Aptiv Senior Design Engineer Interview Questions and Answers

Q1. What are factore that affecting the NVH
Ans. 
Factors affecting NVH include vehicle design, materials used, engine type, and road conditions.
• Vehicle design: Shape, size, weight distribution

• Materials used: Quality of materials, insulation

• Engine type: Number of cylinders, power output

• Road conditions: Smoothness, tire type
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Q2. Noise, Vibration, and Harshness (NVH) in gearboxes are influenced by several factors, which can broadly be categorized into design, material, manufacturing, and operational factors. Here are some key facto...read more
Ans. 
Addressing NVH in gearboxes involves optimizing design, material, manufacturing, and operational factors.
• Optimizing gear geometry like tooth profile and helix angle can reduce noise.

• Proper material quality and heat treatment can minimize vibrations.

• Precision machining and assembly quality are crucial for reducing NVH.

• Consider load conditions, lubrication, and operational speed for NVH control.

• Environmental factors like...read more
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Q1. Design and calculations
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Q1. Experience details and salary discussion
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Q1. Plastic fundamentals, connector design theory, Focused around the CV.
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Q1. CAD test for connector in Soidworks or CATIA
Ans. 
Yes, a CAD test for connector in Solidworks or CATIA can be conducted.
• Create a 3D model of the connector using Solidworks or CATIA

• Ensure the model meets the required specifications and tolerances

• Test the model for functionality and durability

• Make necessary modifications based on test results

• Repeat the testing process until the model meets all requirements
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Q1. Personal interview was taken. CV again focused . HR questions were also asked.
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Q1. Company knowledge
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Q2. CV or resume related questions
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Q1. CNC programming knowledge
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Q2. Material & milling tool knowledge
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Q1. Previous experiences discussion
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Q2. Salary & HR formalities
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First round is aptitude test all type of questions asked like verbal, reasoning and Technical

Q1. Explain stress, strain curve diagram with example?
Ans. 
Stress-strain curve shows relationship between stress and strain in a material under tension.
• Stress-strain curve is a graphical representation of how a material deforms under stress.

• It typically consists of a linear elastic region, a yield point, plastic deformation, and ultimate failure.

• Example: Steel has a high yield strength, so its stress-strain curve shows a steep initial slope.

• Example: Rubber has a low yield stre...read more
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Q2. What is DOF? How many degrees of freedom from any object
Ans. 
DOF stands for Degrees of Freedom. It refers to the number of independent parameters that define the configuration of an object.
• DOF is the number of ways a rigid body can move in 3D space.

• For a rigid body in 3D space, there are 6 degrees of freedom - 3 translational and 3 rotational.

• Examples of DOF include linear motion along x, y, z axes and rotational motion around x, y, z axes.
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Q1. Explain Free body Diagram ?
Ans. 
Free body diagram is a visual representation of all the forces acting on an object in a given situation.
• It shows all the forces acting on an object as vectors, with arrows indicating the direction and magnitude of each force.

• The object of interest is represented as a point or a simple shape, with all external forces acting on it shown around it.

• Internal forces within the object are not shown on a free body diagram.

• Free...read more
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Q2. What is the working principle of a brake system ?
Ans. 
A brake system works by converting kinetic energy into heat energy through friction to slow down or stop a vehicle.
• Brake pedal is pressed by the driver

• Brake fluid is compressed in the master cylinder

• Pressure is transmitted through brake lines to the brake calipers or wheel cylinders

• Brake pads or shoes press against the brake rotor or drum to create friction and slow down the vehicle
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Q1. What is Stack up tolerance ?
Ans. 
Stack up tolerance refers to the accumulation of tolerances in a series of components or parts that are assembled together.
• Stack up tolerance is important in ensuring that all components fit together properly in an assembly.

• It involves considering the individual tolerances of each component and how they may add up or cancel out when assembled.

• For example, if a shaft has a tolerance of +/- 0.1mm and a hole has a toleran...read more
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Q2. What is the difference between cylindricity and roundness in GD&T ?
Ans. 
Cylindricity refers to the overall 3D form of a cylinder, while roundness refers to the deviation of a circle from a perfect circle.
• Cylindricity is a 3D tolerance that controls the overall form of a cylinder, ensuring that all points on the surface lie within a specified tolerance zone.

• Roundness is a 2D tolerance that controls the deviation of a circle from a perfect circle, ensuring that the entire circle lies within ...read more
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Q1. Create 3d model for the given engineering drawing ?
Ans. 
To create a 3D model from an engineering drawing, use CAD software to accurately replicate the dimensions and features.
• Use CAD software such as AutoCAD, SolidWorks, or Fusion 360 to create the 3D model.

• Refer to the engineering drawing for dimensions, angles, and features to accurately replicate in the 3D model.

• Utilize tools within the CAD software to create extrusions, cuts, fillets, and other features as needed.

• Check ...read more
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Q2. Do drafting for the given 3d model ?
Ans. 
Yes, I can create detailed 2D drawings based on the 3D model provided.
• Create orthographic views (top, front, side) of the 3D model

• Include dimensions, annotations, and tolerances in the drawings

• Generate section views to show internal features

• Add surface finish symbols and notes as needed
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