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 decision between sheetmetal bracket or casting is based on factors like complexity, strength, cost, and production volume.

• Consider the complexity of the part - sheetmetal brackets are generally simpler to design and manufacture compared to castings.

• Evaluate the required strength and load-bearing capacity - castings are often preferred for heavy-duty applications due to their superior strength.

• Assess the cost implications - sheetmetal brackets are usually more cost-effecti...read more

Interview questions for Senior Design Engineer position

• Design controls used to ensure product meets user requirements and regulatory standards

• Traceability matrix used to link user requirements to design inputs and outputs

• Design verification ensures design meets requirements, while design validation ensures product meets user needs

• Design validation is performed to ensure product meets user needs in real-world scenarios

• Standards such as ISO 13485 and FDA regulations are commonl...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

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

K Factor is a constant value used in sheet metal design to calculate the neutral axis and bend allowance.

• K Factor determines the amount of stretching that occurs during the bending process.

• It is used to calculate the bend allowance, which is the length of the neutral axis in the bent part.

• The K Factor value depends on the material being used, thickness, and bending method.

• Common K Factor values range from 0.3 to 0.5 for most materials.

• For example, a K Factor of 0.4 means that...read more

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

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

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

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

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

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.

The minimum residual pressure in SVS refers to the lowest pressure that remains in the system after it has been depressurized.

• The minimum residual pressure is important to ensure the system is properly depressurized and safe for maintenance or repair.

• It is typically measured in units of pressure, such as psi or bar.

• The specific value of the minimum residual pressure can vary depending on the design and requirements of the SVS system.

• For example, in a compressed air system, th...read more

Yes, construction stage analysis was considered in the design process.

• Construction stage analysis was considered to ensure the structural integrity of the design throughout the construction process.

• Factors such as temporary loads, construction sequencing, and construction methods were taken into account.

• For example, temporary supports or bracing may have been included in the design to account for construction loads.

• Finite element analysis or other simulation tools may have be...read more

Mechanical engineering encompasses various areas of knowledge.

• Thermodynamics

• Fluid mechanics

• Mechanics of materials

• Machine design

• Control systems

• Manufacturing processes

• CAD/CAM

• Finite element analysis

• Robotics

• Automotive engineering

Cylinders are used in various applications. Types include hydraulic, pneumatic, telescopic, and electro-mechanical.

• Hydraulic cylinders are used in heavy machinery, construction equipment, and industrial applications.

• Pneumatic cylinders are used in automation, robotics, and manufacturing.

• Telescopic cylinders are used in dump trucks, cranes, and other heavy-duty equipment.

• Electro-mechanical cylinders are used in precision positioning and motion control applications.

Inner fins are used in intercooler to increase heat transfer area and improve cooling efficiency.

• Inner fins increase the surface area of the intercooler, allowing for more heat transfer.

• This improves the cooling efficiency of the intercooler, allowing for better performance of the engine.

• Inner fins can be designed in various shapes and sizes to optimize the cooling performance.

• Examples of intercoolers with inner fins include air-to-air intercoolers and liquid-to-air intercool...read more

Parameters for proto model feasibility in existing facility include space availability, equipment compatibility, material sourcing, and cost analysis.

• Evaluate space availability to ensure the facility can accommodate the proto model production process.

• Check equipment compatibility to ensure existing machinery can be used for proto model fabrication.

• Assess material sourcing options to determine availability and cost-effectiveness.

• Conduct cost analysis to determine the feasibil...read more

Yes, I am familiar with springs and plastic manufacturing processes.

• Springs are mechanical devices that store and release energy

• They are commonly used in various applications such as automotive, aerospace, and industrial

• Plastic manufacturing processes include injection molding, blow molding, and extrusion

• These processes involve melting plastic material and shaping it into desired forms

• Examples of plastic products manufactured include bottles, containers, and automotive parts

Gold platings are used on terminals for various reasons.

• Gold is a good conductor of electricity and does not corrode easily.

• It provides a low contact resistance and high reliability.

• It also enhances the appearance of the product.

• Examples include connectors, switches, and circuit boards.

• Gold plating is also used in medical implants due to its biocompatibility.

Solar plus battery process involves capturing solar energy using solar panels and storing it in batteries for later use.

• Solar panels capture sunlight and convert it into electricity.

• The electricity generated can be used to power homes, buildings, or vehicles.

• Excess electricity can be stored in batteries for use during periods of low sunlight or at night.

• Battery management systems ensure efficient charging and discharging of the batteries.

• Combining solar panels with batteries ...read more

SLD stands for Single Line Diagram, while TLD stands for Top Level Design. SLD is a simplified representation of a system's electrical connections, while TLD is a high-level overview of a system's architecture.

• SLD is a graphical representation of a system's electrical connections, showing how components are connected in a single line.

• TLD is a high-level overview of a system's architecture, showing the main components and their interactions.

• SLD is commonly used in electrical e...read more