1500+ Design Engineer Interview Questions and Answers

Using petrol in diesel engine and diesel in petrol engine can cause serious damage to the engine.

• Petrol in diesel engine can cause knocking, damage to fuel pump and injectors, and clog the fuel filter.

• Diesel in petrol engine can cause incomplete combustion, damage to spark plugs and catalytic converter, and clog the fuel system.

• It is important to always use the correct fuel for the engine to avoid costly repairs and potential safety hazards.

Operations like bending, folding, and crimping can increase the strength of sheet metal without changing its thickness.

• Bending: This process involves bending the sheet metal along a straight line to increase its strength.

• Folding: Folding the sheet metal creates multiple layers, increasing its strength.

• Crimping: Crimping involves creating small indentations or folds in the sheet metal to increase its rigidity.

• Rolling: Rolling the sheet metal can also increase its strength by c...read more

Lathe is used for cylindrical workpieces while milling machine is used for flat or irregularly shaped workpieces.

• Lathe rotates the workpiece while the cutting tool remains stationary, while milling machine rotates the cutting tool while the workpiece remains stationary.

• Lathe is used for turning, drilling, and boring operations, while milling machine is used for cutting, drilling, and shaping operations.

• Lathe is ideal for creating cylindrical shapes such as shafts, while milli...read more

Design considerations for a part

• Functionality and purpose of the part

• Material selection based on properties and manufacturing process

• Cost-effectiveness and feasibility of production

• Ease of assembly and maintenance

• Environmental impact and sustainability

• Compliance with regulations and standards

• Aesthetics and user experience

Considerations for selecting engineering materials, calculating sheer strength of a metal bar, and explaining project work.

• Consider factors like strength, durability, cost, and availability when selecting materials for specific applications.

• Calculate sheer strength of a round cross section metal bar using the formula: Sheer Strength = (0.5 * Ultimate Tensile Strength)

• In project work, explain the objectives, methodology, results, and any challenges faced.

Snap fits are used in plastics to join two parts together without the need for additional fasteners.

• Cantilever snap fit

• Annular snap fit

• Torsion snap fit

• Snap hinge

• Snap bead

• Snap tab

• Snap lock

• Snap latch

• Snap hook

Negative slip in reciprocating pump occurs when the pump runs faster than the synchronous speed of the motor.

• Negative slip occurs when the pump runs faster than the synchronous speed of the motor.

• This can happen if the pump is not properly matched to the motor or if there is a mechanical issue causing the pump to run faster.

• Negative slip can lead to decreased efficiency and potential damage to the pump.

To prevent plastic defects, design engineers use methods such as mold flow analysis, material selection, gate design optimization, and part geometry considerations.

• Perform mold flow analysis to identify potential issues before production.

• Select the appropriate plastic material based on the requirements of the part.

• Optimize gate design to ensure proper filling and packing of the mold.

• Consider part geometry to minimize stress concentrations and improve overall quality.

• Use desig...read more

A fuse is an electrical safety device that protects electrical circuits from overloading and short circuits. Its maximum rating depends on the application.

• A fuse contains a metal wire or filament that melts when the current exceeds a certain level, breaking the circuit and preventing damage to the equipment or wiring.

• Fuses are rated based on their current-carrying capacity and voltage rating.

• Examples of fuse ratings include 1A, 5A, 10A, 20A, etc.

• Fuses are commonly used in hou...read more

Warpage and sink marks are common defects in plastic parts caused by uneven cooling. Prevention methods include proper gate design, cooling system optimization, and material selection.

• Warpage is the deformation of a plastic part due to uneven cooling, leading to dimensional inaccuracies.

• Sink marks are depressions on the surface of a plastic part caused by uneven cooling and shrinkage.

• Prevention methods include proper gate design to ensure uniform filling, optimization of cool...read more

Tolerance is the allowable variation in a dimension or property of a product or component.

• Tolerance ensures that a product or component will function properly and fit with other parts

• It helps to control the manufacturing process and reduce costs

• Tolerance can be specified for dimensions, materials, and other properties

• Examples include the tolerance for the diameter of a shaft or the hardness of a metal

• Tolerance can be expressed as a range or a specific value

ASME B31.3, ASME B31.1, API 650, API 620 are some of the piping codes used in designing a chemical plant.

• ASME B31.3 is used for process piping

• ASME B31.1 is used for power piping

• API 650 is used for storage tanks

• API 620 is used for low-pressure storage tanks

• Other codes like ASTM, ANSI, and ISO may also be used depending on the specific requirements of the project

Yes, my skills and experience can contribute to increasing company revenue.

• I have a proven track record of improving revenue in my previous roles.

• I can bring innovative ideas and solutions to the table.

• I am a team player and can collaborate with others to achieve revenue goals.

• I am constantly learning and adapting to new technologies and market trends.

• For example, in my previous job, I implemented a new marketing strategy that increased revenue by 20% in the first quarter.

Yes, I have design knowledge in both Solidworks and Autocad software.

• I have extensive experience using Solidworks and Autocad for designing various mechanical components and systems.

• I am proficient in creating 3D models, assemblies, and detailed drawings using both software.

• I have successfully completed multiple design projects using Solidworks and Autocad, meeting all the required specifications and standards.

• I am familiar with the advanced features and tools in both softwar...read more

Creo environment has various modules for different design tasks.

• Creo Parametric for 3D modeling

• Creo Simulate for simulation and analysis

• Creo Illustrate for technical illustrations

• Creo Schematics for creating electrical schematics

• Creo View for viewing and sharing CAD files

• Creo Direct for direct modeling

• Creo Layout for 2D layout design

• Creo Options Modeler for managing design configurations

To solve manufacturing problems and correlate design, it is important to analyze root causes, communicate effectively with cross-functional teams, and iterate on design improvements.

• Identify the root cause of the manufacturing problem by analyzing data and conducting tests.

• Communicate effectively with cross-functional teams including manufacturing, quality, and design engineers to understand the impact of the problem on the design.

• Iterate on design improvements based on feedb...read more

Factors to consider when designing components for sheet metal and plastic

• Material selection based on properties and application requirements

• Design for manufacturability to ensure ease of production and cost-effectiveness

• Consideration of material thickness and bending radius for sheet metal components

• Wall thickness, draft angles, and rib design for plastic components

• Integration of features like fastening methods, mounting points, and assembly considerations

• Evaluation of enviro...read more

To solve short mold defects in injection molding, adjust injection speed, pressure, temperature, and cooling time.

• Adjust injection speed to ensure proper filling of the mold cavity.

• Increase injection pressure to prevent short shots.

• Optimize melt temperature to improve flow and reduce defects.

• Extend cooling time to allow the plastic to solidify properly.

• Check for any obstructions or blockages in the mold.

• Ensure proper venting to prevent air traps.

• Use mold flow analysis softwar...read more

Low beam light provides short-range visibility without blinding oncoming drivers, while high beam light provides long-range visibility but can blind others.

• Low beam light is angled downwards to illuminate the road directly in front of the vehicle.

• High beam light is angled upwards to illuminate a longer distance ahead of the vehicle.

• Low beam light is used in normal driving conditions to avoid blinding oncoming drivers.

• High beam light is used in dark, unlit areas or when there ...read more

I work as a Design Engineer using CAD software like SolidWorks and AutoCAD.

• I am responsible for creating and designing products or components using CAD software.

• I collaborate with other engineers and stakeholders to ensure designs meet requirements.

• I have experience with SolidWorks, AutoCAD, and possibly other CAD software depending on the project.

• I am proficient in creating 2D drawings and 3D models for manufacturing and prototyping.

• I also have knowledge of GD&T and engineer...read more

The tonnage of molding machine required to fill a 200gm piece depends on the material being used and the design of the piece.

• Calculate the volume of the 200gm piece to determine the amount of material needed.

• Consider the material properties and flow characteristics to determine the appropriate tonnage of the molding machine.

• Methods such as injection molding or compression molding can be used depending on the design and material of the piece.

Rib thickness in plastic components is important for strength and stiffness. Ribs are used to improve structural integrity and reduce warping.

• Rib thickness affects the strength and stiffness of the plastic component

• Ribs are used to improve structural integrity and reduce warping in plastic components

• Proper rib thickness can prevent sink marks and improve mold filling during injection molding

• Rib thickness should be optimized based on the specific design requirements and materi...read more

I used commands like offset, copy, move, match properties, and hatching in AutoCAD to recreate the drawing.

• I used the offset command to create parallel lines at a specified distance from the original lines.

• I used the copy command to duplicate objects in the drawing.

• I used the move command to relocate objects to a different location.

• I used the match properties command to apply the properties of one object to another.

• I used the hatching command to fill in enclosed areas with a ...read more

Flow transmitter senses flow and transmits signal to controller in selected range.

• Use a flow transmitter that is capable of sensing flow and transmitting a signal.

• Connect the flow transmitter to the controller using appropriate wiring and communication protocols.

• Configure the flow transmitter to operate within the desired range.

• Ensure proper calibration of the flow transmitter to accurately measure and transmit flow data.

• Implement suitable signal conditioning techniques to en...read more

Design tools include CAD software, 3D printers, prototyping equipment, and simulation software.

• CAD software such as SolidWorks, AutoCAD, and CATIA are used for creating 2D and 3D designs

• 3D printers are used for rapid prototyping and creating physical models

• Prototyping equipment such as CNC machines and laser cutters are used for creating functional prototypes

• Simulation software such as ANSYS and COMSOL are used for testing and analyzing designs

• Other tools include hand sketchi...read more

Plastic tolerance requirements vary depending on the specific part and its function.

• Plastic tolerance is typically specified in the design phase based on factors like material properties, part function, and assembly requirements.

• Tighter tolerances are often needed for parts that require precise fits or interfaces.

• Looser tolerances may be acceptable for parts that do not have critical dimensions or functional requirements.

• Examples include injection molded parts for consumer el...read more

Sheet metal thickness is decided based on factors like material type, part geometry, function, and cost.

• Consider material type and its properties (e.g. strength, ductility)

• Analyze part geometry and required structural integrity

• Evaluate function of the part and potential stresses it will endure

• Factor in cost implications of different thickness options

• Consult industry standards and guidelines for recommended thickness ranges