100+ Production Graduate Engineer Trainee Interview Questions and Answers

Heat transfer works on the principle of transferring thermal energy from a higher temperature object to a lower temperature object.

• Heat transfer occurs through conduction, convection, and radiation.

• Conduction is the transfer of heat through a material without any movement of the material itself.

• Example: Touching a hot pan and feeling the heat transfer through the metal.

• Convection is the transfer of heat through the movement of fluids (liquids or gases).

• Example: Boiling water ...read more

My favorite topic is heat transfer, specifically modes of heat conduction.

• Modes of heat conduction include conduction, convection, and radiation.

• Conduction is the transfer of heat through a material without any movement of the material itself.

• Convection is the transfer of heat through the movement of fluids, such as air or water.

• Radiation is the transfer of heat through electromagnetic waves.

• Understanding these modes is crucial in designing efficient heat transfer systems.

Countercurrent flow is more effective due to increased concentration gradient and better utilization of resources.

• Countercurrent flow allows for a greater concentration gradient between the two fluids, leading to more efficient mass transfer.

• Countercurrent flow also allows for better utilization of resources as the fluids are in contact for a longer period of time.

• Concurrent flow, on the other hand, results in a lower concentration gradient and may lead to less efficient mass...read more

Number of plates in a distillation column can be found using methods like McCabe-Thiele method, Fenske equation, and Ponchon-Savarit method.

• McCabe-Thiele method involves constructing equilibrium and operating lines to determine number of plates.

• Fenske equation is used for binary distillation to calculate minimum number of plates required.

• Ponchon-Savarit method is graphical method to determine number of plates in a distillation column.

Different types of concrete used in construction include ready-mix concrete, precast concrete, high-strength concrete, and lightweight concrete.

• Ready-mix concrete is a mixture of cement, water, and aggregates that is delivered in a truck and poured on site.

• Precast concrete is made in a controlled environment and then transported to the construction site for installation.

• High-strength concrete is designed to withstand heavy loads and is often used in structures like bridges an...read more

The procedure for designing a heat exchanger involves determining heat transfer requirements, selecting appropriate materials, designing the geometry, and analyzing performance.

• Determine the heat transfer requirements based on the fluids involved, flow rates, temperatures, and desired heat transfer rate.

• Select appropriate materials for the heat exchanger based on compatibility with the fluids, operating conditions, and cost considerations.

• Design the geometry of the heat excha...read more

A portrait engine diesel engine is a type of internal combustion engine with a capacity typically ranging from 1.5L to 3.0L and a compression ratio of around 16:1.

• Portrait engine diesel engines are commonly used in passenger cars and light-duty trucks.

• They are known for their fuel efficiency and torque output.

• Examples of portrait engine diesel engines include the Ford EcoBlue 2.0L and the Volkswagen TDI 1.6L.

• The high compression ratio in these engines helps in achieving bette...read more

Different types of steels used in industry include carbon steel, alloy steel, stainless steel, and tool steel.

• Carbon steel: primarily made of iron and carbon, with small amounts of other elements. Examples include mild steel and high carbon steel.

• Alloy steel: contains additional elements such as manganese, silicon, nickel, and chromium to improve strength, hardness, and corrosion resistance. Examples include chrome moly steel and stainless steel.

• Stainless steel: contains chro...read more

Modes of HT refer to the different ways in which heat treatment can be carried out on materials.

• Annealing

• Normalizing

• Quenching

• Tempering

Quenching, normalising, and properties of martensite are heat treatment processes used to alter the properties of metals.

• Quenching is a rapid cooling process used to harden metals by trapping the atoms in a specific crystalline structure.

• Normalising is a slower cooling process used to refine the grain structure of metals, improving their toughness and ductility.

• Martensite is a hard, brittle phase of steel formed by quenching, known for its high strength and hardness.

• Propertie...read more

Non-conventional manufacturing processes are those that do not involve traditional methods like cutting, drilling, or milling.

• Non-traditional methods like 3D printing, laser cutting, and electrochemical machining

• These processes are often more efficient and precise than traditional methods

• They can also be used to create complex shapes and structures that would be difficult or impossible to produce with traditional methods

To increase corrosion resistance in steel, various methods such as coating, alloying, and controlling environmental factors can be employed.

• Applying protective coatings such as zinc, paint, or polymer can help prevent corrosion

• Alloying steel with elements like chromium, nickel, or copper can improve corrosion resistance

• Controlling environmental factors such as humidity, temperature, and pH levels can also reduce corrosion

Heat exchangers are devices that transfer heat between two or more fluids.

• Types of heat exchangers include shell and tube, plate and frame, and finned tube.

• Shell and tube heat exchangers are the most common and consist of a shell with tubes inside.

• Plate and frame heat exchangers use plates to transfer heat between fluids.

• Finned tube heat exchangers have fins on the outside of the tubes to increase heat transfer.

• The choice of heat exchanger type depends on factors such as the ...read more

Bernoulli's theorem relates the pressure, velocity, and elevation of a fluid in a steady flow. Pascal's law states that a change in pressure applied to an enclosed fluid is transmitted undiminished to all portions of the fluid.

• Bernoulli's theorem states that in a steady flow of an incompressible, frictionless fluid, the sum of pressure energy, kinetic energy, and potential energy per unit volume remains constant.

• Pascal's law states that a change in pressure applied to an encl...read more

Electronic & Communication Engineering is a branch of engineering that deals with the study of electronic devices and communication systems.

• It involves the design, development, and testing of electronic circuits, devices, and systems.

• It covers a wide range of topics such as analog and digital electronics, signal processing, communication systems, and control systems.

• Electronic & Communication Engineers work in various industries such as telecommunications, aerospace, defense,...read more

Different types of gums include xanthan gum, guar gum, and locust bean gum. They are removed through various methods depending on the type of gum.

• Xanthan gum is commonly used in food products as a thickening agent and can be removed by simply washing it off with water.

• Guar gum is another common food additive that is used as a thickener and can be removed by soaking it in water and then straining it out.

• Locust bean gum, also known as carob gum, is used in food products as a st...read more

Welding is a process of joining two or more metal pieces together by melting and fusing them. Casting is a manufacturing process where a liquid material is poured into a mold and allowed to solidify.

• Welding involves the use of heat and pressure to join metal pieces.

• Types of welding include arc welding, gas welding, and spot welding.

• Casting defects can include porosity, shrinkage, and misruns.

• Porosity is the presence of small holes or voids in the cast metal.

• Shrinkage defects ...read more

The scope of chemical engineering is vast, encompassing various industries and applications.

• Chemical engineering involves the design, development, and operation of processes and systems that convert raw materials into useful products.

• It is applicable in industries such as pharmaceuticals, petrochemicals, food and beverage, energy, environmental engineering, and more.

• Chemical engineers work on improving efficiency, safety, and sustainability of processes, as well as developing...read more

Stress is internal resistance to deformation, while pressure is force applied over an area. Strength is the ability to withstand stress, and process refers to a series of actions or steps.

• Stress is the internal resistance to deformation in a material, measured in force per unit area (e.g. N/m^2 or Pa).

• Pressure is the force applied perpendicular to the surface of an object, measured in force per unit area (e.g. N/m^2 or Pa).

• Strength is the ability of a material to withstand st...read more

Differential is a mechanical device that allows a vehicle's wheels to rotate at different speeds while maintaining control.

• Allows wheels to rotate at different speeds

• Helps maintain control during turns

• Transfers power from the engine to the wheels efficiently

• Reduces tire wear and improves traction

• Commonly found in vehicles with rear-wheel or all-wheel drive

Pump curve shows the relationship between flow rate and head. Cavitation and priming are common issues in pump operation.

• Pump curve is a graph that shows the performance of a pump at different flow rates and heads.

• It helps in selecting the right pump for a specific application and also in troubleshooting pump problems.

• Cavitation occurs when the pressure in the pump drops below the vapor pressure of the liquid, causing bubbles to form and collapse, damaging the impeller and re...read more

A machine is a device that uses energy to perform a specific task. SolidWorks is a computer-aided design software used for creating 3D models and simulations.

• A machine is a mechanical or electrical device that performs a specific function.

• SolidWorks is a CAD software used for designing and modeling mechanical components.

• SolidWorks allows engineers to create 3D models, perform simulations, and generate technical drawings.

• SolidWorks is commonly used in industries such as automo...read more

IC engine stands for Internal Combustion engine and SI engine stands for Spark Ignition engine. Sump pressure refers to the pressure inside the oil sump of an engine.

• IC engine is a type of engine where the combustion of fuel takes place internally, such as in a car engine.

• SI engine is a specific type of IC engine where the fuel is ignited by a spark plug, commonly used in gasoline-powered vehicles.

• Sump pressure refers to the pressure inside the oil sump, which is the reservoi...read more

Number of theoretical plates can be calculated using the plate theory or the distillation column design equation.

• The plate theory method involves using the equilibrium data for the components being separated and the operating conditions of the column.

• The distillation column design equation method involves using the height equivalent to a theoretical plate (HETP) and the total number of plates in the column.

• Example: For a distillation column with a HETP of 0.5 ft and a total h...read more

4-stroke engines have separate intake, compression, power, and exhaust strokes, while 2-stroke engines combine intake and compression in one stroke and power and exhaust in another.

• 4-stroke engines have a more complex design with separate components for each stroke

• 2-stroke engines are simpler and lighter due to combining functions in fewer strokes

• 4-stroke engines are more fuel efficient and produce less pollution

• 2-stroke engines have a higher power-to-weight ratio and are com...read more

The purpose of a differential is to allow the wheels on an axle to rotate at different speeds while still receiving power from the engine.

• Allows wheels on an axle to rotate at different speeds

• Helps in turning corners smoothly

• Prevents wheel slippage on different terrains

• Balances power distribution between wheels

• Commonly found in vehicles with rear-wheel or all-wheel drive

Friction is the force that opposes the motion of an object when in contact with another object.

• Friction is caused by the roughness of surfaces in contact

• It can be reduced by using lubricants

• Static friction prevents an object from moving while kinetic friction acts when the object is in motion

• Examples of gears used include in bicycles, cars, and industrial machinery

Apart from technical skills, I possess strong communication, problem-solving, and teamwork skills.

• Excellent communication skills - able to effectively convey ideas and information to others

• Strong problem-solving skills - able to analyze situations and come up with creative solutions

• Teamwork skills - able to collaborate with others to achieve common goals

• Time management skills - able to prioritize tasks and meet deadlines

• Adaptability - able to quickly adjust to new situations ...read more

Stress-strain graph for ductile materials shows a linear elastic region followed by plastic deformation until fracture.

• Elastic region: linear relationship between stress and strain

• Yield point: point where plastic deformation begins

• Plastic deformation: material undergoes permanent deformation without increase in stress

• Necking: reduction in cross-sectional area before fracture

• Fracture: final failure of the material

• Example: Steel, aluminum

Cycle time is the total time it takes to complete a task, while takt time is the rate at which a product must be produced to meet customer demand.

• Cycle time is the total time taken to complete a process or task.

• Takt time is the rate at which a product must be produced to meet customer demand.

• Cycle time includes both value-added and non-value-added time.

• Takt time is calculated as available production time divided by customer demand.

• For example, if a process takes 10 minutes to...read more

Diode, capacitor, and inductor are basic electronic components used in circuits.

• A diode is a semiconductor device that allows current to flow in one direction only.

• A capacitor is a device that stores electrical energy in an electric field.

• An inductor is a passive electronic component that stores energy in a magnetic field.

• All three components are commonly used in electronic circuits to control the flow of electricity and store energy.

• Diodes are used in rectifiers, voltage reg...read more

To improve ADAS systems in cars, focus on enhancing sensor technology, increasing accuracy of algorithms, and integrating with V2X communication.

• Enhance sensor technology to improve detection capabilities

• Increase accuracy of algorithms for better decision-making

• Integrate ADAS systems with V2X communication for real-time data exchange

• Regular software updates to ensure system stays up-to-date with latest advancements

My goal in the coming 5 years is to gain valuable experience in the production engineering field, develop my technical skills, and work towards becoming a proficient engineer.

• Gain hands-on experience in various aspects of production engineering

• Complete relevant training programs and certifications to enhance my skills

• Work on challenging projects to apply theoretical knowledge in practical scenarios

• Seek opportunities for career advancement within the company or industry

• Build a...read more

Gears are mechanical components used to transmit motion and power between rotating shafts. There are various types of gears including spur, helical, bevel, and worm gears.

• Gears are toothed mechanical components that mesh together to transmit motion and power.

• Spur gears have straight teeth and are the most common type of gear.

• Helical gears have angled teeth for smoother and quieter operation.

• Bevel gears have cone-shaped teeth and are used to change the direction of rotation.

• Wo...read more

A full-adder is a digital circuit that performs addition of three binary numbers, while a half adder is a digital circuit that performs addition of two binary numbers.

• Full-adder adds three binary numbers (A, B, and carry-in) to produce a sum and a carry-out.

• Half adder adds two binary numbers (A and B) to produce a sum and a carry.

• Full-adder is used in complex arithmetic operations, while half adder is used in simple addition tasks.

• Example: Full-adder is used in CPUs for arith...read more

Strength of material, production, and manufacturing are key aspects of engineering that involve understanding the properties of materials and processes involved in creating products.

• Strength of materials involves analyzing the behavior of materials under different types of loads and stresses.

• Production focuses on the process of creating goods or services, including planning, designing, and optimizing production processes.

• Manufacturing involves the actual production of goods t...read more

Different types of steel used in construction include carbon steel, alloy steel, stainless steel, and tool steel.

• Carbon steel is the most common type used in construction due to its strength and affordability.

• Alloy steel contains additional elements such as manganese, silicon, and copper to enhance its properties.

• Stainless steel is corrosion-resistant and often used in environments where rust is a concern.

• Tool steel is used for making tools and equipment due to its hardness a...read more

Process sheet for manufacturing a plastic water bottle

• Step 1: Injection molding to create the bottle shape

• Step 2: Cooling and solidifying the plastic

• Step 3: Trimming excess plastic from the bottle

• Step 4: Adding a cap and seal to the bottle

• Step 5: Quality control inspection

• Step 6: Packaging and labeling the finished product

4 stroke engines have separate intake, compression, power, and exhaust strokes, while 2 stroke engines combine intake and compression in one stroke and power and exhaust in another.

• 4 stroke engines have a more complex design with separate components for each stroke.

• 2 stroke engines are simpler in design and have fewer moving parts.

• 4 stroke engines are more fuel efficient and produce less pollution.

• 2 stroke engines have a higher power-to-weight ratio but are less fuel efficien...read more

Cast iron is hard and brittle, while mild steel is softer and more ductile.

• Cast iron contains 2-4% carbon, while mild steel contains less than 0.3% carbon.

• Cast iron has a higher melting point than mild steel.

• Cast iron is more resistant to wear and abrasion compared to mild steel.

• Mild steel is easier to weld and machine than cast iron.

The melting point of plain steel is approximately 2,500 degrees Fahrenheit.

• Melting point of plain steel can vary depending on the specific composition of the steel.

• Generally, plain carbon steel melts at around 2,500 degrees Fahrenheit.

• Alloy steels may have different melting points due to the addition of other elements.

• Melting point can also be affected by the rate of heating and cooling.

The best efficiency point of a centrifugal pump is the operating point where the pump achieves the highest efficiency.

• The best efficiency point is typically located near the pump's BEP (Best Efficiency Point) on the pump curve.

• At the best efficiency point, the pump operates with the least amount of energy consumption and highest output.

• Operating the pump away from the best efficiency point can lead to decreased efficiency and increased energy consumption.

• Regular maintenance a...read more

Performance curves of centrifugal pump show the relationship between flow rate, head, and efficiency.

• Performance curves show how a pump performs at different flow rates and heads.

• The curve typically includes lines for efficiency, power consumption, and NPSH requirements.

• The shape of the curve can indicate the pump's operating range and efficiency.

• Operating a pump outside of its recommended range can lead to issues like cavitation or excessive energy consumption.

Series and parallel operation of pumps involve connecting multiple pumps together to achieve desired flow rates and pressures.

• In series operation, pumps are connected one after the other to increase the total head or pressure that the system can deliver.

• In parallel operation, pumps are connected side by side to increase the total flow rate that the system can deliver.

• Series operation is used when high pressure is required, while parallel operation is used when high flow rate ...read more

Tolerance refers to the allowable deviation from a specified dimension or value in engineering.

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

• It is typically specified as a range, such as +/- 0.1mm.

• Tolerance can be applied to dimensions, angles, surface finishes, and other characteristics.

• For example, a hole may have a tolerance of +/- 0.05mm to allow for variations in the drilling process.

A diode is a semiconductor device that allows current to flow in one direction only.

• Diodes have two terminals - an anode and a cathode.

• They have a forward voltage drop, typically around 0.7V for silicon diodes.

• Diodes exhibit non-linear current-voltage characteristics.

• They are commonly used in rectifiers, voltage regulators, and signal demodulation.

• Examples of diodes include silicon diodes, Schottky diodes, and light-emitting diodes (LEDs).

Hot working and cold working are metal forming processes used to shape materials at different temperatures.

• Hot working involves shaping materials at high temperatures, making them easier to deform without cracking or fracturing.

• Cold working involves shaping materials at room temperature or below, increasing their strength and hardness but also making them more brittle.

• Examples of hot working include forging and extrusion, while examples of cold working include rolling and dra...read more

I have experience in using simulation software and conducting CFD analysis for various engineering projects.

• Utilized software like ANSYS Fluent and SolidWorks Flow Simulation for CFD analysis

• Performed simulations to optimize designs and improve performance

• Used simulation results to validate theoretical calculations and make design decisions

• Experience in heat transfer analysis and fluid flow simulations