Aptiv Senior R&D Engineer Interview Questions, Process, and Tips

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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. What is the relay
Ans. 
A relay is an electrically operated switch that uses an electromagnet to mechanically operate a switch.
• Relays are used to control high power circuits with low power signals

• They are commonly used in automotive, industrial, and household applications

• Relays can be classified based on their operation, such as electromechanical relays or solid-state relays
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Q2. Ohm's law and current
Ans. 
Ohm's law states that the current flowing through a conductor is directly proportional to the voltage across it, given constant resistance.
• Ohm's law equation: V = I * R (voltage = current * resistance)

• Current is the flow of electric charge through a conductor

• Higher voltage leads to higher current flow, given constant resistance

• Lower resistance leads to higher current flow, given constant voltage
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Q1. Explain various GD&T
Ans. 
Geometric Dimensioning and Tolerancing (GD&T) is a system for defining and communicating engineering tolerances.
• GD&T is used to specify the allowable variations in form, size, and orientation of features on a part.

• It uses symbols, such as concentricity, flatness, and perpendicularity, to communicate the desired tolerances.

• GD&T helps ensure that parts fit together properly and function as intended.

• Examples of GD&T symbo...read more
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Q2. Explain DFM, DFS, DFA
Ans. 
DFM, DFS, and DFA stand for Design for Manufacturing, Design for Service, and Design for Assembly, respectively.
• DFM focuses on designing products that are easy and cost-effective to manufacture.

• DFS focuses on designing products that are easy to service and maintain.

• DFA focuses on designing products that are easy to assemble.

• Consideration of DFM, DFS, and DFA principles can lead to more efficient and cost-effective prod...read more
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Q1. Few questions about SFD and BMD
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Tough one to attempt

Q1. Asked questions related to few mechanical engineering topics
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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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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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