Fainger Leser Valves Mechanical Design and Development Engineer Interview Questions and Answers

Interviewer asked to create a case study on the current project and mention all the technologies involved

Q1. Implement Immutable class
Ans. 
Immutable class is a class whose state cannot be modified after creation.
• Use final keyword to make class immutable

• Make all fields private and final

• Do not provide setter methods

• If mutable objects are used, return a copy instead of original object
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Q2. Solid principles, questions followed by each principle with good and bad examples
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Q1. Introduce Yourself? What software/work you do, biref about it? Windchill CCN & ECN ? How to revise DRAWING AND BOM In Windchill? How and when to do CCN & ECN ?
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Aptitude test is of 60 minutes with 20 question

Q1. What are the types of manufacturing process
Ans. 
Manufacturing processes include casting, forging, machining, welding, and more.
• Casting: pouring molten metal into a mold to create a solid object

• Forging: shaping metal by heating and hammering

• Machining: using tools to remove material from a workpiece

• Welding: joining two pieces of metal by melting them together

• Additive manufacturing: building up layers of material to create a 3D object

• Forming: shaping metal without remo...read more
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Q2. What is broaching and surface finish
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Broaching is a machining process that uses a toothed tool to remove material. Surface finish refers to the texture of a machined surface.
• Broaching is a process of removing material using a broach tool with teeth that gradually increase in size.

• Surface finish is the texture of a machined surface, which can be measured in terms of roughness or smoothness.

• Surface finish can be improved by using different cutting tools, ad...read more
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Q3. Draw single point cutting tool and it's angle
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A single point cutting tool is a tool used in machining to remove material from a workpiece. It has a pointed end and various angles.
• The tool has a pointed end that is used to cut the material.

• The angle of the tool is important for achieving the desired cut.

• The angle of the tool is measured in relation to the workpiece.

• Common angles for single point cutting tools include 60 degrees, 75 degrees, and 90 degrees.

• The angle...read more
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Q4. Where do we require surface finish
Ans. 
Surface finish is required in various applications for improved functionality and aesthetics.
• Surface finish is important in manufacturing to improve the performance and durability of products.

• In automotive industry, surface finish is required for improved aerodynamics and fuel efficiency.

• In medical devices, surface finish is crucial for preventing bacterial growth and ensuring biocompatibility.

• Surface finish is also im...read more
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Q5. What is maximum shear stress theory
Ans. 
Maximum shear stress theory is a theory used to determine the failure of materials under shear stress.
• Also known as Tresca's theory or Guest's theory

• States that failure occurs when the maximum shear stress in a material exceeds a certain value

• Used in designing materials for ductile failure

• Not applicable for brittle materials

• Formula: τmax = (σ1 - σ2) / 2

• Where σ1 and σ2 are the principal stresses
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Q6. What is factor of safety and why we use it
Ans. 
Factor of safety is a measure of how much stronger a structure is than it needs to be for its intended purpose.
• Factor of safety is the ratio of the maximum load a structure can handle to the actual load it is expected to handle.

• It is used to ensure that a structure or component can withstand unexpected loads or stresses.

• For example, a bridge may have a factor of safety of 2, meaning it can handle twice the maximum expe...read more
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Q7. Draw stress strain diagram of MS, Cast iron
Ans. 
Stress-strain diagrams of MS and cast iron.
• Mild Steel: linear elastic up to yield point, plastic deformation after that, ultimate strength at fracture point.

• Cast Iron: brittle material, low ductility, low yield strength, high compressive strength.

• MS has higher tensile strength than cast iron.

• MS has higher elongation at break than cast iron.
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Q8. Which theory of failure is suitable for ductile and which is for brittle
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The theory of failure suitable for ductile materials is the Von Mises criterion, and for brittle materials, it is the Maximum Principal Stress theory.
• Ductile materials undergo plastic deformation before failure, so the Von Mises criterion, which considers the yield strength of the material, is suitable.

• Brittle materials fail suddenly without any plastic deformation, so the Maximum Principal Stress theory, which conside...read more
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Q1. Technical question about our field?
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Q2. Ex: which insert used for threading?
Ans. 
There are various inserts used for threading depending on the material being threaded and the type of thread required.
• The most common inserts are carbide inserts, ceramic inserts, and high-speed steel inserts.

• Carbide inserts are suitable for threading hard materials like stainless steel and titanium.

• Ceramic inserts are used for high-speed threading of aluminum and other non-ferrous materials.

• High-speed steel inserts ar...read more
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Q1. Tell me about yourself?
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Q2. Based on our experience questions
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Q1. Why are you change your current job?
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Q2. What is your salary expectation?
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Q1. 1)Pressure Rating Standards 2) Stress strain,iron carbon diagrams 3) carbon percentage in all metals
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Q1. Questions related to core mechanical engg
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Q2. Product related questions
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Q1. Thumb rules for sheet metal design
Ans. 
Thumb rules for sheet metal design include minimum bend radius, hole spacing, and material thickness considerations.
• Minimum bend radius should be at least equal to the material thickness to avoid cracking

• Hole spacing should be at least 2 times the material thickness to prevent distortion

• Material thickness should be chosen based on the application and required strength

• Avoid sharp corners to reduce stress concentrations

• U...read more
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Overall or general review

Steam engineering knowledge on steam products

Q1. What is steam engineering
Ans. 
Steam engineering involves the design, operation, and maintenance of systems that utilize steam for various industrial applications.
• Involves designing steam systems for power generation, heating, and industrial processes

• Requires knowledge of thermodynamics, fluid mechanics, and heat transfer

• Includes maintenance of boilers, steam turbines, and piping systems

• Examples: steam power plants, steam heating systems in building
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