1000+ Design Engineer Interview Questions and Answers

Buoyancy in a balloon is not affected by the car taking a turn due to the principle of relative motion.

• Buoyancy is a force exerted by a fluid that opposes the weight of an immersed object.

• The balloon and the air inside it are both moving with the car, so the buoyant force remains constant.

• The buoyant force is determined by the displaced fluid, not the motion of the object.

• Therefore, the balloon will continue to float in the same manner regardless of the car's movement.

Mechanical properties of materials include strength, stiffness, toughness, hardness, ductility, and elasticity.

• Strength: Ability to withstand applied force without failure (e.g. tensile strength, compressive strength)

• Stiffness: Resistance to deformation under load (e.g. Young's modulus)

• Toughness: Ability to absorb energy and deform plastically before fracturing (e.g. impact toughness)

• Hardness: Resistance to indentation or scratching (e.g. Rockwell hardness)

• Ductility: Ability ...read more

Various pneumatic equipments were used in the previous organisation including air compressors, pneumatic cylinders, pneumatic valves, and pneumatic actuators.

• Air compressors were used to generate compressed air for various applications.

• Pneumatic cylinders were utilized for linear motion in different machinery.

• Pneumatic valves controlled the flow of compressed air in the system.

• Pneumatic actuators were employed for converting energy into mechanical motion.

To design a hopper, inputs required are material properties, flow rate, hopper geometry, and discharge method.

• Determine the material properties such as bulk density, particle size, and flowability.

• Calculate the required hopper geometry based on the material properties and desired flow rate.

• Choose a suitable discharge method such as gravity, vibration, or pneumatic.

• Consider factors such as material bridging, segregation, and dust control.

• Prototype and test the hopper design to...read more

Isometric view and parametric view have different advantages and disadvantages.

• Isometric view provides a 3D representation of an object, making it easier to visualize and understand.

• Parametric view allows for easy modification of dimensions and parameters, saving time and effort.

• Isometric view can be misleading in terms of proportions and distances.

• Parametric view can be complex and difficult to set up initially.

• Isometric view is commonly used in engineering and architecture....read more

Chassis is the framework of a vehicle on which the body and components are mounted.

• Components mounted on chassis include engine, transmission, suspension, steering system, and wheels.

• Bottom top approach refers to designing the chassis from the bottom up, starting with the foundation and building upwards.

• My role in the current company involves designing and optimizing chassis structures for various vehicles.

Annotations, PMI & GD&T are tools used in engineering to communicate design and manufacturing requirements.

• Annotations are notes or labels added to a drawing to provide additional information.

• PMI (Product Manufacturing Information) includes dimensions, tolerances, materials, and other specifications needed for manufacturing.

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

• GD&T uses symbols like concentricity, flat...read more

Benchmarking is the process of comparing one's business processes and performance metrics to industry bests or best practices from other companies.

• Benchmarking helps identify areas for improvement and opportunities for innovation.

• It involves analyzing data and metrics to understand how well a company is performing compared to others in the industry.

• Master section refers to a standardized set of criteria or best practices that serve as a benchmark for comparison.

• For example, a...read more

GD&T stands for Geometric Dimensioning and Tolerancing. It is a system for defining and communicating engineering tolerances.

• GD&T is used to specify the allowable variations in form, size, and orientation of part features.

• It helps ensure that parts fit together properly and function as intended.

• GD&T uses symbols, such as position, concentricity, and flatness, to communicate tolerance requirements.

• It is commonly used in industries such as automotive, aerospace, and manufacturi...read more

Various methods are used for making BIW (Body in White) including hydroforming, stamping, welding, and bonding.

• Hydroforming: shaping metal using fluid pressure

• Stamping: pressing metal into a desired shape

• Welding: joining metal pieces together using heat

• Bonding: using adhesives to attach metal components

CHS stands for Circular Hollow Section, a type of steel tube used in construction and engineering.

• CHS is commonly used in the construction of buildings, bridges, and other structures.

• It is known for its strength and durability.

• CHS is often used in applications where weight is a concern, as it is lighter than solid steel.

• It is available in a range of sizes and thicknesses to suit different applications.

• CHS can be used in both compression and tension applications.

A sheet metal component needs to be designed using CAD software for testing purposes.

• Understand the specifications and requirements of the component

• Choose the appropriate sheet metal material and thickness

• Create a 2D sketch of the component

• Use sheet metal tools to add bends, flanges, and other features

• Add necessary cutouts and holes

• Check for interference and collisions

• Export the design in the required file format

Simulation is the imitation of a real-world process or system, while modeling is the creation of a simplified representation of a system.

• Simulation involves running a model to observe its behavior in different scenarios.

• Modeling involves creating a simplified representation of a system or process.

• Simulation is used to predict the behavior of a system under different conditions.

• Modeling is used to understand the behavior of a system and make predictions about its future behavi...read more

I have used ASME B31.1 and B31.3 codes in my previous organization.

• ASME B31.1 for Power Piping

• ASME B31.3 for Process Piping

• Used for design and construction of piping systems

• Ensured compliance with safety standards

• Reviewed and interpreted code requirements

Types of commercially available solar modules include monocrystalline, polycrystalline, thin-film, and bifacial.

• Monocrystalline solar modules have high efficiency and sleek appearance.

• Polycrystalline solar modules are cost-effective but slightly less efficient than monocrystalline.

• Thin-film solar modules are lightweight and flexible, suitable for curved surfaces.

• Bifacial solar modules can capture sunlight from both sides, increasing energy production.

Various methods such as injection molding, blow molding, extrusion, and rotational molding are used in plastic manufacturing.

• Injection molding: molten plastic is injected into a mold to create a part

• Blow molding: air pressure is used to expand molten plastic into a mold

• Extrusion: plastic is melted and forced through a die to create a continuous profile

• Rotational molding: powdered plastic is rotated in a mold until it coats the entire surface

Kaplan turbines are used for low head because they are designed to operate efficiently in low head conditions.

• Kaplan turbines have adjustable blades that allow for optimal performance in low head situations

• They have a higher specific speed compared to other turbine types, making them suitable for low head applications

• Examples of low head applications include run-of-river hydroelectric plants and irrigation systems

A3 paper sheet size is 297 x 420 mm.

• A3 paper size is commonly used for drawings, diagrams, and posters.

• It is part of the ISO 216 standard paper sizes.

• The dimensions of A3 paper are 297 x 420 mm or 11.7 x 16.5 inches.

PFMEA focuses on potential failures in the manufacturing process, while DFMEA focuses on potential failures in the design process.

• PFMEA stands for Process Failure Mode and Effects Analysis, while DFMEA stands for Design Failure Mode and Effects Analysis.

• PFMEA is used to identify and prioritize potential failure modes in the manufacturing process, while DFMEA is used to identify and prioritize potential failure modes in the design process.

• PFMEA helps in improving the manufactu...read more

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

Minimum reinforcement for RCC columns, beams, slabs is specified in codes and depends on various factors.

• Minimum reinforcement is specified in codes such as IS 456 for Indian standards and ACI 318 for American standards.

• The minimum reinforcement depends on factors such as the size of the member, the type of loading, and the exposure conditions.

• For example, the minimum reinforcement for a column may be 0.8% of the cross-sectional area for mild exposure conditions.

• Similarly, th...read more

I am proficient in using SolidWorks, AutoCAD, and SketchUp for designing.

• Proficient in SolidWorks for 3D modeling and simulation

• Skilled in AutoCAD for 2D drafting and detailing

• Experienced in SketchUp for architectural and interior design

• Familiar with Adobe Creative Suite for graphic design

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

Balancing procedure for rotating equipment involves identifying unbalance, measuring vibration, and adding or removing weight to achieve balance.

• Identify unbalance by measuring vibration

• Determine the amount and location of unbalance

• Add or remove weight to achieve balance

• Repeat the process until vibration is within acceptable limits

• Use balancing equipment such as a balancing machine or portable balancer

• Examples include balancing of fans, turbines, and rotors

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

Analyze servo motors in Ansys using appropriate simulation techniques

• Identify the type of servo motor and its specifications

• Create a 3D model of the motor in Ansys

• Apply appropriate boundary conditions and loads

• Run simulations to analyze the motor's performance

• Evaluate results and make necessary design changes

• Repeat simulations until desired performance is achieved

To design a swimming diving board, I will consider the material, dimensions, weight capacity, and safety features.

• Choose a durable and non-slip material like fiberglass or aluminum

• Determine the appropriate length, width, and thickness based on the intended use and user demographics

• Calculate the weight capacity and ensure it can support the maximum weight of a user

• Incorporate safety features like a non-slip surface, rounded edges, and a secure mounting system

• Consider the heigh...read more

Rubber component design requires consideration of material properties, application requirements, and manufacturing processes.

• Identify the application requirements and environmental conditions

• Select appropriate rubber material based on properties such as hardness, elasticity, and chemical resistance

• Design for manufacturability, considering factors such as mold design and tooling

• Consider post-processing requirements such as curing and finishing

• Perform testing and validation to ...read more

Answering questions related to stress and strain, drawing, and Solidworks commands.

• Stress is the force per unit area applied to a material, while strain is the deformation caused by stress.

• First angle and third angle projection are two methods of representing a 3D object in 2D drawings.

• Drawing is the process of creating a visual representation of an object or idea.

• Solidworks is a computer-aided design software used for creating 3D models and drawings.

• Examples of Solidworks co...read more

VFD stands for Variable Frequency Drive. It is a power electronic product used to control the speed of an AC motor by varying the frequency and voltage supplied to the motor.

• VFDs are commonly used in industrial applications to control the speed of pumps, fans, compressors, and other motor-driven equipment.

• They work by converting fixed frequency AC power to variable frequency AC power using semiconductor devices such as insulated gate bipolar transistors (IGBTs).

• VFDs provide e...read more

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

• Core subjects: mechanical engineering

• Software: AutoCAD, SolidWorks

Yes, I am able to perform robot maintenance tasks such as greasing and mechanical equipment replacement.

• I have experience in performing routine maintenance tasks on robots, including greasing moving parts to ensure smooth operation.

• I am skilled in identifying and replacing worn-out mechanical components to prevent breakdowns and ensure optimal performance.

• I am familiar with following maintenance schedules and procedures to keep robots in good working condition.

• I have successf...read more

Materials used for plates, pipes, flanges, and fittings vary depending on the application and requirements.

• Plates: commonly made from steel, aluminum, stainless steel, or composite materials

• Pipes: materials include steel, copper, PVC, and stainless steel

• Flanges: typically made from carbon steel, stainless steel, or alloy steel

• Fittings: materials range from brass, copper, PVC, to stainless steel

The minimum thickness required for bending materials depends on the material type, bending method, and equipment used.

• Minimum thickness is influenced by material type - softer materials can be bent at thinner thicknesses compared to harder materials.

• Bending method plays a role - air bending requires thicker materials compared to bottoming or coining.

• Equipment used also affects minimum thickness - higher tonnage machines can bend thicker materials with ease.

• Generally, a rule o...read more

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

Renloyds number is a dimensionless number used in fluid mechanics to characterize the flow of a fluid over a surface.

• Renloyds number is defined as the ratio of inertial forces to viscous forces in a fluid flow.

• It is used to determine the type of flow (laminar or turbulent) that occurs over a surface.

• Renloyds number is calculated using the formula: Re = (ρ * V * L) / μ, where ρ is the density of the fluid, V is the velocity of the fluid, L is a characteristic length, and μ is ...read more

Yes, AutoCAD is a widely used software for creating 2D and 3D designs in various industries.

• AutoCAD is used for creating precise technical drawings and models.

• It is commonly used in architecture, engineering, and construction industries.

• Users can create detailed floor plans, blueprints, and 3D models using AutoCAD.

• The software allows for accurate measurements, annotations, and layering of designs.

• AutoCAD files can be easily shared and edited by multiple users.

• Proficiency in A...read more

Plastic wall thickness is decided based on factors like material properties, part geometry, and manufacturing process.

• Consider material properties such as strength, flexibility, and cost

• Evaluate part geometry to ensure structural integrity and proper function

• Take into account the manufacturing process to determine moldability and cost-effectiveness

Draw a sheet metal design in Creo and draft it according to given input sheet.

• Open Creo and create a new part file

• Use the sheet metal module to create the design

• Add bends, flanges, and other features as required

• Create a drawing of the design using the given input sheet

• Add dimensions, annotations, and other necessary details

• Ensure the design meets all required specifications

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

There are several types of welding including MIG, TIG, Stick, Flux-Cored, and Submerged Arc Welding.

• MIG (Metal Inert Gas) welding uses a wire electrode and a shielding gas to join two metal pieces together.

• TIG (Tungsten Inert Gas) welding uses a tungsten electrode and a shielding gas to create a precise and clean weld.

• Stick welding uses a consumable electrode coated in flux to create a strong bond between two metal pieces.

• Flux-Cored welding uses a wire electrode with a flux c...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

Design exor, nand and d latch using 2:1 mux and frequency divide by 3 circuit

• For exor using 2:1 mux, connect one input to select line and other to output of nand gate using 2:1 mux

• For nand using 2:1 mux, connect one input to select line and other to inverted output of and gate using 2:1 mux

• For d latch using 2:1 mux, connect data input to select line and connect inverted output to one input and output to other input

• For frequency divide by 3 circuit, use two d flip flops and an...read more

K factor and bend allowance are important factors in sheet metal bending.

• K factor is a ratio that determines the location of the neutral axis in relation to the thickness of the material.

• Bend allowance is the amount of material that is required to make a bend.

• K factor and bend allowance are used to calculate the length of material needed for a bend.

• K factor and bend allowance vary depending on the material being used and the type of bend being made.

• K factor and bend allowance...read more

I have extensive experience with designing and implementing gauges, fixtures, and Single Purpose Machines (SPM) in various engineering projects.

• Designed and developed gauges for precision measurement in automotive industry

• Created fixtures for holding and positioning components during manufacturing processes

• Engineered Single Purpose Machines (SPM) for specific manufacturing tasks such as welding or assembly

• Utilized CAD software to design and simulate the functionality of gauge...read more

Shut off angle in molding refers to the angle at which the mold halves meet and close to form a complete part.

• Shut off angle is crucial for ensuring proper part ejection and preventing flash formation.

• It is typically between 0.5 to 3 degrees, depending on the material and part design.

• A larger shut off angle may be required for parts with deep cavities or complex geometries.

• Improper shut off angle can lead to part defects like flash or incomplete filling of the mold.