Senior Design Engineer

200+ Senior Design Engineer Interview Questions and Answers

Updated 6 Feb 2025
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Q1. Noise, Vibration, and Harshness (NVH) in gearboxes are influenced by several factors, which can broadly be categorized into design, material, manufacturing, and operational factors. Here are some key factors af...

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Ans.

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

Q2. How many methods are used to forecast population

Ans.

There are multiple methods used to forecast population.

  • Demographic analysis

  • Cohort-component method

  • Time series analysis

  • Mathematical models

  • Survival analysis

  • Migration analysis

Senior Design Engineer Interview Questions and Answers for Freshers

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Q3. 1. What is GD and T? 2. Selection of motor as per weight. 3. Types of gears. 4 Basic conveyor related questions.

Ans.

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

Q4. What is the internal band radius for a rod sheet with a thickness of 0.3 mm and a total length of 100 meters?

Ans.

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

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Q5. How to decide sheetmetal bracket or casting is required.

Ans.

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

Q6. What are the formulae of area of circle, rectangle, square, cone and formulae of volume of cube, cuboid, cylinder, cone, etc?

Ans.

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

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Q7. 1. Design controls used 2. Traceability between user requirement, Design input, and design output with an example 3. Difference between Design Verification and Design validation with an example 4. Why is design...

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Ans.

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

Q8. For Design Pumping machinery and ESR what is the design period.

Ans.

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

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Q9. Geometric dimensioning and tolerancing symbols and their use.

Ans.

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

Q10. What is the concept of Geometric Dimensioning and Tolerancing (GD&T) in depth, and what are the different types of GD&T and their symbols?

Ans.

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

Q11. What types of different materials have you used, and what are their machinability characteristics and properties?

Ans.

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

Q12. What is Rosov, dbbv, BQD, Barrigade logic, PLC, SCADA

Ans.

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

Q13. What is K Factor in Sheet metal Design Explain?

Ans.

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

Q14. What factors do you consider when evaluating the quality of your design?

Ans.

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

Q15. What is meant by band radius, and what factors should be considered in the design of sheet metal?

Ans.

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.

Q16. How to design the underground concrete structures and what are the checks need to do?

Ans.

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

Q17. What is GD&T , How we can measure and through which instruments

Ans.

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

Q18. 1. PWHT & PFHT requirement / Cycle. 2. Difference between Stress relieving & Normalising. 3. U stamp nameplate description 4. UG- 44b significance 5. Rate of Heating/Cooling formula during heat treatment cycle....

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Ans.

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

Q19. What is the difference between control module and relay module

Ans.

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

Q20. Tell us about the welded assembly?. and what are the factors consider while selecting the weld size for the particular type of joint.

Ans.

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

Q21. What is the peak factor are used for Distribution design

Ans.

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

Q22. What is needs of Designing, although you can make the parts without drawing too?

Ans.

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

Q23. Materials grades,which area working in rolling stock, PDM, VPM, CATIA, STACKUP ANALYSIS, CDR, DDR, PDR etc

Ans.

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

Q24. What is relief valve, check valve and flow control valve?

Ans.

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

Q25. Whats is the difference between continuous and continual improvement?

Ans.

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

Q26. How do you determine the appropriate thickness for sheet metal?

Ans.

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

Q27. For Distribution system and Headwork what is the design period

Ans.

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

Q28. How to decide bore of the cylinder if pressure and load given?

Ans.

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

Q29. What is the importance of spring back effect in sheet metal design. How we will defining the bend radius for the any sheet metal part.

Ans.

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

Q30. How Roll is basically designed? What are the basics criteria to select the dimensions of Roll?

Ans.

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

Q31. What is meaning of 3.2,/1.6/0.8 in Surface finishing? What is it's purpose for giving it?

Ans.

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

Q32. What do you know about heat treatment of metals and rubbers?

Ans.

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

Q33. Day to day activities in current role, how to collect inputs about Design

Ans.

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

Q34. What is difference between Geometric Dimensioning and Tolerancing?

Ans.

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

Q35. How to calculate BOQ quantity for FAS system

Ans.

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

Q36. What is system architecture of FAS,BMS systems

Ans.

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

Q37. Difference between architecture drawing and structural drawing ?

Ans.

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

Q38. What factors should be considered when selecting a pneumatic cylinder?

Ans.

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

Q39. What is the process for calculating motor selection?

Ans.

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

Q40. Material selection and which material used in current working?

Ans.

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

Q41. Modelling & Detailing of large sheet metal

Ans.

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

Q42. Welding Symbols like leg weld and throat weld difference.

Ans.

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

Q43. What is 2 k moulding technology and what type of mould design you have work on

Ans.

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

Q44. What is difference between Limits, fits & Tolerance?

Ans.

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

Q45. Can you design valves if yes what are the basic parameters to consider while designing the same?

Ans.

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

Q46. Tell us the procedure of the creo cabling manual routing

Ans.

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

Q47. What is GDnT explain with Example

Ans.

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

Q48. How can the quality of design be ensured?

Ans.

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

Q49. What is the Component in the water supply scheme

Ans.

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.

Q50. What is the minimum residual pressure in SVS

Ans.

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

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