BIW Design Engineer Interview Questions and Answers

India follows the Bharat New Vehicle Safety Assessment Program (BNVSAP) for crash testing.

• BNVSAP is based on the United Nations' Global Technical Regulation (GTR) standards.

• It includes frontal, side, and pedestrian protection tests.

• The program is being implemented in phases, with mandatory compliance for all new cars from October 2023.

• Currently, India follows the Bharat Stage (BS) emission standards, which also include some safety regulations.

GD&T provides precise communication of design requirements, while bonus tolerance allows for additional variation beyond basic tolerances.

• GD&T (Geometric Dimensioning and Tolerancing) ensures clear and precise communication of design requirements

• It allows for more detailed control over form, orientation, location, and profile of features

• Bonus tolerance is an additional tolerance that can be applied to a feature beyond the basic tolerance

• It provides flexibility for manufacturi...read more

Various joining techniques are used for BIW parts including welding, adhesive bonding, riveting, and clinching.

• Welding is commonly used for joining metal parts together

• Adhesive bonding is used for joining dissimilar materials

• Riveting is used for joining parts that cannot be welded

• Clinching is used for joining sheet metal parts without additional fasteners

Catia remastering using surfacing is a technique to recreate a 3D model using surface features.

• Catia remastering involves recreating a 3D model from an existing physical part or a 2D drawing.

• Surfacing is a technique used to create complex 3D shapes using multiple surfaces.

• The process involves creating surfaces that match the contours of the original part and then joining them to create a solid model.

• This technique is commonly used in industries such as automotive and aerospac...read more

Spring back effect is the tendency of a material to return to its original shape after being deformed.

• Spring back effect occurs in materials like metals, plastics, and composites.

• It is caused by the release of internal stresses that were introduced during the forming process.

• Factors affecting spring back include material properties, forming process, and tooling design.

• Examples include metal sheets returning to their original shape after being bent and released.

Types of fits include clearance fit, interference fit, and transition fit, each offering different advantages.

• Clearance fit: allows for easy assembly and disassembly, used in applications where relative motion is required (e.g. sliding fits)

• Interference fit: provides a tight connection with no relative movement, used in applications where rigidity is important (e.g. press fits)

• Transition fit: offers a compromise between clearance and interference fits, used in applications wh...read more

I am proficient in CAD softwares such as SolidWorks, AutoCAD, and CATIA.

• Proficient in SolidWorks, AutoCAD, and CATIA

• Experience in creating 3D models and assemblies

• Ability to read and interpret technical drawings

• Familiarity with GD&T and tolerance analysis

• Experience in design for manufacturing and assembly

• Knowledge of FEA and CFD analysis

• Experience in creating detailed BOMs and engineering documentation