10+ Lead Design Engineer Interview Questions and Answers

The strength value of a fillet joint is typically calculated using a thumb rule value based on the size of the fillet weld.

• The thumb rule value for the strength of a fillet joint is typically considered to be around 70-80% of the strength of the base metal.

• The actual strength value of a fillet joint can vary based on factors such as the size of the weld, material properties, and loading conditions.

• It is important to consider factors such as stress concentration and fatigue wh...read more

RCA methods involve identifying root causes of issues and working with suppliers on part development.

• Utilize RCA methods such as 5 Whys or Fishbone Diagram to identify root causes of part development issues

• Collaborate with suppliers to address and resolve identified root causes

• Communicate effectively with suppliers to ensure alignment on part development goals and timelines

• Regularly review progress and make adjustments as needed to ensure successful part development

We use ER70S-6 welding wire for general welding applications.

• ER70S-6 is a common choice for welding carbon and low alloy steels.

• It provides good weld puddle control and produces strong, quality welds.

• Other types of welding wire include ER308L for stainless steel and ER4043 for aluminum.

• The diameter of the welding wire can vary depending on the specific welding process and material thickness.

I have handled over 20 projects and worked with numerous customers in my role as Lead Design Engineer.

• Managed 20+ projects from start to finish

• Collaborated with various customers to understand their needs and requirements

• Implemented design solutions for different industries such as automotive, aerospace, and consumer electronics

Tools commonly used for system engineering include requirements management tools, modeling and simulation software, and configuration management tools.

• Requirements management tools help capture, track, and manage system requirements throughout the development process (e.g. IBM DOORS, Jama Connect)

• Modeling and simulation software allows engineers to create virtual models of systems to analyze performance and behavior (e.g. MATLAB Simulink, ANSYS)

• Configuration management tools ...read more

Bulk Modulus is a measure of a substance's resistance to compression under pressure.

• Bulk Modulus is a measure of a substance's resistance to compression.

• It is defined as the ratio of the applied pressure to the resulting fractional decrease in volume.

• It is commonly used in materials science and engineering to characterize the compressibility of a material.

• Example: Rubber has a low bulk modulus, while diamond has a high bulk modulus.

Ductile material is a type of material that can undergo significant plastic deformation before failure.

• Ductile materials can be stretched into wires without breaking.

• They exhibit large deformations under tensile stress.

• Examples include gold, copper, and aluminum.

Sheet metal design involves considering factors like material selection, thickness, bend radius, and manufacturing processes.

• Material selection is crucial for strength, corrosion resistance, and cost.

• Thickness affects the strength and weight of the part.

• Bend radius determines the minimum achievable bend angle without cracking.

• Consider manufacturing processes like laser cutting, bending, and welding.

• Design for manufacturability to minimize costs and lead times.

Accuracy refers to how close a measured value is to the true value, while precision refers to how close the measured values are to each other.

• Accuracy is the closeness of a measured value to a standard or known value.

• Precision is the closeness of two or more measurements to each other.

• Accuracy can be affected by systematic errors, while precision can be affected by random errors.

• For example, hitting the bullseye on a target consistently would be high accuracy and high precisi...read more

Section size is decided based on structural requirements, loads, material properties, and design codes.

• Consider the structural requirements and loads the section will be subjected to

• Take into account the material properties such as strength and stiffness

• Refer to design codes and standards for guidance on minimum section sizes

• Perform structural analysis to optimize section size for efficiency

• Consider factors such as cost, fabrication constraints, and aesthetics