Co-op II
Stephen
Experience Information
Employer: Shape
Job Title: CAE Analyst
Major: Mechanical Engineering
Received Credit: Yes
Paid: Yes
Abroad: No
Description of the Organization
Shape Corporation mainly serves the automotive industry. They are well known for manufacturing car bumper assemblies and other energy management systems for low-speed impacts. They also make energy absorbers for pedestrian protection. Shape was founded in Grand Haven, MI, and has expanded throughout the U.S. and into Mexico, Europe, and Asia.
Description of the Tasks/Projects Completed
I worked as a CAE analyst. I did FEA analyses of the crash tests we perform in the tech center. When we crash a vehicle into a wall, we simulate the same crash in the computer and compare results. We heavily rely on FEA in the design process to improve our designs. My main projects were simulating two manufacturing processes: (i) stretch-bending aluminum extruded beams and (ii) sweeping roll formed steel beams. Both of these simulations were created to evaluate manufacturing feasibility.
Skills/Knowledge Gained Through The Experience
I learned how to use HyperWorks software and LS-Dyna solver. These are the tools Shape (and many other companies) use to do FEA. I gained a lot of skill in applying strain gages and collecting strain gage data. I gained knowledge in the processes of stretch-bending, roll forming, sweeping, and other metal forming processes. I now know a lot more about aluminum and AHSS (advanced high strength steels) materials. Also, I learned how beneficial FEA can be in the design process because it saves a lot of time and money.
Favorite Part of the Experience
My favorite part of this co-op was modeling some of the manufacturing processes used at Shape. I enjoyed the challenge of creating an FE model to simulate a complex process. I had to evaluate the actual process carefully to know how to accurately constrain my model. I also enjoyed working and problem-solving with other engineers. There were times when I would communicate with people in the U.S., India, Japan, and Europe all in the same work day.
How the Experience Influenced Future Career Goals
I think that Shape would be a great place to work long-term.