50+ CAE Engineer Interview Questions and Answers

The material with lower Young's modulus will deflect more.

• Young's modulus determines the stiffness of a material.

• The material with lower Young's modulus will have more deflection under the same force.

• For example, rubber has a lower Young's modulus than steel and will deflect more under the same force.

Density is the measure of mass per unit volume. Weight can be calculated using density and volume.

• Density is calculated by dividing the mass of an object by its volume.

• Weight can be calculated using the formula: weight = density x volume x gravity

• Gravity is a constant value of 9.81 m/s^2 on Earth.

• For example, the weight of a 1 cubic meter block of iron with a density of 7.87 g/cm^3 would be 77,910 N.

Stiffness varies with material, geometry, and loading conditions.

• Stiffness is the ability of a material to resist deformation under load.

• Materials with higher Young's modulus have higher stiffness.

• Stiffness also depends on the geometry of the structure.

• For example, a thicker beam will be stiffer than a thinner beam.

• Loading conditions such as the magnitude and direction of the load also affect stiffness.

• For instance, a beam will be stiffer when loaded in compression than in be...read more

Frequency is the number of vibrations per unit of time, while vibration is the oscillation or movement back and forth of an object.

• Frequency refers to the rate at which an object vibrates or oscillates.

• Vibration is the physical movement or oscillation of an object.

• Frequency is measured in hertz (Hz), while vibration is measured in amplitude or displacement.

• Frequency can be constant or varying, while vibration can have different patterns and amplitudes.

• For example, a guitar st...read more

Mechanical vibration refers to the oscillation or movement of an object or structure due to an applied force or disturbance.

• Mechanical vibration is the back-and-forth motion of an object or structure.

• It occurs when an external force or disturbance is applied to the object.

• Vibration can be caused by various factors such as machinery, engines, earthquakes, or even human activities.

• It can have both beneficial and detrimental effects depending on the context.

• Examples of mechanica...read more

Answers to questions related to CAE engineering including stress, bending moment, quality criteria in FEA, tet collapse, test correlation, FEA modelling process, and types of elements in Nastran and Dyna.

• Stress is the force per unit area that a material experiences when subjected to an external load.

• Bending moment is the moment that causes a beam to bend.

• Quality criteria in FEA include accuracy, convergence, and stability.

• Tet collapse is a phenomenon where tetrahedral element...read more

Stress is the force per unit area, Poisson's ratio is the ratio of lateral to axial strain, and endurance limit is the maximum stress a material can withstand without breaking after a certain number of cycles.

• Stress is the measure of the internal forces acting within a material, which can cause deformation or failure.

• Poisson's ratio is a measure of a material's ability to deform in response to an applied force, and is defined as the ratio of lateral strain to axial strain.

• End...read more

Stress-strain curve of elastic materials shows relationship between applied stress and resulting strain.

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

• Elastic materials return to their original shape after stress is removed within the linear region.

• Yield point marks the transition from elastic to plastic deformation.

• Plastic deformation is permanent and leads to structural changes in the material.

• Ultimate failure o...read more

Quality criteria for 2D and 3D meshing include element shape, aspect ratio, skewness, and element size.

• Element shape should be close to regular shapes like triangles or quadrilaterals for 2D meshing and tetrahedra or hexahedra for 3D meshing.

• Aspect ratio should be close to 1 for both 2D and 3D meshing to avoid distorted elements.

• Skewness should be minimized to ensure better accuracy in simulation results.

• Element size should be appropriate for capturing the geometry details an...read more

Various types of transmission systems used in two-wheelers include manual, automatic, semi-automatic, and CVT.

• Manual transmission: Requires the rider to manually shift gears using a clutch and gear lever.

• Automatic transmission: Shifts gears automatically without the need for manual intervention.

• Semi-automatic transmission: Allows the rider to manually shift gears without using a clutch.

• CVT (Continuously Variable Transmission): Offers seamless gear ratio changes for smooth acc...read more

Common materials used in electric scooters include aluminum, steel, plastic, and rubber.

• Aluminum: Lightweight and durable, commonly used for scooter frames and components.

• Steel: Provides strength and stability, often used in structural parts like handlebars and forks.

• Plastic: Used for body panels, covers, and other non-structural components.

• Rubber: Found in tires, grips, and suspension components for traction and vibration dampening.

I have worked on various components including engine blocks, suspension systems, and body structures.

• Designed and analyzed engine blocks for durability and performance

• Optimized suspension systems for ride comfort and handling

• Performed crash simulations on body structures to ensure safety

• Conducted thermal analysis on exhaust systems to prevent overheating

• Collaborated with cross-functional teams to integrate components into vehicle designs

Young's modulus of steel is around 200 GPa.

• Young's modulus is a measure of the stiffness of a material.

• It is defined as the ratio of stress to strain within the elastic limit.

• Steel has a high Young's modulus, making it a strong and rigid material.

• The value of Young's modulus for steel can vary depending on the specific type and grade of steel.

• For example, the Young's modulus of mild steel is around 200 GPa, while for high-strength steel it can be up to 300 GPa.

Ductile materials can undergo significant plastic deformation before failure, while brittle materials fail without significant deformation.

• Ductile materials can be stretched into wires or hammered into thin sheets without breaking.

• Brittle materials break with little or no plastic deformation.

• Ductile materials have high toughness and are able to absorb a large amount of energy before fracturing.

• Examples of ductile materials include metals like copper and aluminum.

• Examples of b...read more

Process capability is the ability of a process to produce output within specification limits. PP is for initial process setup and CP is for ongoing process control.

• Process capability is a statistical measure of the ability of a process to produce output within specification limits.

• PP (Process Performance) is used for initial process setup and measures the process's ability to meet specifications.

• CP (Process Capability) is used for ongoing process control and measures the proc...read more

Meshing with quality criteria involves creating a finite element mesh that meets specific requirements.

• Understand the quality criteria and how it affects the simulation results

• Choose appropriate meshing techniques and element types

• Use mesh refinement to improve accuracy in critical areas

• Perform mesh sensitivity analysis to ensure mesh independence

• Validate the mesh with experimental or analytical data

• Optimize the mesh for computational efficiency

Hypermesh tools & shortcuts are used for meshing and pre-processing tasks in CAE. They help in saving time and improving efficiency.

• Use Ctrl + M to open the mesh panel

• Use Ctrl + Shift + M to open the model panel

• Use Ctrl + G to group selected components

• Use Ctrl + Shift + G to ungroup selected components

• Use F12 to toggle between graphics and text view

• Use Ctrl + E to edit the selected component

• Use Ctrl + Shift + E to edit the selected property

• Use Ctrl + D to duplicate the select...read more

Shell meshing is a technique used in Hypermesh to create a mesh of thin-walled structures.

• Shell meshing is used for structures that have a thickness much smaller than their other dimensions.

• It involves creating a mesh of the mid-surface of the structure and then extruding it to create a 3D mesh.

• Shell meshing is commonly used in the aerospace and automotive industries for components such as panels and shells.

• It can help reduce the computational time and memory required for sim...read more

My UG project focused on optimizing airflow in automotive engines using computational fluid dynamics. I used ANSYS Fluent and MATLAB for simulations.

• Studied airflow patterns in automotive engines

• Utilized computational fluid dynamics for simulations

• Optimized engine performance using ANSYS Fluent and MATLAB

I am very comfortable with the software and have extensive experience using it.

• I have been using the software for several years and have mastered its features and capabilities.

• I have completed numerous projects using the software, showcasing my proficiency.

• I regularly attend training sessions and workshops to stay updated on the latest software updates and enhancements.

Pascal's law states that pressure applied to a fluid in a confined space is transmitted equally in all directions.

• Pascal's law is a fundamental principle in fluid mechanics.

• It states that when pressure is applied to a fluid in a closed container, the pressure is transmitted equally in all directions.

• This means that if you apply pressure to one part of a fluid, the entire fluid will experience the same increase in pressure.

• Pascal's law is the basis for many hydraulic systems a...read more

I have a strong understanding of basic concepts in structural mechanics.

• I have a solid foundation in statics and dynamics, including concepts such as equilibrium, forces, moments, and motion.

• I am familiar with stress and strain analysis, including concepts like Hooke's Law and material properties.

• I understand the principles of structural analysis, including methods like finite element analysis (FEA) and boundary conditions.

• I am knowledgeable about structural behavior under di...read more

Elasticity is the ability of a material to return to its original shape after being deformed. Stress and strain curve shows the relationship between stress and strain.

• Elasticity is a property of materials that allows them to return to their original shape after being stretched or compressed.

• Stress is the force applied to a material per unit area, while strain is the resulting deformation of the material.

• The stress-strain curve shows the relationship between stress and strain ...read more

Degree of Freedom refers to the number of independent parameters required to define the position or configuration of a system.

• It is a measure of the number of ways a system can move or change.

• In engineering, it is used to describe the number of independent variables that can be changed to alter the behavior of a system.

• For example, a rigid body in three-dimensional space has six degrees of freedom: three for translation and three for rotation.

• In CAE, degree of freedom is used...read more

Spot welds and bolts can be created in ANSA using various tools and methods.

• For spot welds, use the Spot Weld tool and select the two surfaces to be welded together.

• For bolts, use the Bolt tool and select the two surfaces to be bolted together. Specify the bolt type, size, and other parameters.

• ANSA also provides options to create spot welds and bolts automatically based on predefined rules and criteria.

• Ensure that the spot welds and bolts are placed correctly and in the appro...read more

I have worked on ANSYS, Abaqus, and SolidWorks Simulation. FEA basics include meshing, boundary conditions, and solving equations.

• I have experience with ANSYS, Abaqus, and SolidWorks Simulation

• FEA basics include meshing, boundary conditions, and solving equations

• Meshing involves dividing the model into small elements

• Boundary conditions define how the model interacts with its environment

• Solving equations involves using numerical methods to calculate stresses and strains

The number of modes to extract in modal analysis is typically determined based on the desired accuracy of the analysis and the computational resources available.

• Consider the complexity of the structure being analyzed - more complex structures may require more modes to be extracted

• Take into account the desired accuracy of the analysis - higher accuracy may require more modes to be extracted

• Evaluate the computational resources available - extracting a large number of modes can ...read more

Hypermesh quality criteria and definitions

• Hypermesh quality criteria are used to ensure the accuracy and reliability of finite element models

• Some of the criteria include element quality, mesh density, and mesh size

• Element quality refers to the shape and distortion of individual elements

• Mesh density refers to the number of elements in a given area

• Mesh size refers to the size of individual elements

• Hypermesh also provides tools for checking and improving mesh quality

RBE2 and RBE3 are different types of rigid elements used in finite element analysis.

• RBE2 connects multiple grid points to a single reference grid point with rigid bars or beams.

• RBE3 connects multiple grid points to a single reference grid point with independent springs or dampers.

• RBE2 is suitable for transferring loads in a single direction, while RBE3 allows for more flexibility in load transfer.

• RBE3 is more computationally expensive than RBE2 due to the additional degrees o...read more

Stress is the force applied to a material, while strain is the resulting deformation or change in shape of the material.

• Stress is a measure of the internal forces within a material that resist deformation.

• Strain is the measure of the amount of deformation or change in shape that occurs in a material when subjected to stress.

• Stress and strain are related through the material's elastic modulus, which describes its stiffness.

• Stress is typically measured in units of force per uni...read more

Types of stresses for design calculation include tensile, compressive, shear, bending, and torsional stresses.

• Tensile stress: Occurs when a component is pulled apart, stretching it.

• Compressive stress: Occurs when a component is pushed together, compressing it.

• Shear stress: Results from forces applied parallel to the surface, causing one part of the material to slide past another.

• Bending stress: Arises when a component is subjected to bending moments, causing tension on one si...read more

Yes, I am flexible to learn new tools.

• I am always open to learning new tools and technologies in the CAE field.

• I believe that staying updated with the latest tools can enhance my skills and productivity.

• I have previously learned and adapted to various CAE tools such as ANSYS, Abaqus, and HyperMesh.

• I am confident in my ability to quickly grasp new tools and utilize them effectively in my work.

Fatigue analysis of weld is performed by applying cyclic loading to the weld and analyzing stress concentrations.

• Apply cyclic loading to the weld to simulate real-world conditions

• Analyze stress concentrations at critical points using finite element analysis

• Calculate fatigue life based on stress levels and material properties

• Consider factors such as weld geometry, residual stresses, and material defects

• Use standards like BS 7608 or API 579 for guidance

Finite Element Analysis (FEA) is a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects.

• FEA is a numerical method used to solve complex engineering problems

• It involves dividing a complex structure into smaller, simpler parts called finite elements

• Each element is analyzed for its behavior under different conditions and the results are combined to predict the overall behavior of the structure

• FEA is...read more

FEA stands for Finite Element Analysis, a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects.

• FEA is a numerical technique used to analyze the behavior of structures or components under various conditions.

• It divides a complex structure into smaller, simpler parts called finite elements to simulate the behavior of the entire structure.

• FEA is commonly used in engineering fields such as mechanical,...read more

CAE stands for Computer-Aided Engineering. It is the use of computer software to simulate performance and optimize designs before physical prototypes are built.

• CAE involves using computer software to analyze and simulate the performance of engineering designs.

• It helps in optimizing designs, reducing the need for physical prototypes and testing.

• Common applications of CAE include structural analysis, fluid dynamics simulations, and thermal analysis.

• CAE tools are used in various...read more

I have a strong understanding of HyperWorks and have used it extensively in my previous projects.

• I have experience using HyperMesh for meshing and pre-processing

• I am proficient in running simulations using OptiStruct and Radioss solvers

• I have utilized HyperView for post-processing and result visualization

• I have worked on optimization studies using HyperStudy

• I am familiar with HyperWorks' capabilities in structural, thermal, and fluid analysis

A 3D element typically has 6 degrees of freedom.

• A 3D element has 3 translational degrees of freedom (displacement along x, y, and z axes)

• A 3D element also has 3 rotational degrees of freedom (rotation about x, y, and z axes)

• Examples include tetrahedral, hexahedral, and pyramid elements

Finite Element Method is a numerical technique used to solve complex engineering problems by dividing them into smaller, simpler parts.

• It involves dividing a complex structure into smaller elements and analyzing each element separately.

• The behavior of each element is described using mathematical equations.

• The equations are then combined to create a system of equations that describes the behavior of the entire structure.

• This method is widely used in engineering fields such as ...read more

Stress is the internal force per unit area, while pressure is the external force per unit area.

• Stress is a measure of the internal force experienced by a material, while pressure is a measure of the external force applied to a material.

• Stress is a vector quantity, while pressure is a scalar quantity.

• Stress is measured in units of force per unit area, while pressure is measured in units of force per unit area.

• Examples of stress include tensile stress, compressive stress, and s...read more

Stress is the force applied to a material, while strain is the resulting deformation or change in shape.

• Stress is measured in units of force per unit area, such as Pascals or pounds per square inch.

• Strain is a dimensionless quantity representing the amount of deformation compared to the original size of the material.

• Stress and strain are related by the material's modulus of elasticity, which describes how much a material will deform under a given amount of stress.

• For example,...read more

Tolerances refer to the allowable deviation from a specified dimension or value.

• Geometric tolerance: specifies the allowable deviation in form, orientation, location, and runout of a feature

• Dimensional tolerance: specifies the allowable deviation in size or distance

• Surface texture tolerance: specifies the allowable deviation in surface roughness or waviness

• Material property tolerance: specifies the allowable deviation in material properties such as hardness or strength

• Functio...read more

To validate a CAE model, various methods can be used such as comparing simulation results with experimental data, conducting sensitivity analyses, and performing model correlation.

• Compare simulation results with experimental data to ensure accuracy

• Conduct sensitivity analyses to assess the impact of input parameters on the model

• Perform model correlation by comparing predicted behavior with real-world observations

• Validate against known benchmarks or established standards

• Use st...read more

Material stress strain diagram shows the relationship between stress and strain in a material.

• Shows how a material deforms under stress

• Helps in determining material properties like yield strength and modulus of elasticity

• Can be used to predict material behavior under different loading conditions