100+ Design Engineer Interview Questions and Answers for Freshers

Design Engineer interview questions covering topics like design, GD&T, joints, standards, failure, material properties, vernier caliper, boiler, Bernoulli theorem, Pascal law, welding.

• Design is the process of creating a solution to a problem or need.

• GD&T (Geometric Dimensioning and Tolerancing) is a system for defining and communicating engineering tolerances.

• Joints are connections between two or more parts, types include welded, bolted, and riveted joints.

• Standards commonly ...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

The volume of a septic tank for a residential building typically ranges from 750 to 1,250 gallons.

• The volume of a septic tank is determined based on the number of bedrooms in the residential building.

• A general rule of thumb is to allocate 250-300 gallons per bedroom.

• For example, a 3-bedroom house would require a septic tank with a volume of 750-900 gallons.

• Factors such as soil type, water usage, and local regulations also impact the tank size.

Logic gates are fundamental building blocks of digital circuits that perform logical operations based on input signals.

• Logic gates are electronic components that take one or more binary inputs and produce a single binary output based on a specific logic function.

• Common types of logic gates include AND, OR, NOT, NAND, NOR, XOR, and XNOR gates.

• Logic gates are used in various electronic devices such as computers, calculators, and digital clocks to perform arithmetic and logical ...read more

The volume of a septic tank can be calculated by multiplying the length, width, and depth of the tank.

• Calculate the length, width, and depth of the septic tank in feet or meters.

• Multiply the length, width, and depth together to get the volume in cubic feet or cubic meters.

• For example, if the septic tank is 10 feet long, 5 feet wide, and 6 feet deep, the volume would be 10 x 5 x 6 = 300 cubic feet.

I know and have worked with several design software. I am highly efficient in using them.

• I am proficient in using AutoCAD, SolidWorks, SketchUp, and Adobe Creative Suite

• I have completed several projects using these software with high accuracy and efficiency

• I am always eager to learn and explore new design software to enhance my skills

I have used various measuring devices such as calipers, micrometers, height gauges, and dial indicators.

• Calipers for measuring length and thickness

• Micrometers for measuring small distances and thicknesses

• Height gauges for measuring heights and depths

• Dial indicators for measuring small distances and deflections

ECU ground, also known as earthing, is the connection of the electronic control unit to the vehicle's chassis to provide a reference point for electrical circuits.

• ECU ground is essential for proper functioning of electronic systems in a vehicle.

• It helps to prevent electrical interference and ensures stable operation of the ECU.

• The ground connection is typically made using a wire or a metal strap between the ECU and the chassis.

• Proper grounding is crucial for safety and perfor...read more

Micrometre screw gauge least count is the smallest measurement that can be read on the gauge.

• Micrometre screw gauge is used to measure small distances with high accuracy.

• The least count of a micrometre screw gauge is typically 0.01 mm or 0.001 mm.

• To measure an object, the spindle is turned until it touches the object and the reading is taken from the thimble and sleeve scales.

• For example, if the thimble scale reads 5 and the sleeve scale reads 0.5 mm, the measurement is 5.5 m...read more

To draw bending moment and shear force of a standard portal frame, one needs to analyze the frame's geometry and loading conditions.

• Identify the geometry of the portal frame

• Determine the loading conditions on the frame

• Calculate the reactions at the supports

• Draw the shear force and bending moment diagrams

• Label the diagrams with values and units

I admire core subjects like mechanical engineering and software like AutoCAD and SolidWorks.

• Core subjects: mechanical engineering

• Software: AutoCAD, SolidWorks

Answering questions related to engineering concepts such as tolerance and fits, types of interference, lathe operations, rotary to linear motion, formulas, GD&T, dimensions, sheet format, model trees, and density of materials.

• Tolerance refers to the allowable variation in a dimension or measurement

• Fits refer to the degree of tightness or looseness between two mating parts

• Types of interference include press fit, shrink fit, and force fit

• Lathe operations include turning, facing...read more

Failure theories are used to predict the failure of materials under different loading conditions.

• Theories include maximum shear stress theory, maximum normal stress theory, and maximum strain energy theory

• Maximum shear stress theory states that failure occurs when the maximum shear stress in a material exceeds the shear strength of the material

• Maximum normal stress theory states that failure occurs when the maximum normal stress in a material exceeds the tensile or compressiv...read more

Entropy is a measure of disorder or randomness in a system.

• Entropy increases with time in a closed system

• A messy room has higher entropy than a clean room

• Melting of ice is an example of increase in entropy

• Burning of wood is another example of increase in entropy

Various commands are used for modeling and drawing in software.

• For modeling: extrude, revolve, sweep, loft, fillet, chamfer, boolean operations

• For drawing: line, circle, arc, rectangle, polygon, dimensioning, text

• Software-specific commands: SketchUp - push/pull, Fusion 360 - timeline, SolidWorks - feature manager

• Keyboard shortcuts can also be used to speed up the modeling and drawing process

I am proficient in using Solid Edge software for designing and engineering tasks.

• I have extensive experience using Solid Edge software for creating 3D models and assemblies.

• I am skilled in utilizing features such as parametric modeling, simulation, and rendering in Solid Edge.

• I have successfully completed projects using Solid Edge for product design and development.

• I am familiar with advanced tools and functionalities in Solid Edge for efficient design processes.

Valves are made of materials that can withstand high pressure, temperature, and corrosive environments.

• Materials used in valves include stainless steel, brass, bronze, and plastic.

• Stainless steel is commonly used due to its strength, durability, and resistance to corrosion.

• Brass and bronze are used for their excellent thermal conductivity and resistance to corrosion.

• Plastic valves are used in applications where chemical resistance and low cost are important.

• Other materials ma...read more

Tyre pressure is less in front and more in rear wheel in bikes for better handling, stability, and traction.

• Better handling: Lower pressure in front tire allows for easier steering and maneuverability.

• Stability: Higher pressure in rear tire helps distribute weight evenly and maintain stability during acceleration and braking.

• Traction: Higher pressure in rear tire increases the contact patch with the road, improving traction for better grip.

• Example: In sports bikes, front tire...read more

Heat load calculation can be done using Excel sheet E-20

• Open Excel sheet E-20

• Enter the relevant data such as room dimensions, insulation, and equipment

• Use formulas to calculate the heat load

• Consider factors such as solar gain and occupancy

• Review and adjust calculations as necessary

Preparation for safety includes risk assessment, safety training, use of personal protective equipment, and emergency response planning.

• Conducting a thorough risk assessment to identify potential hazards

• Providing safety training to all employees on proper procedures and protocols

• Ensuring the use of personal protective equipment such as helmets, gloves, and safety goggles

• Developing an emergency response plan and conducting regular drills to ensure preparedness

• Regularly reviewi...read more

The least count of micrometer, vernier calipers, and height gauge varies depending on their precision.

• Micrometer least count ranges from 0.001mm to 0.0001mm

• Vernier calipers least count ranges from 0.02mm to 0.05mm

• Height gauge least count ranges from 0.02mm to 0.05mm

• Least count is the smallest measurement that can be read on the device

• The precision of the device determines the least count

The rho value for different conic sections varies depending on the shape of the section.

• Circle: rho = r (radius)

• Ellipse: rho = a * b / sqrt(a^2 * sin^2(theta) + b^2 * cos^2(theta))

• Parabola: rho = 2p / (1 + cos(theta))

• Hyperbola: rho = sqrt(a^2 + b^2)

I use tools like Altium Designer and Eagle for schematic design. These tools offer advanced features and a user-friendly interface.

• Altium Designer and Eagle are popular tools for schematic design in the industry.

• These tools offer advanced features such as real-time design synchronization, interactive routing, and 3D visualization.

• Altium Designer and Eagle have user-friendly interfaces that make it easier to create complex schematics and PCB layouts.

• They also provide extensive...read more

If nozzle repad reinforcement is inadequate, consider redesigning the repad or increasing the thickness of the shell.

• Evaluate the loads and stresses on the repad and shell

• Consider increasing the thickness of the shell

• Redesign the repad to increase its strength

• Consult with a qualified engineer for further analysis

• Consider alternative materials or fabrication methods

The difference between == and === is that == compares the values of two variables, while === compares both the values and the data types.

• The == operator performs type coercion, meaning it converts the operands to a common type before comparison.

• The === operator does not perform type coercion and requires both the values and the data types to be the same for a true comparison.

• For example, 1 == '1' returns true because the operands are coerced to the same type (number), but 1 =...read more

Vernier caliper least count is the smallest measurement that can be read on the scale of a vernier caliper.

• It is the difference between the smallest division on the main scale and the smallest division on the vernier scale.

• For example, if the main scale has a smallest division of 1 mm and the vernier scale has a smallest division of 0.05 mm, then the least count is 0.95 mm.

• It determines the accuracy of the measurement taken with the vernier caliper.

• The smaller the least count...read more

AutoCAD is a computer-aided design software used for creating 2D and 3D designs.

• Line - creates a straight line between two points

• Circle - creates a circle with a specified radius

• Rectangle - creates a rectangle with specified dimensions

• Trim - removes parts of a line or object that intersect with another object

• Mirror - creates a mirrored copy of an object

Engineering Drawing is a graphical representation of an object or structure used to communicate design and manufacturing information.

• Engineering Drawing is a visual representation of an object or structure.

• It includes detailed information about dimensions, materials, and manufacturing processes.

• It serves as a communication tool between designers, engineers, and manufacturers.

• Engineering drawings can be 2D or 3D and may include various views, sections, and annotations.

• Examples...read more

CG, Moment of Inertia, and Bending Moment can be calculated using mathematical formulas and physical measurements.

• CG can be calculated by finding the weighted average of the individual CGs of each component in a system.

• Moment of Inertia can be calculated using the formula I = mr^2, where m is the mass and r is the distance from the axis of rotation.

• Bending Moment can be calculated using the formula M = F*d, where F is the force applied and d is the distance from the point of ...read more

Shell thickness calculation involves considering factors like material properties, pressure, and temperature.

• Shell thickness calculation involves determining the minimum thickness required to withstand the pressure and temperature of the fluid inside the shell.

• Factors to consider include material properties, pressure, temperature, and corrosion allowance.

• Heat treatment process involves heating and cooling a material to alter its properties, such as increasing its strength or ...read more

To calculate duct manually with help of Ishare, follow these steps:

• Determine the airflow rate required for the space

• Calculate the friction loss in the duct using the Darcy-Weisbach equation

• Select the appropriate duct size based on the airflow rate and friction loss

• Use Ishare to calculate the pressure drop across the duct

• Adjust the duct size and/or airflow rate as necessary to meet design requirements

Signals interface from electrical to instrument involves various types of connections and protocols.

• Analog signals are commonly used for transmitting data from electrical to instrument

• Digital signals such as RS-232, RS-485, and Ethernet are also used for communication

• Common protocols include Modbus, Profibus, and HART

• Signal conditioning may be required to convert signals between electrical and instrument domains

Trim is a tool used to remove excess material from a part, while quick trim is a feature that allows for faster trimming process.

• Trim is a general term for removing excess material from a part

• Quick trim is a specific feature that allows for faster trimming process

• Quick trim may have predefined settings for faster trimming

Understanding basic strength of materials formula, material properties, and pump operation is essential for a design engineer.

• Strength of materials formula includes stress, strain, and modulus of elasticity

• Material properties include density, thermal conductivity, and coefficient of thermal expansion

• Pump operation involves understanding flow rate, head, and efficiency

First and third angle projection are two methods of representing a 3D object on a 2D surface.

• First angle projection is commonly used in Europe and Asia, while third angle projection is commonly used in North America.

• In first angle projection, the object is placed in front of the viewing plane and the views are drawn as if looking at the object from the front.

• In third angle projection, the object is placed behind the viewing plane and the views are drawn as if looking at the o...read more

1st, 2nd, 3rd, and 4th angle projections are different methods of representing a 3D object on a 2D plane in engineering drawings.

• 1st angle projection: Commonly used in Europe and Asia, where the object is placed in the first quadrant.

• 2nd angle projection: Commonly used in North America, where the object is placed in the fourth quadrant.

• 3rd angle projection: Commonly used in Australia and the UK, where the object is placed in the third quadrant.

• 4th angle projection: Rarely use...read more

Sub-type or specific failure stress for springs can include yield stress, ultimate tensile stress, fatigue stress, etc.

• Different types of springs may have different failure stresses

• Yield stress is the point at which a material begins to deform plastically

• Ultimate tensile stress is the maximum stress a material can withstand before failure

• Fatigue stress is the stress level at which a material fails after repeated loading cycles

The dielectric constant for a terminal block depends on the material used for insulation.

• Dielectric constant is a measure of a material's ability to store electrical energy in an electric field.

• Terminal blocks can be made of various materials such as ceramic, plastic, or bakelite, each with different dielectric constants.

• The dielectric constant affects the capacitance of the terminal block, which in turn affects its electrical performance.

• The dielectric constant can be measur...read more

Skills in mechanical domain include CAD software proficiency, knowledge of materials and manufacturing processes, problem-solving abilities, and project management skills.

• Proficiency in CAD software such as SolidWorks or AutoCAD

• Knowledge of materials and their properties

• Understanding of manufacturing processes like machining and injection molding

• Strong problem-solving abilities to troubleshoot design issues

• Project management skills to oversee design projects from concept to c...read more

To calculate forces of a cylinder, use the formula F = P x A. To calculate load cell capacity, consider the maximum weight it will measure.

• Forces of a cylinder can be calculated using the formula F = P x A, where F is the force, P is the pressure, and A is the area of the cylinder.

• Load cell capacity depends on the maximum weight it will measure. Choose a load cell with a capacity slightly higher than the maximum weight to be measured.

• Consider the type of load cell needed for ...read more

Rubber vulcanization is a chemical process that converts natural rubber or related polymers into more durable materials.

• Vulcanization involves heating rubber with sulfur and other additives to improve its strength, elasticity, and resistance to heat and chemicals.

• The process can be carried out in a variety of ways, including compression molding, injection molding, and extrusion.

• Vulcanized rubber is used in a wide range of products, from tires and hoses to shoe soles and elect...read more

Tolerance is the allowable variation in a dimension or measurement. Least count is the smallest measurement that can be read by an instrument.

• Tolerance is the difference between the maximum and minimum limits of a dimension or measurement.

• It is important in manufacturing to ensure that parts fit together properly.

• Least count is the smallest measurement that can be read by an instrument, and is determined by the instrument's precision.

• For example, a ruler with a least count of...read more

I use a variety of software depending on the project requirements and client preferences.

• For 3D modeling, I use SolidWorks and Autodesk Inventor.

• For rendering and visualization, I use KeyShot and Blender.

• For PCB design, I use Altium Designer and Eagle CAD.

• For programming and simulation, I use MATLAB and Simulink.

• I am also proficient in Adobe Creative Suite for graphic design and branding.

K-factor in sheet metal design is a constant representing the ratio of the location of the neutral axis to the material thickness.

• K-factor helps determine how much a sheet metal part will stretch during bending.

• It is used in calculating the bend allowance, bend deduction, and other parameters in sheet metal bending.

• Different materials and bending processes have different K-factors.

• Typical K-factor values range from 0.3 to 0.5, but can vary based on material and tooling.

• Unders...read more

GD&T symbols are geometric dimensioning and tolerancing symbols used to define and communicate engineering tolerances.

• GD&T symbols are used to specify the allowable variation in form, orientation, and location of features on a part.

• They are commonly used in engineering drawings and blueprints.

• Examples of GD&T symbols include concentricity, perpendicularity, and position.

• GD&T symbols help ensure that parts are manufactured to the correct specifications and fit together properl...read more

Yes, I am proficient in both SolidWorks and AutoCAD.

• I have used SolidWorks extensively for 3D modeling and design of mechanical parts and assemblies.

• I am also skilled in AutoCAD for 2D drafting and design.

• I have experience in creating detailed drawings, schematics, and blueprints using both software.

• I am comfortable with both software's user interface and can work efficiently to meet project deadlines.

Valves are mechanical devices that control the flow of fluids or gases by opening, closing, or partially obstructing various passageways.

• Valves are used in various industries such as oil and gas, water treatment, pharmaceuticals, and more.

• They can be operated manually or automatically.

• Valves can regulate the flow rate, pressure, temperature, and direction of fluids or gases.

• Examples of valves include ball valves, gate valves, globe valves, and check valves.