100+ Senior Engineer Mechanical Interview Questions and Answers

Different sheet metal manufacturing processes and their suitability based on volume, lead time, and cost.

• Laser cutting for high volume and precision

• Punching for medium volume and cost-effective production

• Waterjet cutting for low volume and complex shapes

• Bending for forming and shaping

• Stamping for high volume and repetitive shapes

• Roll forming for continuous production of long parts

• Choosing the right process based on the required tolerances, material thickness, and complexity o...read more

The questions cover various topics related to mechanical engineering, including transmission of a wheel loader, SAP PM working system, hydraulic diagram of an excavator, suspension system of a dumper, working of a Cummins engine, and common problems in truck gearboxes and differentials.

• Transmission of a wheel loader involves the transfer of power from the engine to the wheels through a series of gears and shafts.

• SAP PM is a computerized maintenance management system that help...read more

The company produces automotive components and has plants in multiple countries.

• The company specializes in manufacturing automotive components such as engines, transmissions, and chassis.

• They have plants in countries like the United States, Mexico, Germany, and China.

• The company's products are used in various vehicles including cars, trucks, and motorcycles.

Handling worsted conditions in a manufacturing job requires staying calm, problem-solving skills, and effective communication.

• Stay calm and composed under pressure to make rational decisions

• Utilize problem-solving skills to quickly address and resolve issues

• Communicate effectively with team members and supervisors to keep them informed of the situation

• Prioritize tasks based on urgency and importance to manage worsted conditions efficiently

There were major breakdowns in the last year for Mps & vrm mill, maintenance time varied depending on the issue.

• There were 3 major breakdowns in the last year for Mps & vrm mill

• Maintenance time ranged from 2 days to 1 week depending on the issue

• Examples: gearbox failure took 3 days to repair, motor malfunction took 1 week to repair

The processes involved in manufacturing a part include design, material selection, machining, assembly, and quality control.

• Design: Create detailed drawings and specifications for the part.

• Material selection: Choose the appropriate material based on the part's function and requirements.

• Machining: Use various techniques such as milling, turning, and drilling to shape the part.

• Assembly: Put together the individual components to create the final part.

• Quality control: Inspect the...read more

Types of columns and reactors, and utilities such as steam boilers.

• Types of columns include packed columns, tray columns, and bubble columns.

• Types of reactors include batch reactors, continuous stirred tank reactors, and plug flow reactors.

• Utilities are systems or equipment used to support a process, such as steam boilers for generating steam.

• Steam boilers are used to generate steam for heating, power generation, and other industrial processes.

The interview questions cover topics such as grades of bolts, bearing types, types of oil and grease, iron carbon diagram, hydraulic systems, and hydraulic hose pipe nomenclature.

• HT bolt grades are determined based on the material and strength requirements, such as Grade 8.8 or Grade 10.9.

• Bearing definition: Bearings are components that support and guide moving parts, with types including ball bearings, roller bearings, and plain bearings.

• Types of oil: Engine oil, hydraulic o...read more

Implementing a visual management system to reduce waste in production processes.

• Implemented color-coded labels for different parts to reduce search time and inventory waste

• Created visual work instructions to reduce errors and rework

• Utilized kanban boards to optimize inventory levels and reduce overproduction

The number of counter weights available for a rope suspended platform varies depending on the specific design and requirements.

• The number of counter weights is determined by factors such as the weight capacity of the platform, the length of the platform, and the load distribution.

• Typically, rope suspended platforms require multiple counter weights to balance the weight of the platform and the load being lifted.

• The counter weights are usually attached to the opposite end of th...read more

Hydraulic systems use liquid to transmit power while pneumatic systems use gas.

• Hydraulic systems use incompressible fluid (usually oil) while pneumatic systems use compressible gas (usually air)

• Hydraulic systems can handle higher loads and pressures compared to pneumatic systems

• Pneumatic systems are generally faster in operation compared to hydraulic systems

• Hydraulic systems are more suitable for heavy-duty applications like construction equipment, while pneumatic systems are...read more

Stress strain curve shows the relationship between stress and strain in a material. Steel is stronger but less ductile than aluminum.

• Stress strain curve is a graphical representation of the behavior of a material under stress

• Steel has a higher yield strength and ultimate strength than aluminum

• Aluminum is more ductile and has a higher strain hardening capacity than steel

• Steel is more brittle than aluminum and is prone to fracture under high stress

• The modulus of elasticity of s...read more

Hydraulic systems use fluid to transmit power and are commonly used in various mechanical applications.

• Hydraulic systems use a fluid (usually oil) to transmit power.

• They consist of a hydraulic pump, valves, cylinders, and hydraulic fluid.

• Schematic diagrams show the flow of hydraulic fluid and components in the system.

• Examples of hydraulic systems include hydraulic brakes in cars and hydraulic lifts in construction equipment.

Maintenance of machineries is important to ensure their optimal performance and prevent breakdowns.

• Regular maintenance helps to identify and fix small issues before they become major problems.

• It increases the lifespan of the machinery and reduces the need for costly repairs or replacements.

• Proper maintenance also ensures the safety of workers who operate the machinery.

• Examples of maintenance tasks include lubrication, cleaning, inspection, and calibration.

• Maintenance can also...read more

A free body diagram is a visual representation of the forces acting on a body.

• It shows all the external forces acting on a body

• It helps in analyzing the forces and their effects on the body

• It is used in engineering to design and analyze structures and machines

• It is important to label all the forces and their directions in the diagram

Actuator, solenoid valve, gear type gearbox, and chain sprocket are mechanical components used in various systems.

• An actuator is a device that converts energy into motion, often used to control or move a mechanism.

• A solenoid valve is an electromechanical device that controls the flow of fluid or gas using an electric current.

• A gear type gearbox is a mechanical device that uses gears to transmit power and change the speed or torque of a rotating shaft.

• A chain sprocket is a too...read more

Various tools and equipment are used for alignment, such as laser alignment tools, dial indicators, alignment bars, and optical alignment systems.

• Laser alignment tools

• Dial indicators

• Alignment bars

• Optical alignment systems

To decrease expenditure cost of machinery, focus on optimizing maintenance, improving energy efficiency, and streamlining production processes.

• Implement preventive maintenance programs to reduce breakdowns and costly repairs.

• Optimize energy consumption by using energy-efficient equipment and technologies.

• Streamline production processes to minimize waste and increase productivity.

• Invest in automation and robotics to reduce labor costs and improve efficiency.

• Negotiate better de...read more

Engine oil, gear oil, axle oil, and hydraulic oil serve different purposes in a vehicle and have specific grades for optimal performance.

• Engine oil is used to lubricate internal combustion engines and comes in different grades such as 5W-30 or 10W-40.

• Gear oil is designed for transmissions, differentials, and transfer cases to reduce friction and wear. Common grades include 75W-90 or 80W-90.

• Axle oil is specifically formulated for axles to provide lubrication and cooling. Grade...read more

Ventilation is necessary in tunneling work to ensure the safety and health of workers.

• To remove harmful gases and fumes from the tunnel

• To control the temperature and humidity levels

• To provide fresh air for workers to breathe

• To prevent the buildup of dust and debris

• To maintain proper air pressure inside the tunnel

• Examples: subway tunnels, mining tunnels, road tunnels

I have worked in a pumping station with a capacity of 10,000 cubic meters per hour.

• Worked in a pumping station with a capacity of 10,000 cubic meters per hour

• Managed operations and maintenance of pumps, valves, and pipelines

• Implemented efficiency improvements to optimize pumping station performance

I have handled a wide range of machinery including CNC machines, 3D printers, industrial robots, and hydraulic systems.

• CNC machines

• 3D printers

• Industrial robots

• Hydraulic systems

Efficiency of rotary equipment can be calculated by dividing the actual output by the theoretical output.

• Efficiency = (Actual Output / Theoretical Output) x 100%

• Actual Output can be measured using instruments like flow meters, pressure gauges, etc.

• Theoretical Output can be calculated using manufacturer's data or engineering calculations.

• Efficiency can be improved by reducing friction, optimizing design, and regular maintenance.

• Example: To calculate the efficiency of a pump, m...read more

I manage vendors and subcontractors by establishing clear communication channels, setting expectations, monitoring progress, and resolving any issues promptly.

• Establish clear communication channels with vendors and subcontractors

• Set expectations regarding deliverables, timelines, and quality standards

• Monitor progress regularly to ensure project milestones are being met

• Resolve any issues or conflicts promptly to prevent delays

• Maintain positive relationships with vendors and su...read more

APQP is Advanced Product Quality Planning, a framework used in the automotive industry to ensure quality in new product development.

• APQP is a structured method for defining and establishing the steps necessary to ensure that a product satisfies the customer.

• APQP documents include FMEA (Failure Mode and Effects Analysis), Control Plan, PPAP (Production Part Approval Process), etc.

• Current company product knowledge refers to understanding the products manufactured by the company...read more

PMS stands for Piping Material Specification. One class for LPG system piping is Class 150.

• PMS is a document that specifies the materials, standards, and requirements for piping systems.

• Class 150 is a common class for LPG system piping, indicating the pressure rating of the piping components.

• PMS helps ensure that the piping system is designed and constructed according to industry standards and safety regulations.

We have a Bosch 500W drill machine at our site.

• We use a Bosch 500W drill machine for drilling holes in metal and wood.

• The drill machine has a variable speed control and a keyless chuck.

• It is lightweight and easy to handle, making it ideal for our needs.

• We also have a set of drill bits for different sizes and materials.

• The drill machine has been reliable and efficient for our projects.

Tact time is the time taken to produce one unit, while process time is the total time taken to complete a process.

• Tact time is the time taken to produce one unit of a product, while process time is the total time taken to complete the entire process.

• Tact time is usually shorter than process time as it focuses on the time taken for one unit, while process time considers all units produced.

• Correlating tact time and process time helps in identifying bottlenecks and improving ove...read more

There are three main types of defects in die casting industry: surface defects, internal defects, and dimensional defects.

• Surface defects include issues like gas porosity, shrinkage porosity, and cold shuts.

• Internal defects can be caused by trapped air, inclusions, or improper metal flow.

• Dimensional defects may result from issues with the die or improper cooling.

• Examples of defects include porosity, cracks, and misshapen parts.

Value Analysis and Value Engineering are systematic approaches to improve the value of a product or service by optimizing its functions and reducing its cost.

• Value Analysis is a process of analyzing a product or service to identify its functions and costs.

• Value Engineering is a systematic approach to improve the value of a product or service by optimizing its functions and reducing its cost.

• Value Engineering involves a team of professionals from different disciplines who work...read more

Increasing cylinder movement speed can be achieved by optimizing the design, reducing friction, increasing pressure, or using a more powerful actuator.

• Optimize the design to reduce unnecessary weight and improve efficiency

• Reduce friction by using high-quality materials, lubricants, or coatings

• Increase pressure in the system to provide more force for faster movement

• Use a more powerful actuator with higher torque or speed capabilities

• Implement advanced control systems for preci...read more

If wbt & dbt are equal, the air is fully saturated and the relative humidity is 100%.

• The air is fully saturated with water vapor.

• The relative humidity is 100%.

• Condensation may occur on surfaces due to the high moisture content in the air.

• This condition is known as the dew point temperature.

The gear module for bar rolling mills depends on various factors such as the size and weight of the bars, desired speed and torque, and the type of rolling process.

• The gear module should be selected based on the size and weight of the bars being rolled. Heavier bars may require larger gear modules to handle the increased load.

• The desired speed and torque of the rolling mill also play a role in determining the appropriate gear module. Higher speeds and torques may require smal...read more

A roots blower is a type of positive displacement pump that operates by pumping fluid between a pair of meshing lobes.

• Consists of two counter-rotating lobes that trap and move fluid through the blower

• Fluid is pushed from the inlet to the outlet without compression

• Commonly used in applications such as wastewater treatment, pneumatic conveying, and vacuum systems

To reduce cost effectiveness of damages, focus on preventive maintenance, training, risk assessment, and using quality materials.

• Implement regular preventive maintenance schedules to identify and address potential issues before they become costly damages

• Provide training to employees on proper equipment usage and maintenance procedures to prevent accidents and damages

• Conduct regular risk assessments to identify and mitigate potential hazards that could lead to damages

• Use high-...read more

Regular maintenance schedules, monitoring equipment performance, training staff on proper usage and maintenance

• Implement regular maintenance schedules for all equipment

• Monitor equipment performance and look for signs of wear or potential issues

• Train staff on proper usage and maintenance procedures to prevent breakdowns

• Keep spare parts on hand for quick repairs when needed

PEB structures are pre-engineered buildings that are fabricated off-site and then erected on-site.

• PEB structures are cost-effective and time-efficient compared to traditional construction methods.

• They are made of steel and are designed to meet specific requirements and standards.

• PEB structures are used in various industries such as warehouses, factories, and sports facilities.

• Fabrication and erection of PEB structures require skilled labor and specialized equipment.

• Quality co...read more

I follow various parameters to ensure quality and efficiency in mechanical engineering.

• I follow industry standards and regulations

• I consider safety, reliability, and durability

• I analyze and optimize designs for performance

• I use appropriate materials and manufacturing processes

• I consider environmental impact and sustainability

• I collaborate with cross-functional teams

• I continuously learn and improve my skills

Gpm for water supply pump can be calculated by dividing the flow rate in gallons by the time in minutes.

• Calculate the flow rate in gallons per minute (GPM)

• Determine the time in minutes over which the flow rate is measured

• Divide the flow rate by the time to get the GPM value

Turbines are machines that convert fluid energy into mechanical energy. There are four main types of turbines.

• Turbines are used in power generation, aviation, and marine propulsion.

• The four main types of turbines are steam, gas, hydro, and wind turbines.

• Steam turbines are used in power plants to generate electricity.

• Gas turbines are used in aviation and power generation.

• Hydro turbines are used in hydroelectric power plants.

• Wind turbines are used to generate electricity from w...read more

Material handling systems are used to move, store, and control materials throughout a manufacturing or distribution facility.

• Types include conveyors, cranes, hoists, automated guided vehicles (AGVs), and robotic systems.

• Conveyors are used to transport materials along a fixed path.

• Cranes and hoists are used for lifting and moving heavy materials.

• AGVs are autonomous vehicles that can transport materials without human intervention.

• Robotic systems are used for tasks such as picki...read more

A load sensing pump adjusts its flow rate based on the load demand to optimize energy efficiency.

• A load sensing pump has a pressure compensator that adjusts the flow rate based on the load pressure.

• It senses the load pressure and adjusts the pump displacement to meet the demand.

• This helps in reducing energy consumption and improving overall system efficiency.

• Examples of load sensing pumps include variable displacement piston pumps and load sensing gear pumps.

I maintain a detailed logbook for each machine, including maintenance schedules, repairs, and any upgrades.

• Create a logbook for each machine

• Record maintenance schedules, repairs, and upgrades

• Include dates, details of work done, and any parts replaced

• Regularly update the logbook

• Use digital tools like spreadsheets or specialized software for easier tracking

Material science is the study of the properties and behavior of materials.

• It involves the study of the structure, properties, and performance of materials.

• It encompasses a wide range of materials including metals, ceramics, polymers, and composites.

• Material scientists use various techniques to analyze and manipulate materials, such as microscopy, spectroscopy, and mechanical testing.

• The field of material science has many practical applications, such as developing new material...read more

Oxidation process is a chemical reaction where a substance loses electrons, while bus bar calculation involves determining the size and material of bus bars for electrical distribution.

• Oxidation process involves the loss of electrons by a substance, leading to the formation of oxides.

• Bus bar calculation is the process of determining the size, material, and configuration of bus bars based on the electrical load and distribution requirements.

• Example: In oxidation process, iron ...read more

Heat exchangers are devices used to transfer heat between two or more fluids, ensuring efficient heat transfer and temperature control.

• Transfer heat between fluids

• Maintain temperature control

• Increase energy efficiency

• Commonly used in HVAC systems, refrigeration units, and chemical processing plants

Chillers are refrigeration systems used to cool water or air for air conditioning systems. TR is the unit of cooling capacity.

• Chillers use refrigeration cycles to remove heat from water or air.

• TR stands for 'ton of refrigeration' and is equal to the amount of heat required to melt one ton of ice in 24 hours.

• To find TR, calculate the heat load of the space to be cooled and divide by 12,000.

• For example, if the heat load is 240,000 BTU/hr, the TR would be 20 (240,000/12,000).