70+ 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

Atmospheric pressure refers to the force exerted by the weight of the air in the Earth's atmosphere.

• Atmospheric pressure is the pressure exerted by the weight of the air above a given point on the Earth's surface.

• It is caused by the gravitational attraction of the Earth on the air molecules.

• At sea level, the average atmospheric pressure is about 1013.25 millibars or 14.7 pounds per square inch (psi).

• As you go higher in the atmosphere, the air becomes less dense and the atmosp...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

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

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

Plastic material grades commonly used in automotive industry.

• Polypropylene (PP)

• Polyethylene (PE)

• Acrylonitrile Butadiene Styrene (ABS)

• Polyamide (PA)

• Polycarbonate (PC)

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

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.

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

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

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.

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

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

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

CAD and CAM software enhance design and manufacturing efficiency but have limitations in flexibility and cost.

• Increased accuracy: CAD software allows for precise designs, reducing errors in the manufacturing process.

• Time-saving: CAM automates machining processes, significantly speeding up production times.

• Enhanced collaboration: CAD files can be easily shared among team members, facilitating better communication.

• Cost efficiency: Reduces material waste through optimized design...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

Accepting a 27 month service agreement with 14 in hand and 2.2 lpa, including Saturday working for one year.

• Consider the overall compensation package including salary and benefits

• Evaluate the long-term career growth opportunities with the company

• Assess the impact of Saturday working on work-life balance

• Negotiate for potential changes in the terms if necessary

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