1000+ Design Engineer Interview Questions and Answers

Yes, the symbol for position tolerance is a circle with a horizontal line through the middle.

• The symbol for position tolerance is a circle with a horizontal line through the middle

• It is used in engineering drawings to specify the allowable deviation in the location of a feature

• Position tolerance controls the location of a feature relative to a specified datum

A slope is the steepness of a surface while a gradient is the rate of change of a variable.

• Slope refers to the angle of inclination of a surface, while gradient refers to the change in elevation or value of a variable over a distance.

• Slope is measured in degrees or percentage, while gradient is measured in units of the variable per unit of distance.

• For example, the slope of a hill is 30 degrees, while the gradient of the same hill is 10 meters per kilometer.

• Slope is a geometr...read more

Customisation of vehicles in India follows norms set by Automotive Research Association of India (ARAI) and Automotive Component Manufacturers Association of India (ACMA).

• Customisation should adhere to safety regulations set by ARAI.

• Modifications should not violate emission norms set by the government.

• Customisation of vehicles should not compromise the structural integrity of the vehicle.

• Aftermarket modifications should be approved by the manufacturer to maintain warranty.

• Cus...read more

I would implement automation in the design process, streamline communication between teams, and introduce regular design reviews.

• Implement automation tools to speed up the design process

• Establish clear communication channels between design and engineering teams

• Introduce regular design reviews to gather feedback and improve designs

Torque on a bar is directly proportional to its Young's Modulus and the angle of twist.

• The formula is T = (G * J * θ) / L

• T is the torque on the bar

• G is the shear modulus of the material

• J is the polar moment of inertia of the cross-sectional area

• θ is the angle of twist

• L is the length of the bar

• Example: A steel bar with a length of 1 meter and a Young's Modulus of 200 GPa is twisted by 0.1 radians. The torque on the bar is T = (200 * 0.0000785 * 0.1) / 1 = 0.00157 Nm

The discharge will increase when the end of pipe is dropped down in the bucket.

• Dropping the end of pipe in the bucket will increase the head pressure and hence the discharge.

• The height of the water column above the end of the pipe will increase, resulting in higher pressure.

• This is similar to the concept of a siphon, where the height difference between the two ends of the pipe determines the flow rate.

• However, if the end of the pipe is completely submerged in the water, the d...read more

Different sheetmetal manufacturing processes include cutting, bending, forming, and joining.

• Cutting: processes like shearing, laser cutting, and waterjet cutting are used to cut sheetmetal into desired shapes.

• Bending: techniques such as press brake bending and roll forming are used to bend sheetmetal into specific angles.

• Forming: methods like deep drawing and hydroforming are used to shape sheetmetal into complex forms.

• Joining: welding, riveting, and adhesive bonding are comm...read more

Factors considered for concept design

• Client requirements and specifications

• Market research and analysis

• Feasibility and technical constraints

• Budget and resources

• Design trends and innovation

• User experience and ergonomics

I am interested in Freescale because of their innovative technology and strong reputation in the industry.

• Freescale has a history of developing cutting-edge technology

• Their reputation in the industry is strong and respected

• I am excited about the opportunity to work with a company that values innovation and excellence

DOF stands for Degrees of Freedom. It refers to the number of independent parameters that define the configuration of an object.

• DOF is the number of ways a rigid body can move in 3D space.

• For a rigid body in 3D space, there are 6 degrees of freedom - 3 translational and 3 rotational.

• Examples of DOF include linear motion along x, y, z axes and rotational motion around x, y, z axes.

Types of tolerance include bilateral, unilateral, and limit. AutoCAD stands for Automatic Computer Aided Design. It is used for creating 2D and 3D designs. Measuring instruments like micrometers and calipers are used for precise measurements.

• Types of tolerance: bilateral, unilateral, limit

• AutoCAD full form: Automatic Computer Aided Design

• AutoCAD is used for creating 2D and 3D designs

• Measuring instruments like micrometers and calipers are used for precise measurements

To create a closed volume of a surface using the master section in CAD, you can use the extrude or loft feature.

• Use the extrude feature to extend a 2D shape into a 3D volume by specifying a distance or depth.

• Use the loft feature to create a solid shape by connecting two or more profiles with a smooth transition.

• Ensure that the profiles used for extrusion or lofting are closed shapes to create a watertight volume.

Machining operations involve using various tools and techniques to shape and cut raw materials into the desired shape and size.

• The job may involve using lathes, milling machines, grinders, or other specialized equipment.

• The machinist must carefully measure and mark the material before cutting or shaping it.

• The machinist may need to use different cutting tools or techniques depending on the material being worked on.

• Examples of machining operations include drilling holes, turni...read more

Grid check is a process to verify the accuracy of a grid system in a design.

• Grid check involves measuring the spacing between grid lines to ensure they meet the specified dimensions.

• Inputs required for grid check include grid line spacing, grid line thickness, and overall grid dimensions.

• Grid check can be done using tools like rulers, calipers, or specialized grid check templates.

• Grid check is important in ensuring alignment and consistency in a design layout.

I am familiar with CAD software such as SolidWorks and AutoCAD. I am also knowledgeable in GD&T and roll forming.

• I have experience using SolidWorks and AutoCAD for designing and modeling parts and assemblies.

• I am familiar with GD&T and its use in specifying tolerances and geometric features on engineering drawings.

• UTS (Ultimate Tensile Strength) is the maximum stress a material can withstand before breaking, while Yield Strength is the stress at which a material begins to def...read more

Preventing plastic defects involves proper material selection, design optimization, and quality control measures.

• Selecting the right type of plastic for the specific application

• Optimizing the design to minimize stress concentrations and molding issues

• Implementing quality control measures during manufacturing process

• Regular maintenance and inspection of molds and equipment

• Training staff on proper handling and processing techniques

I have experience working with various tonnage molding machines, including 50-ton, 100-ton, and 200-ton machines.

• 50-ton molding machine

• 100-ton molding machine

• 200-ton molding machine

I am proficient in drawing sections of projects, identifying plastic defects, and creating bending moment diagrams of beams. I am also familiar with GD&T symbols.

• I can draw sections of projects to show different layers and components

• I can identify plastic defects such as warping, sink marks, and flash

• I can create bending moment diagrams of beams to show the distribution of forces

• I am familiar with GD&T symbols and can use them to communicate design requirements

• I have experien...read more

A bolted connection design involves selecting appropriate bolts, nuts, and washers to join two or more components together.

• The design must consider the loads and stresses that the connection will experience

• The bolt size, grade, and material must be selected based on the required strength and corrosion resistance

• The number and spacing of bolts must be determined to evenly distribute the load

• Proper tightening torque must be applied to ensure the connection remains secure

• Washers...read more

I have a basic understanding of hydrology and its principles.

• I have studied hydrology as part of my civil engineering degree

• I understand the water cycle and how it relates to hydrology

• I am familiar with common hydrological models such as HEC-HMS and SWMM

• I have worked on projects that involved hydrological analysis and design

• I am willing to learn more about hydrology to improve my skills

A foundation is designed by analyzing soil conditions, determining load requirements, selecting appropriate materials, and creating a structural design.

• Conduct a soil investigation to determine soil type, bearing capacity, and potential for settlement

• Calculate the load requirements based on the weight of the structure and any anticipated loads

• Select appropriate materials for the foundation, such as concrete, steel, or wood

• Design the foundation structure, including the size an...read more

Plastic injection molding involves various types of plastics, molds, ejectors, parting lines, sink marks, and defects.

• Types of plastics used in injection molding include ABS, polycarbonate, nylon, and polypropylene.

• Molds are made of steel or aluminum and consist of two halves that create the parting line.

• Ejectors are used to remove the part from the mold and can leave marks on the part.

• Sink marks occur when the plastic cools and shrinks unevenly, causing depressions on the su...read more

Crosstalk is the unwanted transfer of signals between communication channels.

• Crosstalk occurs when signals from one channel interfere with signals on another channel.

• It can result in distorted or degraded signal quality.

• Example: In audio systems, crosstalk can cause a faint echo or noise from one channel to be heard in another channel.

Designing any industry involves planning and organizing various sections to ensure smooth operations and efficiency.

• Identify the specific industry and its requirements

• Design the layout and infrastructure of the industry, including production areas, storage facilities, and office spaces

• Develop processes and workflows for each section to optimize productivity

• Implement technology and automation where applicable to streamline operations

• Ensure compliance with industry regulations ...read more

Consider user needs, functionality, manufacturability, cost, and aesthetics when designing a new product.

• Understand user needs and requirements

• Ensure functionality meets specifications

• Consider manufacturability and ease of assembly

• Keep cost constraints in mind

• Pay attention to aesthetics and user experience

• Iterate and test prototypes for improvements

Types of fits include clearance, interference, and transition fits. First and third angle projection are methods of technical drawing.

• Clearance fit: parts are intended to have a gap between them, e.g. a shaft and a hole

• Interference fit: parts are intended to be pressed or forced together, e.g. a bearing and a housing

• Transition fit: parts have both clearance and interference, e.g. a gear and a shaft

• First angle projection: object is viewed from above and projected onto a plane ...read more

ASME Boiler and Pressure Vessel Code is the main standard for designing pressure vessels.

• ASME Boiler and Pressure Vessel Code is the primary standard used for designing pressure vessels

• Other standards include API 510, API 570, and API 653 for specific types of pressure vessels

• Designers must also consider materials, fabrication methods, and safety factors when designing pressure vessels

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

Slack in routing refers to the amount of time a task can be delayed without affecting the project schedule.

• Slack allows for flexibility in project timelines

• It is the difference between the earliest and latest start time of a task

• Tasks with zero slack are critical and cannot be delayed

• Slack is calculated using the Critical Path Method (CPM)

• Example: If a task has a duration of 5 days and a slack of 2 days, it can be delayed by 2 days without impacting the project deadline

Setting boundary conditions in Star CCM+ involves defining the behavior of fluid flow at the boundaries of the computational domain.

• In Star CCM+, go to the 'Boundary Conditions' tab in the simulation tree.

• Select the boundary you want to set the condition for, such as inlet, outlet, wall, etc.

• Specify the type of boundary condition, such as velocity inlet, pressure outlet, no-slip wall, etc.

• Enter the relevant values or profiles for the selected boundary condition.

• Make sure to r...read more

GD&T is a system for defining and communicating engineering tolerances. It is applied to ensure parts are manufactured accurately.

• GD&T stands for Geometric Dimensioning and Tolerancing.

• It uses symbols, such as concentricity, perpendicularity, and position, to specify geometric characteristics of parts.

• GD&T helps ensure parts fit together correctly and function properly.

• It is commonly used in industries like automotive, aerospace, and manufacturing.

• By applying GD&T, designers ...read more

During a fire incident, I quickly assessed the situation and directed people to safety.

• Remained calm and composed during the emergency

• Evaluated the situation and identified potential dangers

• Directed people to safety and ensured everyone was accounted for

• Coordinated with emergency services to provide necessary information

• Followed up with affected individuals to provide support and assistance

Components mounted on chassis include power supply, motherboard, CPU, RAM, storage devices, graphics card, and cooling system.

• Power supply

• Motherboard

• CPU

• RAM

• Storage devices

• Graphics card

• Cooling system

Valves are devices that regulate, direct or control the flow of fluids or gases. There are various types of valves used in different applications.

• Gate valves for on/off control

• Ball valves for quick shut-off

• Butterfly valves for low-pressure applications

• Globe valves for regulating flow

• Check valves for preventing backflow

• Needle valves for precise flow control

• Diaphragm valves for corrosive fluids

• Pressure relief valves for safety

• Solenoid valves for automation

• Control valves for pro...read more

I used the ASME Y14.5 drawing standard in my current job.

• ASME Y14.5 is a widely recognized drawing standard in the engineering industry.

• It provides guidelines for dimensioning and tolerancing of engineering drawings.

• The standard ensures clear communication and consistency in design documentation.

• It includes rules for geometric dimensioning and tolerancing (GD&T).

• ASME Y14.5 helps in ensuring the manufacturability and interchangeability of parts.

• It also aids in reducing errors ...read more

The K factor is a value used in sheet metal design to determine the amount of springback that occurs during bending.

• The K factor is a ratio that relates the neutral axis to the material thickness.

• It is used to calculate the bend allowance and bend deduction in sheet metal bending operations.

• A higher K factor indicates more springback, while a lower K factor indicates less springback.

• Different materials and bending processes have different K factor values.

• For example, the K fa...read more

Remastering in plastics is the process of improving the quality of recycled plastic materials.

• It involves adding new additives to the recycled plastic to enhance its properties.

• The process can also involve removing impurities and contaminants from the recycled plastic.

• Remastering helps to increase the value and usability of recycled plastic materials.

• Examples of remastered plastics include PET bottles, HDPE containers, and PVC pipes.

A brake system works by converting kinetic energy into heat energy through friction to slow down or stop a vehicle.

• Brake pedal is pressed by the driver

• Brake fluid is compressed in the master cylinder

• Pressure is transmitted through brake lines to the brake calipers or wheel cylinders

• Brake pads or shoes press against the brake rotor or drum to create friction and slow down the vehicle

Densities of steel, aluminum, rubber, and plastic vary due to their composition and structure.

• Steel: ~7850 kg/m^3

• Aluminum: ~2700 kg/m^3

• Rubber: ~1100 kg/m^3

• Plastic: Varies depending on type (e.g. HDPE ~950 kg/m^3, PVC ~1400 kg/m^3)

Design library in SolidWorks is a feature that allows users to store and reuse commonly used parts, features, and assemblies.

• Design library provides easy access to standard components like screws, nuts, bolts, etc.

• Users can drag and drop items from the design library directly into their designs.

• It helps in saving time by reusing pre-designed components instead of creating them from scratch.

• Design library can be customized to include user-specific components and features.

• Examp...read more

GD&T is a system used to define and communicate engineering tolerances for manufacturing processes.

• GD&T ensures that parts are manufactured with the correct dimensions and tolerances to meet design requirements

• It allows for clear communication between designers, engineers, and manufacturers

• GD&T helps to reduce errors, improve quality, and increase efficiency in the manufacturing process

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

Plastic defects can be controlled through proper quality control measures and process optimization.

• Implement regular quality checks during production process

• Optimize processing parameters such as temperature, pressure, and cooling rate

• Train staff on proper handling and maintenance of equipment

• Utilize advanced technologies like sensors and automated inspection systems

• Collaborate with suppliers to ensure high-quality raw materials

To change the connector in an inline wiring harness, follow these steps:

• Identify the type of connector needed for the replacement

• Disconnect the existing connector from the wiring harness

• Cut off the old connector, leaving enough wire length for the new connector

• Strip the insulation from the wire ends

• Crimp or solder the wires to the new connector

• Secure the new connector to the wiring harness

• Test the connection for proper functionality

NPD (New Product Development) involves the process of designing, developing, and launching new products or services.

• Identifying market opportunities and customer needs

• Concept development and testing

• Design and engineering

• Prototyping and testing

• Commercialization and launch

• Continuous improvement and feedback loop

Pile foundation is used for heavy structures while isolated foundation is used for light structures.

• Pile foundation transfers load to deeper soil layers while isolated foundation transfers load to the soil directly beneath it.

• Pile foundation is used for structures like bridges, high-rise buildings, and industrial plants while isolated foundation is used for houses, small buildings, and sheds.

• Pile foundation requires more excavation and material while isolated foundation requi...read more

Stress is the force per unit area acting on a material. Formula: Stress = Force/Area

• Stress is a measure of the internal forces in a material

• It is calculated by dividing the force applied to the material by its cross-sectional area

• Stress can be tensile, compressive, or shear

• Examples of stress include the weight of a book on a table, the force of wind on a building, and the pressure of water on a dam

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