1000+ Design Engineer Interview Questions and Answers

Validating a tool/equipment for production line involves testing its functionality, reliability, and safety.

• Performing functional tests to ensure the tool/equipment operates as intended

• Conducting reliability tests to assess the tool/equipment's durability and performance over time

• Ensuring the tool/equipment meets safety standards and regulations

• Collaborating with production line operators to gather feedback on usability and efficiency

• Analyzing data from testing to identify an...read more

Different types of foundations include shallow foundations, deep foundations, and specialized foundations.

• Shallow foundations: spread footings, mat foundations, strip footings

• Deep foundations: piles, drilled shafts, caissons

• Specialized foundations: floating foundations, pile caps, raft foundations

Designing a beam involves several steps to ensure structural integrity and safety.

• Determine the load requirements and constraints

• Select appropriate materials based on load and design specifications

• Calculate the beam dimensions and cross-sectional properties

• Analyze the beam for stress, deflection, and other structural considerations

• Iterate on the design to optimize for cost, weight, and performance

• Create detailed drawings and specifications for fabrication and construction

I am familiar with various types of beams including cantilever beams, simply supported beams, and fixed beams.

• Cantilever beams

• Simply supported beams

• Fixed beams

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

The material used in refrigerators for insulation is usually polyurethane foam.

• Polyurethane foam is a common choice for refrigerator insulation due to its high thermal resistance and low thermal conductivity.

• Other materials used for insulation include polystyrene foam and fiberglass.

• The thickness of the insulation layer can vary depending on the desired energy efficiency of the refrigerator.

• The insulation helps to keep the cold air inside the refrigerator and prevent warm air...read more

Ball valve designing involves selecting materials, determining dimensions, and creating a 3D model.

• Select materials based on the application and fluid being handled

• Determine dimensions based on flow rate and pressure drop requirements

• Create a 3D model using CAD software

• Perform simulations and testing to ensure proper functionality

• Consider factors such as ease of maintenance and installation

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

I find SolidWorks to be the best and most user-friendly software for design engineering.

• SolidWorks is widely used in the industry for its powerful design capabilities

• It has a user-friendly interface with easy-to-use tools for creating 3D models and assemblies

• SolidWorks also offers a wide range of features for simulation, rendering, and documentation

• Other popular design software options include AutoCAD, CATIA, and Creo

Density is the measure of mass per unit volume of a substance.

• Density is calculated by dividing the mass of a substance by its volume.

• It is expressed in units such as kg/m³ or g/cm³.

• Density is an important property in fields such as materials science and engineering.

• For example, the density of steel is around 7.8 g/cm³, while the density of water is 1 g/cm³.

Protection of equipment focuses on preventing damage or malfunction, while safety of equipment focuses on preventing harm to individuals.

• Protection of equipment involves measures to prevent damage or malfunction, such as using surge protectors or enclosures.

• Safety of equipment involves measures to prevent harm to individuals, such as implementing safety guards or warning signs.

• Protection is more focused on the equipment itself, while safety is more focused on the people inter...read more

Flatten length of a sheet can be calculated using a formula based on the dimensions of the sheet.

• Measure the width and thickness of the sheet

• Use the formula: Flatten Length = (Width^2 + Thickness^2)^(1/2)

• For example, if the width is 10 cm and thickness is 2 cm, Flatten Length = (10^2 + 2^2)^(1/2) = (100 + 4)^(1/2) = 104^(1/2) = 10.2 cm

Design steps for a column include determining load requirements, selecting materials, calculating dimensions, and creating a detailed drawing.

• Determine load requirements based on the intended use of the column

• Select appropriate materials based on load requirements and aesthetic preferences

• Calculate dimensions of the column based on load requirements and material properties

• Create a detailed drawing of the column design, including all necessary dimensions and specifications

Synchronous speed of a motor is the speed at which the rotating magnetic field produced by the stator rotates.

• It is determined by the number of poles and frequency of the power supply.

• It is the speed at which the motor would run if there was no load or slip.

• It is expressed in revolutions per minute (RPM).

Design methodology and working methods on software involve a systematic approach to software development.

• Design methodology involves identifying requirements, creating a plan, and executing the plan.

• Working methods involve using tools and techniques to develop software efficiently.

• Examples of design methodologies include Agile, Waterfall, and Spiral models.

• Examples of working methods include version control, testing, and debugging.

• Design methodology and working methods are im...read more

Yes, I have knowledge of Solid Edge.

• I have used Solid Edge for 3D modeling and design.

• I am familiar with its features such as assembly modeling, sheet metal design, and drafting.

• I have also worked with Solid Edge simulation tools for analysis and validation.

• I have completed Solid Edge training courses to enhance my skills.

To calculate the flat pattern of sheet metal, use mathematical formulas and measurements to determine the dimensions and shapes needed for cutting and bending.

• Measure the dimensions of the sheet metal piece

• Calculate the bend allowances for each bend in the sheet metal

• Use mathematical formulas to determine the flat pattern layout

• Consider factors such as material thickness and bend radius

• Create a drawing or template for cutting and bending the sheet metal

Nonblocking operations allow the program to continue executing other tasks while waiting for a response, while blocking operations halt the program until a response is received.

• Nonblocking operations allow for asynchronous communication, while blocking operations are synchronous.

• Nonblocking operations are typically used in event-driven programming, while blocking operations are common in traditional procedural programming.

• Example: Nonblocking I/O operations in networking allo...read more

The symbol for first angle projection is a right angle symbol, while the symbol for third angle projection is an inverted right angle symbol.

• First angle symbol: Right angle symbol (∟)

• Third angle symbol: Inverted right angle symbol (⊿)

Countermeasures on sheet metal issue involve identifying root causes, implementing corrective actions, and continuously monitoring for improvements.

• Identify root causes of sheet metal issues such as warping, cracking, or distortion

• Implement corrective actions such as adjusting tooling, changing material specifications, or modifying the manufacturing process

• Continuously monitor the production process to ensure the effectiveness of the countermeasures

• Utilize quality control too...read more

There are several standards used for design depending on the industry and application.

• ISO 9001:2015 for quality management systems

• ASME Y14.5 for geometric dimensioning and tolerancing

• IEEE 802.11 for wireless networking

• NFPA 70 for electrical systems

• API 650 for storage tanks

• ASTM for materials and testing

• ANSI for safety standards

Details view is a specific view in a drawing that provides a close-up and enlarged representation of a specific part or feature.

• Details view is used to show intricate or complex features that may not be clearly visible in the main drawing.

• It allows designers to provide additional information and dimensions for specific areas of interest.

• Details view helps in highlighting critical design elements or specific assembly instructions.

• It aids in better understanding and interpretat...read more

To solve a manufacturing issue, identify the root cause, brainstorm solutions, implement changes, and monitor results.

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

• Brainstorm potential solutions with a cross-functional team to gather diverse perspectives.

• Implement changes based on the chosen solution, considering cost, time, and resources.

• Monitor the results of the changes to ensure they effectively solve the manufacturing issue.

• Continuously impr...read more

First angle projection and third angle projection are two methods used in engineering drawings to represent a 3D object in 2D.

• 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 the first quadrant and the views are projected onto the planes of projection.

• In third angle projection, the object is placed in the third quadrant and the views are projected away ...read more

Molding is a manufacturing process where a liquid or pliable material is poured into a mold to create a specific shape.

• Types of molding include injection molding, blow molding, compression molding, and rotational molding.

• Silicon molding involves using silicone rubber as the mold material, which is flexible and durable.

• The principle of silicon molding involves creating a negative mold using a master pattern, pouring silicone rubber into the mold, allowing it to cure, and then ...read more

By understanding the customer's needs, we can modify the product design, features, and specifications accordingly.

• Conduct market research to understand customer needs

• Gather feedback from customers through surveys or focus groups

• Collaborate with the customer to identify specific modifications

• Make necessary changes to the product design, features, and specifications

• Test the modified product to ensure it meets the customer's requirements

Hydraulic designs of stormwater involve planning and designing systems to manage and control the flow of stormwater.

• Hydraulic designs of stormwater focus on preventing flooding and managing runoff.

• They involve designing drainage systems, including pipes, channels, and storage facilities.

• The goal is to safely collect and convey stormwater away from developed areas.

• Design considerations include rainfall intensity, catchment area, and hydraulic capacity.

• Hydraulic designs may als...read more

This question covers topics related to material properties and geometric dimensioning and tolerancing.

• Density of material refers to its mass per unit volume.

• Stress-strain curve shows the relationship between stress and strain in a material.

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

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

A spring fails under stress beyond its elastic limit.

• A spring fails when it is subjected to stress beyond its elastic limit.

• The elastic limit is the maximum stress a spring can withstand without permanent deformation.

• Factors affecting the failure of a spring include material properties, design, and operating conditions.

• Examples of spring failure include fracture, fatigue, and creep.

• Fracture occurs when the spring is subjected to stress beyond its ultimate strength.

• Fatigue fai...read more

Different types of connections in steel structures include welded connections, bolted connections, and riveted connections.

• Welded connections involve joining steel members by welding them together.

• Bolted connections use bolts and nuts to connect steel members.

• Riveted connections use rivets to connect steel members.

• Other types of connections include pinned connections and moment-resisting connections.

• Examples: Welded beam-to-column connection, bolted splice connection, riveted...read more

Materials used in aerospace industry include titanium, aluminum, carbon fiber, and composites.

• Titanium

• Aluminum

• Carbon fiber

• Composites

Cable tray size can be calculated based on the number and size of cables to be installed.

• Determine the number and size of cables to be installed

• Calculate the total cross-sectional area of the cables

• Select a cable tray size that can accommodate the total cross-sectional area of the cables

• Consider factors such as cable spacing, fill ratio, and tray depth

• Use manufacturer's specifications and industry standards as a guide

• Ensure proper clearance and support for the cable tray

To avoid failures in components, I will follow a rigorous testing process and ensure proper maintenance.

• Conduct thorough testing of components before installation

• Regularly inspect and maintain components to prevent wear and tear

• Use high-quality materials and components

• Ensure proper installation and alignment of components

• Monitor performance and address any issues promptly

I was responsible for designing plastic moulding cycles to optimize production efficiency and quality.

• Designed plastic moulding cycles to reduce cycle time by 15%

• Collaborated with production team to improve moulding process for better product quality

• Implemented new moulding techniques to reduce material waste by 20%

• Worked on designing moulds for new product prototypes

Tool testing in Catia for plastic trims design

• Catia is a CAD software used for designing and testing

• Tool testing is important to ensure proper fit and function

• Plastic trims design requires consideration of material properties

• Simulation can be used to test tool performance and identify potential issues

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

Stress is the force applied to a material, while strain is the resulting deformation or change in shape.

• Stress is a measure of the internal forces within a material that resist deformation.

• Strain is the measure of the amount of deformation or change in shape that occurs due to stress.

• Stress and strain are related through the material's elastic modulus, which describes its stiffness.

• For example, when a metal rod is pulled, stress is applied to it, causing it to elongate (strai...read more

Plastic shrinkage varies for different materials: ABS has low shrinkage, PP has moderate shrinkage, and Nylon has high shrinkage.

• ABS has low shrinkage due to its high thermal stability and low moisture absorption.

• PP has moderate shrinkage because it has a lower melting point compared to ABS.

• Nylon has high shrinkage due to its high moisture absorption and tendency to absorb water from the environment.

• Shrinkage can be minimized by adjusting processing parameters such as mold te...read more

The second law of thermodynamics states that the total entropy of an isolated system can never decrease over time.

• Entropy in a closed system tends to increase over time

• Heat naturally flows from hot to cold objects

• Efficiency of energy conversion processes is limited by the second law of thermodynamics

The hole to hole distance with a feature control frame with MMC modifier at a specific diameter is determined by the geometric tolerance specified in the feature control frame.

• The maximum and minimum distances between the holes are determined by the size of the feature control frame and the MMC modifier.

• The MMC modifier allows for the maximum material condition of the part, which affects the allowable tolerance for the feature.

• The feature control frame specifies the geometric...read more

Geometric tolerances are specified dimensions used to control the form, profile, orientation, and location of features on a part.

• Geometric tolerances ensure that parts are manufactured within specified limits for form, fit, and function.

• They include symbols such as concentricity, perpendicularity, parallelism, and position to define allowable variations.

• Geometric tolerances are often used in conjunction with traditional linear dimensions to fully define part geometry.

• They hel...read more

To check leakage of any auto component, perform visual inspection, pressure testing, and fluid dye testing.

• Perform a visual inspection to check for any visible signs of leakage such as oil stains, wet spots, or puddles.

• Conduct pressure testing by applying air or fluid pressure to the component and monitoring for any drop in pressure, indicating a leak.

• Use fluid dye testing by adding a colored dye to the component's fluid system and inspecting for any leaks using UV light or s...read more

Listen actively, empathize, communicate clearly, set expectations, follow up.

• Listen actively to understand their needs and concerns.

• Empathize with their situation and show genuine care.

• Communicate clearly and effectively to ensure mutual understanding.

• Set realistic expectations and deliver on promises.

• Follow up to ensure satisfaction and address any issues that may arise.

Geometric dimensions and tolerance refer to the specified limits of size, form, and orientation of a part or feature in engineering design.

• Geometric dimensions define the size and shape of a part or feature in terms of length, width, height, diameter, etc.

• Tolerance is the allowable variation or deviation from the specified dimensions.

• Geometric tolerances ensure that parts fit together properly and function as intended.

• Examples of geometric dimensions and tolerance include con...read more

SFD and BMD of a continuous beam

• Calculate reactions at supports

• Draw SFD by taking sections and finding net forces

• Draw BMD by integrating SFD

• Identify points of maximum bending moment

• Check for shear and moment continuity at supports

DFMEA for motor in production involves identifying potential failure modes and their effects on the system.

• Identify all potential failure modes of the motor

• Determine the severity of each failure mode

• Assess the likelihood of each failure mode occurring

• Evaluate the detectability of each failure mode

• Develop actions to mitigate or eliminate high-risk failure modes

• Continuously monitor and update the DFMEA throughout production

• Example: Failure mode - overheating due to inadequate c...read more

Casting design considerations include material selection, part geometry, draft angles, surface finish, and shrinkage.

• Material selection is crucial for the desired properties and performance of the final part.

• Part geometry should be designed to minimize stress concentrations and ensure proper flow of molten metal.

• Draft angles are necessary for easy removal of the part from the mold.

• Surface finish requirements should be considered for the final appearance and functionality of t...read more