200+ Senior Design Engineer Interview Questions and Answers

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

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

The testing standard for cylinders depends on the type of cylinder and its intended use.

• Cylinders used for compressed gases are tested according to DOT regulations in the US.

• Cylinders used for liquefied gases are tested according to UN regulations.

• Cylinders used for medical gases are tested according to ISO standards.

• Testing typically involves hydrostatic testing to ensure the cylinder can withstand pressure.

• Cylinders must also be visually inspected for damage or corrosion be...read more

The kg/m2 of a normal building varies depending on factors such as materials used, height, and purpose.

• The kg/m2 of a normal building can range from 150 to 400 kg/m2.

• Factors such as the type of construction materials, height of the building, and purpose (residential, commercial, industrial) can affect the kg/m2.

• For example, a steel-framed commercial building may have a higher kg/m2 compared to a wood-framed residential building.

I have experience in developing and implementing various test methods for product validation.

• Developed and executed test plans for new product development

• Conducted various tests such as environmental, durability, and performance tests

• Used various testing equipment and software to collect and analyze data

• Collaborated with cross-functional teams to ensure product met customer requirements

• Implemented improvements to existing test methods to increase efficiency and accuracy

Sheet metal design involves creating parts and products from thin, flat sheets of metal through various manufacturing processes.

• Sheet metal design requires knowledge of material properties, forming processes, and manufacturing techniques.

• Designers must consider factors such as bend radius, material thickness, and tolerances.

• Manufacturing processes include cutting, bending, punching, and welding.

• Computer-aided design (CAD) software is commonly used in sheet metal design.

• Protot...read more

The platings used on the terminals include gold, tin, and silver.

• Gold plating is used for its high conductivity and corrosion resistance.

• Tin plating is used for its low cost and solderability.

• Silver plating is used for its excellent conductivity and low contact resistance.

Use Solidworks to create a 3D part from a 2D drawing with specified tolerances.

• Start by importing the 2D drawing into Solidworks.

• Use the extrude feature to create the 3D part based on the dimensions in the drawing.

• Apply the specified tolerances to ensure accurate manufacturing.

• Check for any interferences or errors in the design before finalizing.

• Consider using features like fillets, chamfers, and patterns to enhance the part.

Key electrical parameters include voltage, current, power, speed, torque, efficiency, and frequency.

• Voltage: Ensure motor voltage matches power supply voltage.

• Current: Select motor with current rating suitable for application.

• Power: Consider power requirements for desired performance.

• Speed: Choose motor with appropriate speed for application.

• Torque: Determine required torque for motor selection.

• Efficiency: Opt for motor with high efficiency to reduce energy consumption.

• Freque...read more

Torque is a measure of the force that causes an object to rotate around an axis.

• Torque is calculated by multiplying force and distance from the axis of rotation.

• The SI unit of torque is Newton-meter (Nm).

• Torque can be positive or negative depending on the direction of rotation.

• Examples of torque include twisting a bolt with a wrench or the force applied by a motor to rotate a shaft.

Yes, I have experience in designing enclosures and costing for various projects.

• I have experience in designing enclosures for electronic devices, machinery, and other products.

• I am familiar with CAD software for creating 3D models of enclosures.

• I have knowledge of materials and manufacturing processes to determine the cost of the enclosure.

• I have worked on projects where cost optimization was a key factor in enclosure design.

• I have experience in collaborating with suppliers t...read more

Single line drawing is a simplified diagram that shows the electrical connections and components of a power system.

• It is used to represent the electrical system in a simplified manner

• It shows the main components of the system and their interconnections

• It is commonly used in power distribution systems

• LT panels are low tension panels used for power distribution up to 415V

• HT panels are high tension panels used for power distribution above 415V

• HT panels are used in industries and...read more

Key features and benefits of electric vehicles include environmental friendliness, lower operating costs, and improved performance.

• Environmental friendliness: Electric vehicles produce zero tailpipe emissions, reducing air pollution and greenhouse gas emissions.

• Lower operating costs: Electric vehicles have lower fuel and maintenance costs compared to traditional gasoline vehicles.

• Improved performance: Electric vehicles offer instant torque, smooth acceleration, and quieter op...read more

Direction control valve controls the flow of fluid in hydraulic systems. Different center positions include open, closed, and neutral.

• Direction control valve regulates the flow of fluid in hydraulic systems

• Different center positions include open, closed, and neutral

• Open center position allows fluid to flow through the valve even when it is not actuated

• Closed center position blocks the flow of fluid when the valve is not actuated

• Neutral center position allows fluid to flow thr...read more

Yes, I have extensive experience with hoses and fittings in various engineering projects.

• I have designed and implemented hose and fitting systems for hydraulic machinery.

• I have conducted testing and analysis on hoses and fittings to ensure durability and performance.

• I have worked with different types of hoses and fittings such as PVC, rubber, and stainless steel.

• I have experience with selecting the appropriate hoses and fittings based on specific project requirements.

• I have c...read more

I rate myself 8 out of 10 for power electronics circuit designing.

• I have extensive experience in designing power electronics circuits for various applications.

• I am proficient in using simulation tools like LTSpice and MATLAB for circuit analysis and design.

• I have designed and implemented several power electronics circuits, including DC-DC converters, inverters, and motor drives.

• I keep myself updated with the latest trends and advancements in power electronics technology.

• I hav...read more

Tolerance stack up is the accumulation of variations in dimensions and tolerances in a product design. IT grades are international standards for tolerances.

• Tolerance stack up occurs when the cumulative effect of individual part tolerances results in a deviation from the intended design.

• IT grades, such as IT01, IT0, IT1, etc., are used to specify the level of tolerance allowed for a particular dimension or feature.

• Understanding tolerance stack up is crucial in ensuring that pa...read more

To create individual discipline Revit files, use the 'Save As' function and select the desired discipline template.

• Open the Revit model that contains multiple disciplines.

• Go to 'File' and select 'Save As'.

• Choose the desired discipline template (e.g. Architectural, Structural, MEP).

• Save the file with a new name to create an individual discipline Revit file.

Process design and development involves creating and improving processes to meet specific goals and requirements.

• Identifying the goals and requirements of the process

• Designing the process flow and layout

• Developing prototypes and testing them

• Implementing the process in a real-world setting

• Continuous improvement and optimization

The process of opening a 3 plate mold involves separating the mold into three plates to release the molded part.

• 1. Release the locking mechanism holding the mold plates together.

• 2. Separate the mold into three plates: A, B, and C.

• 3. Remove the molded part from the cavity in plate B.

• 4. Open plates A and C to release the part.

• 5. Inspect the part for any defects or imperfections.

• 6. Close the mold plates back together for the next molding cycle.

I have worked on designing various plastic parts for consumer electronics, automotive, and household appliances.

• Designed plastic enclosures for electronic devices such as smartphones and laptops

• Developed plastic components for automotive interior and exterior parts

• Created plastic housings for household appliances like vacuum cleaners and kitchen gadgets

To execute multiple product development on time, I prioritize tasks, set clear deadlines, communicate effectively with team members, and regularly track progress.

• Prioritize tasks based on importance and deadlines

• Set clear deadlines for each stage of product development

• Communicate effectively with team members to ensure everyone is on the same page

• Regularly track progress and make adjustments as needed

• Utilize project management tools to stay organized and efficient

I have worked on designing components and systems for various industries including automotive, aerospace, and consumer electronics.

• Designed automotive engine components for improved performance and efficiency

• Developed aerospace systems for navigation and communication

• Created consumer electronics products with focus on user experience and functionality

General checks in FEA calculations

• Check for convergence of the solution

• Verify the boundary conditions and loads

• Ensure the mesh quality and element type

• Validate the material properties

• Compare results with analytical or experimental data

TAS is True Airspeed, OIC is Operational Information Center, TFMS is Traffic Flow Management System, Radar is a detection system, DCV is a Digital Control Valve.

• TAS is the speed of an aircraft relative to the air through which it is flying.

• OIC is a facility that provides real-time situational awareness and decision support to air traffic managers.

• TFMS is a system that manages the flow of air traffic in the National Airspace System.

• Radar is a detection system that uses radio w...read more

PFC topology refers to Power Factor Correction topology, which is used to improve the power factor of electrical systems.

• PFC topology is used to reduce reactive power and improve the power factor of electrical systems.

• It involves the use of active or passive components to correct the phase difference between voltage and current.

• Common PFC topologies include boost converters, buck-boost converters, and flyback converters.

• PFC circuits can be implemented using various control te...read more

Circularity refers to the overall roundness of a feature, while runout refers to the amount of wobble or variation in a feature's position relative to a reference axis.

• Circularity is a 2D tolerance that controls the overall roundness of a feature, ensuring it is within a specified circular boundary.

• Runout is a 3D tolerance that measures the amount of wobble or variation in a feature's position relative to a reference axis.

• Circularity is typically used for features like holes ...read more

I use a variety of tools for design, including CAD software, simulation tools, and prototyping equipment.

• CAD software: I use programs like AutoCAD and SolidWorks to create detailed 2D and 3D designs.

• Simulation tools: I utilize software like ANSYS and MATLAB to simulate and analyze the performance of designs.

• Prototyping equipment: I work with tools such as 3D printers and CNC machines to create physical prototypes of designs.

• Other tools: Depending on the specific project, I ma...read more

The design involves calculations for stress analysis and material selection.

• Calculations for stress analysis to ensure structural integrity

• Calculations for material selection based on properties like strength, weight, and cost

• Finite element analysis (FEA) for simulating real-world conditions

• Thermal analysis for determining heat dissipation

• Tolerance analysis for ensuring proper fit and function

Yes, I am okay with the alwar location.

• I am willing to relocate for the job.

• I have researched the location and am comfortable with it.

• I have no personal or professional commitments that would prevent me from moving.

• I am excited about the opportunity and am ready to start work as soon as possible.

The EV charging plan process involves determining the location, type, and capacity of charging stations.

• Identify suitable locations for charging stations based on factors like population density, traffic patterns, and proximity to major highways.

• Select the type of charging stations to be installed (e.g. Level 1, Level 2, DC fast charging) based on the needs of the area and target users.

• Determine the capacity of each charging station to ensure adequate power supply for chargin...read more

I can provide a Cad model of Bracket in Creo with drawing.

• I am proficient in Creo and can create a 3D model of the bracket with accurate dimensions.

• I can also create a detailed drawing of the bracket with all necessary views and annotations.

• I have experience designing brackets for various applications, including automotive and aerospace industries.

• I can ensure that the bracket is designed to meet all necessary specifications and requirements.

ESR capacity can be calculated by measuring the equivalent series resistance (ESR) of a component or circuit.

• ESR capacity is determined by measuring the ESR of the component or circuit.

• ESR is the resistance that exists in series with the ideal capacitance of a component.

• To calculate ESR capacity, use an ESR meter or measure the voltage drop across a known current.

• ESR capacity is important in determining the performance and reliability of capacitors.

• Example: To calculate the E...read more

The thumb rule for welding is to ensure proper preparation, use the right welding technique, and follow safety precautions.

• Ensure proper cleaning and preparation of the materials to be welded

• Select the appropriate welding technique based on the materials and desired outcome

• Follow safety precautions such as wearing protective gear and ensuring proper ventilation

• Maintain the correct temperature and welding parameters for a strong and durable weld

• Inspect the weld for quality and...read more

Duplex stainless steels are used in various applications due to their high strength and corrosion resistance.

• Used in chemical processing industries for handling corrosive materials

• Commonly used in oil and gas industry for pipelines and offshore platforms

• Used in pulp and paper industry for equipment like digesters and bleach washers

• Applications in desalination plants for seawater intake systems

Clamping force for a part can be calculated using the formula: Clamping Force = Friction Coefficient x Normal Force

• Calculate the normal force acting on the part

• Determine the friction coefficient between the part and the clamping surface

• Multiply the friction coefficient by the normal force to get the clamping force

• Example: Normal force = 1000 N, Friction coefficient = 0.5, Clamping force = 500 N

The bore size depends on the lifting mechanism and the required lifting speed.

• Consider the lifting mechanism (hydraulic, pneumatic, electric, etc.)

• Determine the required lifting speed

• Calculate the force required to lift 500kg

• Select a bore size that can generate the required force and speed

Yes, a CAD test for connector in Solidworks or CATIA can be conducted.

• Create a 3D model of the connector using Solidworks or CATIA

• Ensure the model meets the required specifications and tolerances

• Test the model for functionality and durability

• Make necessary modifications based on test results

• Repeat the testing process until the model meets all requirements

Designing a motor from scratch involves determining the specifications, selecting the appropriate components, and testing the prototype.

• Determine the required specifications such as torque, speed, and power

• Select the appropriate components such as rotor, stator, and bearings

• Design the motor housing and cooling system

• Create a prototype and test it for efficiency and performance

• Iterate and refine the design based on test results

Selection criteria for pneumatic cylinders and valves

• Consider the application requirements such as force, speed, and stroke length

• Select the appropriate cylinder type such as single-acting, double-acting, or rodless

• Choose the valve type based on the required flow rate and pressure

• Consider the environment and operating conditions such as temperature and humidity

• Ensure compatibility between the cylinder and valve components

• Consider the cost and availability of the components

Sensors are selected based on the type of measurement required. Common types include temperature, pressure, and proximity sensors.

• Consider the range and accuracy required for the measurement

• Choose a sensor that is compatible with the system being used

• Consider environmental factors such as temperature and humidity

• Examples include thermocouples, strain gauges, and ultrasonic sensors