200+ Senior Design Engineer Interview Questions and Answers

Addressing NVH in gearboxes involves optimizing design, material, manufacturing, and operational factors.

• Optimizing gear geometry like tooth profile and helix angle can reduce noise.

• Proper material quality and heat treatment can minimize vibrations.

• Precision machining and assembly quality are crucial for reducing NVH.

• Consider load conditions, lubrication, and operational speed for NVH control.

• Environmental factors like temperature and external vibrations also impact gearbox N...read more

There are multiple methods used to forecast population.

• Demographic analysis

• Cohort-component method

• Time series analysis

• Mathematical models

• Survival analysis

• Migration analysis

GD&T is a system for defining and communicating engineering tolerances. Motor selection depends on weight, power, and speed requirements. Types of gears include spur, helical, bevel, and worm. Conveyor questions may relate to design, operation, or maintenance.

• GD&T is an abbreviation for Geometric Dimensioning and Tolerancing, which is a system for defining and communicating engineering tolerances.

• When selecting a motor for a particular application, factors to consider include...read more

The internal band radius for a rod sheet can be calculated using the formula: radius = thickness / (2 * pi)

• Calculate the internal band radius using the formula: radius = thickness / (2 * pi)

• For a rod sheet with a thickness of 0.3 mm, the internal band radius would be 0.0477 mm

• The total length of 100 meters is not relevant to calculating the internal band radius

Formulae for area and volume of common shapes.

• Area of circle: πr²

• Area of rectangle: l x w

• Area of square: s²

• Area of cone: πr² + πrl

• Volume of cube: s³

• Volume of cuboid: l x w x h

• Volume of cylinder: πr²h

• Volume of cone: (1/3)πr²h

The design period for pumping machinery and ESR refers to the intended lifespan or duration of operation for the equipment.

• The design period is typically determined based on factors such as expected usage, maintenance requirements, and technological advancements.

• It is important to consider the design period when selecting materials, components, and manufacturing processes to ensure durability and reliability.

• For example, in the design of a water pump for a municipal water sup...read more

Geometric dimensioning and tolerancing symbols are used to specify the dimensions, tolerances, and geometric characteristics of a part.

• GD&T symbols are used to communicate design requirements and ensure proper fit, function, and interchangeability of parts.

• Some common GD&T symbols include position, concentricity, perpendicularity, and flatness.

• These symbols are typically placed on engineering drawings and provide precise instructions for manufacturing and inspection processes...read more

GD&T is a system for defining and communicating engineering tolerances using symbols on engineering drawings.

• GD&T is a system used to define and communicate engineering tolerances on drawings.

• It uses symbols to specify the allowable variations in form, size, orientation, and location of features.

• Some common GD&T symbols include concentricity, perpendicularity, flatness, and position.

• Types of GD&T include form controls, orientation controls, location controls, and runout contr...read more

I have experience working with a variety of materials with different machinability characteristics and properties.

• Metals: aluminum, steel, titanium

• Plastics: ABS, polycarbonate, nylon

• Composites: carbon fiber, fiberglass

• Ceramics: alumina, zirconia

• Understanding of material properties such as hardness, strength, thermal conductivity

• Knowledge of machining processes like milling, turning, drilling

Rosov, dbbv, BQD, Barrigade logic, PLC, SCADA are all related to engineering and automation.

• Rosov is a type of valve used in the oil and gas industry.

• dbbv stands for Double Block and Bleed Valve, used to isolate sections of a pipeline.

• BQD is a type of circuit breaker used in electrical systems.

• Barrigade logic is a type of control system used in industrial automation.

• PLC stands for Programmable Logic Controller, used to automate industrial processes.

• SCADA stands for Supervisor...read more

Factors considered include functionality, reliability, manufacturability, cost, and user experience.

• Functionality - Does the design meet all the required specifications and perform its intended function?

• Reliability - Will the design consistently perform as expected over its lifespan?

• Manufacturability - Can the design be easily and cost-effectively produced?

• Cost - Is the design cost-effective to produce and maintain?

• User experience - Does the design meet the needs and expectat...read more

Band radius refers to the minimum inside radius that can be achieved in a sheet metal design.

• Band radius is influenced by material thickness, bend angle, and tooling capabilities.

• Factors to consider in sheet metal design include material selection, bend radius, and tolerances.

• Design for manufacturability is crucial to ensure the sheet metal can be produced efficiently and accurately.

Designing underground concrete structures requires careful planning and consideration of various factors.

• Determine the purpose and function of the structure

• Consider the soil conditions and water table

• Select appropriate materials and reinforcement

• Ensure proper drainage and waterproofing

• Perform structural analysis and testing

• Follow local building codes and regulations

• Regularly inspect and maintain the structure

GD&T stands for Geometric Dimensioning and Tolerancing. It is a system used to define and communicate engineering tolerances.

• GD&T is a symbolic language used to specify the dimensions, form, orientation, and location of features on a part.

• It allows engineers to accurately communicate design requirements and ensure proper fit, function, and interchangeability of parts.

• GD&T uses various symbols, such as position, concentricity, flatness, and perpendicularity, to define toleranc...read more

The interview questions cover topics related to heat treatment, material properties, and industry standards in engineering.

• PWHT (Post Weld Heat Treatment) and PFHT (Preheat and Post Weld Heat Treatment) are required for certain materials to relieve residual stresses and improve mechanical properties.

• Stress relieving involves heating the material to a specific temperature and holding it for a period of time to reduce internal stresses, while normalizing involves heating the ma...read more

A control module is a device that manages and regulates the operation of a system, while a relay module is a device that controls the flow of electrical current.

• Control modules are responsible for monitoring and adjusting various parameters in a system, such as temperature, pressure, or speed.

• Relay modules act as switches that open or close circuits to control the flow of electrical current.

• Control modules are typically more complex and have advanced functionalities, while re...read more

A welded assembly is a joining method where two or more metal pieces are fused together using heat and pressure.

• Factors to consider when selecting weld size include material thickness, joint type, and required strength

• The size of the weld should be sufficient to provide the necessary strength without excess material

• Consideration should also be given to the welding process being used and any applicable codes or standards

• Examples of weld sizes include fillet welds, groove welds...read more

Peak factors are used in distribution design to account for peak loads and ensure safe and efficient operation.

• Peak factors are used to determine the maximum load that a distribution system can handle.

• They take into consideration factors such as diversity of loads, power factor, and future growth.

• For example, a peak factor of 1.5 means that the system should be designed to handle 50% more than the average load.

• Peak factors vary depending on the type of distribution system and...read more

Designing is essential for ensuring parts fit together correctly, meet performance requirements, and can be manufactured efficiently.

• Designing helps ensure parts fit together correctly and function as intended

• Designing allows for optimization of part performance and efficiency

• Designing helps identify potential issues before production, saving time and resources

I have experience working with materials grades in rolling stock and using various software tools such as PDM, VPM, CATIA, and performing stackup analysis, CDR, DDR, and PDR.

• Experience with materials grades in rolling stock

• Proficient in PDM and VPM software

• Skilled in using CATIA for design engineering

• Expertise in performing stackup analysis

• Familiarity with CDR, DDR, and PDR processes

Relief valve, check valve and flow control valve are types of valves used in fluid systems.

• Relief valve is used to release excess pressure in a system to prevent damage or failure.

• Check valve allows fluid to flow in one direction only, preventing backflow and protecting equipment.

• Flow control valve regulates the flow rate of fluid in a system, maintaining a constant flow rate or adjusting it as needed.

• Examples of relief valves include safety valves and pressure relief valves....read more

Continuous improvement is ongoing and focuses on small, incremental changes, while continual improvement is periodic and focuses on larger, more significant changes.

• Continuous improvement involves making small, incremental changes to processes or products on an ongoing basis.

• Continual improvement involves periodic reviews of processes or products to identify larger, more significant changes that can be made.

• Continuous improvement is often associated with Lean or Six Sigma met...read more

The design period for distribution system and headwork refers to the expected lifespan or duration for which the system is designed to function effectively.

• The design period is determined based on factors such as expected growth, technological advancements, and maintenance requirements.

• It is important to consider the long-term needs and goals of the distribution system and headwork when determining the design period.

• For example, if the distribution system is expected to serve...read more

The appropriate thickness for sheet metal is determined based on factors like material type, application, structural requirements, and cost.

• Consider the material type and its properties such as strength and flexibility

• Evaluate the application of the sheet metal, whether it will be used for structural support or aesthetic purposes

• Determine the structural requirements such as load-bearing capacity and resistance to deformation

• Take into account cost considerations, as thicker sh...read more

Bore of cylinder is decided based on pressure and load given.

• Calculate the force required to move the load

• Determine the pressure required to generate the force

• Select a cylinder with a bore size that can generate the required pressure

• Consider safety factors and application requirements

• Consult industry standards and guidelines

• Example: For a load of 1000 N and pressure of 10 bar, bore size can be calculated using formula: bore = (4 x force)/(pi x pressure)

• Example: Safety factor ...read more

I possess extensive knowledge in design calculations for mechanical and electrical engineering, ensuring optimal performance and safety.

• Mechanical calculations include stress analysis, fatigue analysis, and thermal calculations for components like beams and shafts.

• Electrical calculations involve load analysis, circuit design, and power distribution, ensuring systems meet operational requirements.

• For example, using Finite Element Analysis (FEA) to predict stress distribution i...read more

Spring back effect in sheet metal design is important for achieving accurate dimensions and shapes. Bend radius is defined based on material properties and manufacturing processes.

• Spring back effect refers to the tendency of a metal to return to its original shape after being bent or formed.

• It is important to account for spring back in sheet metal design to ensure the final part meets dimensional requirements.

• Bend radius is defined as the inside radius of a bend in a sheet me...read more

Rolls are designed based on specific criteria such as load capacity, speed, material properties, and application requirements.

• Roll dimensions are selected based on load capacity requirements to ensure the roll can support the intended weight without deformation.

• Speed requirements dictate the diameter of the roll to prevent slippage and maintain proper tension in the material being processed.

• Material properties such as hardness, surface finish, and thermal conductivity influen...read more

Surface finishing specification indicating the roughness average in micrometers.

• 3.2/1.6/0.8 refers to the roughness average values in micrometers for different surfaces

• The first number (3.2) represents the roughness average for the initial surface finish

• The second number (1.6) represents the roughness average for the intermediate surface finish

• The third number (0.8) represents the roughness average for the final surface finish

• These values help in specifying the desired smooth...read more

Heat treatment of metals and rubbers involves controlled heating and cooling processes to alter their properties.

• Heat treatment is used to improve the mechanical properties of metals by changing their microstructure.

• Common heat treatment processes for metals include annealing, quenching, tempering, and normalizing.

• Rubbers can also undergo heat treatment processes like vulcanization to improve their strength and elasticity.

• Heat treatment can enhance the hardness, toughness, du...read more

In my current role as a Senior Design Engineer, my day-to-day activities involve collecting inputs about design through various methods.

• Attending design review meetings to gather feedback and suggestions from cross-functional teams

• Conducting interviews with stakeholders to understand their requirements and expectations

• Analyzing customer feedback and incorporating it into the design process

• Collaborating with other engineers and designers to brainstorm ideas and gather differen...read more

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

• GD&T is a more detailed and precise way of defining dimensions and tolerances compared to traditional methods.

• GD&T uses symbols, such as concentricity, flatness, and perpendicularity, to specify tolerances on drawings.

• GD&T allows for clearer communication between designers, engineers, and manufacturers, reducing errors and improving quality.

• GD&T is commonly used in ...read more

BOQ quantity for FAS system can be calculated by determining the required components and their quantities.

• Identify the components needed for the FAS system

• Determine the quantity of each component required based on project specifications

• Consider factors such as system size, layout, and design requirements

• Calculate the total quantity by summing up the quantities of all components

• Example: If the FAS system requires 10 smoke detectors and 5 control panels, the BOQ quantity would ...read more

The system architecture of FAS (Fire Alarm System) and BMS (Building Management System) involves the integration of various components and subsystems to ensure efficient monitoring and control of fire safety and building operations.

• FAS system architecture typically includes fire detectors, control panels, notification devices, and communication interfaces.

• BMS system architecture typically includes sensors, controllers, actuators, and a central management system.

• Both systems m...read more

Architecture drawings focus on the overall design and layout of a building, while structural drawings focus on the specific details and components that support the building's structure.

• Architecture drawings show the overall design concept, including the layout, aesthetics, and functionality of a building.

• Structural drawings provide detailed information about the structural elements, such as beams, columns, and foundations, that support the building.

• Architecture drawings may i...read more

Factors to consider when selecting a pneumatic cylinder

• Load requirements

• Operating environment (temperature, humidity, etc.)

• Stroke length and bore size

• Speed and force requirements

• Mounting options

• Cylinder type (single-acting, double-acting)

• Budget constraints

The process for calculating motor selection involves determining the required torque, speed, power, and other specifications based on the application requirements.

• Identify the application requirements such as torque, speed, power, and operating conditions

• Calculate the required torque using the formula: Torque = Force x Distance

• Determine the speed needed for the application

• Select a motor that meets the torque, speed, power, and other specifications

• Consider factors such as effi...read more

Material selection is crucial for design engineering. Currently using aluminum for its lightweight and corrosion resistance.

• Consider mechanical properties like strength, stiffness, and ductility when selecting materials

• Think about environmental factors such as temperature, moisture, and chemicals

• Aluminum is commonly used for its lightweight nature, corrosion resistance, and ease of machining

Modelling and detailing of large sheet metal involves creating 3D models and producing detailed drawings for manufacturing.

• Use CAD software to create accurate 3D models of sheet metal components

• Consider material thickness, bend radii, and tolerances in the design

• Apply appropriate sheet metal forming techniques such as bending, punching, and welding

• Generate detailed drawings with dimensions, tolerances, and annotations for manufacturing

• Ensure proper nesting and efficient mater...read more

Leg weld and throat weld are two types of welding symbols used to indicate the size and shape of a weld.

• Leg weld refers to the length of the weld on one side of the joint, while throat weld refers to the minimum distance between the root and the face of the weld.

• Leg weld is represented by a straight line perpendicular to the reference line, while throat weld is represented by a diagonal line.

• For example, a leg weld symbol with a length of 1/4 inch would be represented by a st...read more

2K moulding technology involves using two different materials in a single mould to create a single part.

• 2K moulding technology involves injecting two different materials into a single mould to create a single part

• The materials are typically different colors or have different properties

• I have worked on designing moulds for automotive parts using 2K technology

Limits, fits, and tolerance are key concepts in engineering design to ensure proper functioning of mechanical components.

• Limits define the maximum and minimum acceptable dimensions of a part.

• Fits refer to the clearance or interference between mating parts.

• Tolerance is the allowable variation in dimensions of a part to ensure proper assembly and functionality.

• For example, a shaft with a diameter of 25mm may have a tolerance of +/- 0.05mm, and fit into a hole with a clearance f...read more

Yes, basic parameters for designing valves include flow rate, pressure drop, material selection, size, and type of valve.

• Flow rate: Determine the required flow rate for the application.

• Pressure drop: Consider the pressure drop across the valve.

• Material selection: Choose materials based on compatibility with the fluid and operating conditions.

• Size: Determine the appropriate size of the valve for the flow rate and pressure requirements.

• Type of valve: Select the appropriate type...read more

Creo cabling manual routing involves creating and routing cables in a 3D environment using Creo software.

• Create a 3D model of the product

• Define the routing path for the cables

• Select the cable type and size

• Route the cables along the defined path

• Ensure proper clearance and bend radius

• Validate the design for any errors or interferences

GD&T stands for Geometric Dimensioning and Tolerancing, a system used to define and communicate engineering tolerances.

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

• It ensures that parts are manufactured and assembled correctly, leading to better functionality and interchangeability.

• GD&T uses various symbols, such as concentricity, perpendicularity, flatness, and position, to define the desi...read more

Quality of design can be ensured through thorough testing, feedback from stakeholders, adherence to standards, and continuous improvement.

• Thorough testing of prototypes and simulations to identify and address any issues

• Seeking feedback from stakeholders such as end users, clients, and team members

• Adherence to industry standards and best practices in design processes

• Continuous improvement through iteration and learning from past projects

• Utilizing tools like design reviews, ris...read more

Components in a water supply scheme include pipes, pumps, valves, storage tanks, and treatment facilities.

• Pipes: Used to transport water from the source to the distribution network.

• Pumps: Provide the necessary pressure to move water through the system.

• Valves: Control the flow and direction of water within the scheme.

• Storage tanks: Store water for peak demand periods or emergencies.

• Treatment facilities: Purify and disinfect water to make it safe for consumption.