards and Continuous Improvement:

• Ensure all designs comply with relevant industry standards (e.g., AGMA, ISO, DIN).
• Participate in design reviews (DFMEA, DRBFM) and contribute to continuous improvement initiatives for gear design processes and tools.

Qualifications

• Education:

• Master’s degree in Mechanical Engineering, Automotive Engineering, or a related field.

• Technical Skills:

• Proficiency in Creo software for 3D modeling and drafting.
• Strong knowledge of gear theory, design principles, and manufacturing processes.
• Experience with gear design and analysis software (e.g., KISSsoft, ROMAX, MASTA, or similar).
• Solid understanding of engineering materials, heat treatment processes, and metallurgy related to gears.

• Soft Skills:

• Strong analytical and problem-solving skills (e.g. 8D).
• Excellent communication and teamwork abilities.
• Good logic and presentation ability. 

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