50+ Tool Room Engineer Interview Questions and Answers

Different types of arc welding rods used for die steel.

• E7018 electrode is commonly used for welding die steel.

• E312 electrode is used for welding stainless die steel.

• E309 electrode is used for welding high alloy die steel.

• E6010 electrode can be used for welding mild steel dies.

The clearance between punch and die button refers to the gap or space between the punch and the die button in a tooling setup.

• The clearance is necessary to ensure proper functioning of the tooling system.

• It allows for the material to flow smoothly and prevents binding or sticking.

• The clearance can vary depending on the material being worked with and the specific application.

• It is typically measured in terms of percentage of material thickness or in millimeters.

• For example, in...read more

Correct thinning and crack in online can be achieved through proper inspection and repair techniques.

• Thinning and cracks in online can be corrected by identifying the root cause of the issue.

• Thinning can be addressed by applying appropriate coatings or welding techniques to restore the thickness of the material.

• Cracks can be repaired by using techniques like welding, brazing, or applying epoxy resins.

• Regular inspection and maintenance can help identify thinning and cracks at ...read more

Hardness in die steel is determined by its composition and heat treatment process.

• Hardness in die steel is primarily influenced by the amount and type of alloying elements present in the steel.

• Higher carbon content generally results in increased hardness.

• Heat treatment processes like quenching and tempering can further enhance the hardness of die steel.

• Different types of die steels have different hardness levels, such as H13 tool steel typically having a hardness of around 50...read more

Yes

• I worked on a challenging sheet metal tooling project for a client in the automotive industry.

• The project involved designing and manufacturing a complex stamping die for a new car body part.

• One of the difficulties encountered was achieving the desired level of precision in the stamped part.

• To resolve this, I collaborated closely with the client's engineering team to analyze the design and identify potential areas for improvement.

• We made several iterations of the tooling de...read more

Yes, I can read and understand mechanical drawings.

• I have experience in interpreting technical drawings and schematics.

• I am familiar with standard symbols and conventions used in mechanical drawings.

• I can identify different views and dimensions on a drawing.

• I have worked with CAD software to create and modify mechanical drawings.

• I am able to communicate effectively with designers and other engineers to clarify any questions or concerns.

Conventional machines are traditional machines used in manufacturing, while non-conventional medicine refers to alternative forms of medical treatment.

• Conventional machines are commonly used in industries for manufacturing products.

• They are typically mechanical and operate using traditional methods.

• Examples of conventional machines include lathes, milling machines, and drilling machines.

• Non-conventional medicine includes alternative forms of treatment that are not part of mai...read more

A grinding machine is a tool used for removing material from a workpiece by abrasion, typically using a rotating wheel.

• Basic functions in a grinding machine panel include speed control, wheel dressing, coolant system, and feed control.

• Speed control allows for adjusting the rotation speed of the grinding wheel.

• Wheel dressing involves shaping the grinding wheel to the desired form.

• Coolant system helps in reducing heat generated during the grinding process.

• Feed control regulates...read more

Stress relieving in inserts requires heat treatment to reduce internal stresses and improve material properties.

• Heat treatment is necessary to relieve stress in inserts.

• The process involves heating the insert to a specific temperature and holding it for a certain duration.

• The temperature and duration depend on the material and the desired outcome.

• Stress relieving helps to minimize distortion, improve dimensional stability, and enhance mechanical properties.

• Common methods for ...read more

Blanking cuts out a flat shape from a metal sheet, piercing creates a hole in the sheet, and drawing stretches the metal into a desired shape.

• Blanking involves cutting out a flat shape from a metal sheet.

• Piercing creates a hole in the metal sheet.

• Drawing stretches the metal into a desired shape, often using a die and punch set.

• Examples: Blanking - cutting out a washer shape from a metal sheet, Piercing - creating holes for screws in a metal plate, Drawing - forming a metal cu...read more

The drill bit angle and M12&M8 drill size depend on the material being drilled and the desired hole size.

• The drill bit angle should match the material being drilled for optimal performance.

• M12 and M8 refer to the diameter of the drill bit in millimeters.

• For example, a 118 degree angle is suitable for drilling soft materials like wood and plastic, while a 135 degree angle is better for harder materials like metal.

• The size of the drill bit needed depends on the desired hole siz...read more

The material commonly used for core and cavity in tool room engineering is typically tool steel.

• Tool steel is a popular choice for core and cavity material due to its high hardness and wear resistance.

• Common types of tool steel used include P20, H13, and S7.

• Tool steel can be heat treated to achieve desired hardness and toughness properties.

• Other materials such as aluminum or pre-hardened steel may also be used depending on the specific requirements of the tool.

Milling machine removes material by rotating a cutting tool, while turning machine removes material by rotating the workpiece.

• Milling machine uses a cutting tool that moves in all three dimensions to remove material from the workpiece.

• Turning machine rotates the workpiece while a cutting tool removes material to create cylindrical shapes.

• Milling machine is used for creating complex shapes like gears, while turning machine is used for creating cylindrical shapes like shafts.

• Ex...read more

The hardness of core pine varies depending on the specific species and age of the wood.

• The hardness of pine wood is typically measured using the Janka hardness test.

• Different species of pine have different hardness levels.

• Older pine wood tends to be harder than younger wood.

• The Janka hardness rating for Eastern White Pine is around 380 lbf, while Southern Yellow Pine can range from 690 to 870 lbf.

The thickness of the part is 2.5 millimeters.

• The thickness of the part is a critical dimension that needs to be accurately measured.

• It is important to ensure that the part meets the required thickness specifications.

• Examples of tools used to measure thickness include calipers, micrometers, and thickness gauges.

Hot runner is used in mould to maintain the temperature of the plastic material and prevent wastage.

• Prevents wastage of plastic material

• Maintains consistent temperature of plastic material

• Reduces cycle time of injection molding process

• Improves quality of final product

• Examples: automotive parts, medical devices, consumer goods

There are three main types of mould maintenance: preventive maintenance, corrective maintenance, and predictive maintenance.

• Preventive maintenance involves regular inspections and cleaning to prevent issues before they occur.

• Corrective maintenance is done to fix issues that arise during production.

• Predictive maintenance uses data and analytics to predict when maintenance is needed before a breakdown occurs.

There are several types of welding used in mould making.

• Types of welding in mould making include TIG welding, MIG welding, resistance welding, laser welding, and ultrasonic welding.

• Each type of welding has its own advantages and limitations in terms of speed, precision, and heat input.

• For example, TIG welding is often used for precision welding in mould making, while MIG welding is faster but may not provide as much control.

• Resistance welding is commonly used for joining larg...read more

Maintain ejection pin height by regular inspection, cleaning, lubrication, and replacement if necessary.

• Inspect ejection pins regularly to ensure they are at the correct height

• Clean ejection pins to remove any debris or buildup that may affect their height

• Lubricate ejection pins to prevent wear and tear that can cause them to sink

• Replace ejection pins if they are damaged or worn beyond repair

A tool is an object or device used to perform a specific task or function.

• Tools can be hand-held or power-operated

• Examples include hammers, screwdrivers, drills, and saws

• Tools are often designed for specific tasks or materials

• Proper use and maintenance of tools is important for safety and effectiveness

Clearance in die and punch refers to the gap between the punch and die in a tooling setup.

• Clearance is necessary to prevent binding and ensure proper cutting or forming of materials.

• The amount of clearance needed depends on the material being worked with and the type of operation.

• Examples of clearance values include 5-10% of material thickness for cutting operations and 10-20% for bending operations.

There are three types of gates on injection molds: sprue, runner, and gate.

• Sprue gate is the entry point for the molten plastic into the mold.

• Runner gate connects the sprue to the part cavity.

• Gate is the opening through which the plastic enters the part cavity.

• Types of gates include edge gate, submarine gate, tab gate, and more.

• The choice of gate type depends on the part design, material, and production requirements.

Vernier is a measuring instrument used for more precise measurements than a regular scale or ruler.

• Vernier is used to measure small distances with high accuracy.

• It consists of a main scale and a sliding vernier scale that allows for more precise readings.

• Vernier calipers are a common type of vernier used in engineering and machining.

• Vernier is commonly used in tool rooms for accurate measurements of tools and components.

A mould is a hollowed-out block that is filled with a liquid or pliable material to create a specific shape or form. There are several types of moulds used in manufacturing processes.

• Moulds are commonly used in industries such as plastics, ceramics, and metal casting.

• Types of moulds include injection moulds, compression moulds, blow moulds, and rotational moulds.

• Each type of mould has its own unique characteristics and is used for specific manufacturing processes.

• For example,...read more

TPM stands for Total Productive Maintenance and CLITA stands for Cleanliness, Lubrication, Inspection, Tightening, and Adjustment.

• TPM is a proactive approach to maintenance that aims to maximize equipment effectiveness and minimize downtime.

• CLITA is a set of activities focused on maintaining equipment in optimal condition by ensuring cleanliness, proper lubrication, regular inspection, tightening of components, and adjustments as needed.

• TPM involves all employees in the maint...read more

Tool room is a facility where tools and equipment are designed, manufactured, and repaired for use in production processes.

• Tool room engineers are responsible for designing and developing tools and equipment used in manufacturing processes.

• They work closely with production teams to understand their tooling needs and provide solutions.

• Tool room engineers also maintain and repair existing tools to ensure they are functioning properly.

• They may use computer-aided design (CAD) sof...read more

The least count of a vernier caliper is the smallest measurement that can be read on the scale.

• The least count is determined by the number of divisions on the main scale and the vernier scale.

• It is calculated as the difference between one smallest division on the main scale and one division on the vernier scale.

• For example, if the main scale has divisions of 1 mm and the vernier scale has 10 divisions that cover 9 main scale divisions, the least count would be 0.1 mm.

Wedge matching is the process of aligning two wedges to ensure proper fit and function.

• Measure the angles of the wedges to ensure they match

• Use a wedge gauge to check the fit

• Adjust the wedges as necessary to achieve proper alignment

• Ensure the wedges are securely fastened in place

Core and cavity are the two main components of a mold used in injection molding processes.

• Core is the part of the mold that creates the internal features of the final product

• Cavity is the part of the mold that creates the external features of the final product

• They work together to form the shape of the product being manufactured

• Examples: In a plastic cup mold, the core would create the hollow interior while the cavity would create the outer shape

The material of PDC (Polycrystalline Diamond Compact) die is typically made of synthetic diamond.

• PDC die is used in the manufacturing of cutting tools for drilling and milling applications.

• The synthetic diamond material used in PDC die is created through high-pressure, high-temperature (HPHT) processes.

• The diamond material provides exceptional hardness and wear resistance, making it suitable for demanding tooling applications.

• PDC die can be used in various industries such as ...read more

There are various types of molds used in tool rooms, including injection molds, blow molds, and compression molds.

• Injection molds are used to create plastic parts by injecting molten material into a mold cavity.

• Blow molds are used to create hollow plastic products, such as bottles, by blowing air into a molten plastic tube.

• Compression molds are used to shape materials, such as rubber, by applying pressure and heat.

• Other types of molds include transfer molds, rotational molds,...read more

Clearance between punch and die is crucial for proper operation and quality of the finished product.

• Clearance should be determined based on material type and thickness

• Typical clearance ranges from 5% to 20% of material thickness

• Insufficient clearance can lead to burrs or damage to the tooling

• Excessive clearance can result in poor quality cuts or premature tool wear

The type of mould refers to the design and construction of the mould used in tooling processes. The gate point is the location where the molten material enters the mould cavity.

• The type of mould can vary depending on the specific requirements of the tooling process.

• Common types of moulds include injection moulds, blow moulds, and compression moulds.

• The gate point is strategically chosen to ensure proper filling of the mould cavity and minimize defects.

• Examples of gate points ...read more

History card can be checked by reviewing the documented information related to a particular tool or equipment.

• Review the history card for details on maintenance, repairs, inspections, and usage of the tool or equipment.

• Check for dates of previous maintenance activities and any issues reported during inspections.

• Verify that all required information is properly documented on the history card.

• Ensure that the history card is up to date and accurately reflects the current status o...read more

SAP is a software system used for managing business operations and customer relations.

• SAP stands for Systems, Applications, and Products in Data Processing.

• It is used for managing various business operations such as finance, sales, production, and inventory.

• SAP provides a centralized database for storing and retrieving data.

• It helps in streamlining business processes and improving efficiency.

• Examples of SAP modules include SAP FI (Financial Accounting), SAP MM (Materials Mana...read more

I choose tool room because I enjoy working with precision tools and machinery, solving technical problems, and contributing to the manufacturing process.

• I have a passion for working with precision tools and machinery

• I enjoy solving technical problems and challenges

• I like contributing to the manufacturing process by creating and maintaining tools and molds

• I find satisfaction in seeing the end result of my work in the production line

Packaging refers to the process of designing, creating, and producing containers or materials used to protect and transport products.

• Packaging can include boxes, bags, bottles, and other types of containers

• It can also involve labeling, branding, and marketing materials

• Packaging serves to protect products during transportation and storage

• It can also provide information about the product and its contents

• Sustainable packaging is becoming increasingly important in reducing waste ...read more

Types of maintenance include corrective, preventive, predictive, and proactive maintenance.

• Corrective maintenance involves fixing a problem after it has occurred.

• Preventive maintenance involves scheduled maintenance to prevent problems from occurring.

• Predictive maintenance involves using data to predict when maintenance is needed.

• Proactive maintenance involves identifying and addressing potential problems before they occur.

• Examples include replacing worn parts, cleaning equip...read more

Yes, I do have a motorcycle.

• I own a Honda CB500F.

• I enjoy taking it out on weekend rides.

• I always wear proper safety gear when riding.

Blue matching is the process of matching the color of a new part to an existing one.

• Use a spectrophotometer to measure the color of the existing part

• Adjust the color of the new part using pigments or dyes

• Compare the color of the new part to the existing one under different lighting conditions

• Repeat the process until the colors match

Spare management involves tracking, organizing, and optimizing spare parts inventory to ensure timely availability and cost-effectiveness.

• Create a detailed inventory of all spare parts including part numbers, quantities, and locations.

• Implement a system for tracking spare parts usage and reorder points to avoid stockouts.

• Regularly review and update spare parts inventory based on usage patterns and equipment maintenance schedules.

• Establish relationships with reliable suppliers...read more

Preventive maintenance is a proactive approach to maintenance that involves regularly scheduled inspections, repairs, and replacements to prevent equipment breakdowns.

• Regularly scheduled inspections to identify potential issues before they become major problems

• Routine cleaning and lubrication to keep equipment running smoothly

• Replacing worn out parts before they fail to prevent costly breakdowns

• Keeping detailed records of maintenance activities for future reference

• Implementin...read more

A jig is a tool used in manufacturing to guide and control the movement of another tool or workpiece.

• Jigs are used to ensure accuracy and repeatability in the manufacturing process.

• They help in reducing human error and increasing productivity.

• Jigs are commonly used in industries like automotive, aerospace, and electronics.

• Examples of jigs include drill jigs, welding jigs, and assembly jigs.

PM of mold involves regular inspection, cleaning, lubrication, and replacement of parts to ensure optimal performance.

• Inspect mold for wear and damage

• Clean mold surfaces regularly to prevent buildup of debris

• Lubricate moving parts to reduce friction and wear

• Replace worn or damaged parts as needed to maintain quality of output

• Keep detailed records of maintenance activities for future reference

A hot runner mold is a type of injection molding system where the plastic material is kept molten in the runner system and injected directly into the mold cavity.

• Hot runner molds eliminate the need for sprues and runners, reducing material waste.

• They can improve cycle times and reduce production costs.

• Examples include Husky hot runner systems and Mold-Masters hot runner systems.

Hot runner system is a heating system used in injection molding to keep the plastic material molten in the runner and nozzle.

• Hot runner system is used to reduce waste and improve cycle time in injection molding.

• It consists of a manifold, nozzles, and heaters that keep the plastic material molten.

• The system is controlled by a temperature controller that maintains the temperature of the plastic material.

• Hot runner systems can be either internally or externally heated.

• Examples o...read more

Plastic materials can be classified into thermoplastics, thermosets, and elastomers.

• Thermoplastics can be melted and re-molded, examples include polyethylene and PVC.

• Thermosets cannot be melted and re-molded, examples include epoxy and phenolic resins.

• Elastomers are rubber-like materials, examples include silicone and neoprene.