12/22/24, 7:17 PM 500+ Design Engineer Interview Questions & Answers for Experienced (Updated 2024) | AmbitionBox

Design Engineer

500+ Design Engineer Interview Questions and Answers for Experienced

Updated 26 Nov 2024

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Q51. Customer Part Design sheet to view 3D Model in solidworks software

Ans. To view a customer's part design sheet in Solidworks software, follow these steps:
Open Solidworks software
Click on 'Open' and select the customer's part design sheet
The 3D model will be displayed in Solidworks
Use the software's tools to manipulate and analyze the model as needed

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CAD Software

Q52. What is nominal stress for a mild steel plate

Ans. The nominal stress for mild steel plate depends on the thickness of the plate and the yield strength of the steel.

Nominal stress is the maximum stress that a material can withstand before it fails
For mild steel, the nominal stress is typically calculated using the yield strength of the steel
The thickness of the plate also plays a role in determining the nominal stress
The formula for calculating nominal stress is: Nominal stress = Yield strength / Factor of safety
For example, if the yield strength of the mild steel is 250 MPa and the factor of safety is 2, the nominal stress would be 125 MPa
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Q53. What is GD&T, machining operations, fits,CNC & VMC operations, roughness, concentricity, datum and so on.
Ans. GD&T is a system for defining and communicating engineering tolerances. Machining operations involve shaping materials using various tools
and techniques.

GD&T stands for Geometric Dimensioning and Tolerancing, used to specify the allowable variations in form and size of a part.
Machining operations include processes like turning, milling, drilling, and grinding to shape materials into desired forms.

Fits refer to the clearance or interference between mating parts, such as a tig...read more
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Q54. Which types of Plastic componet you are made?

Ans. I have experience in designing various types of plastic components including injection molded parts, extruded profiles, and thermoformed
products.
Injection molded parts

Extruded profiles

Thermoformed products
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Q55. 4. In pp plastic material coating or painting are used?

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Ans. In pp plastic material, coating is preferred over painting for better adhesion and durability.

Coating is commonly used on PP plastic material for better adhesion and durability
Painting is less preferred on PP plastic due to poor adhesion and durability

Examples of coatings for PP plastic include polypropylene-specific primers and adhesion promoters

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Q56. How buoyancy works for a balloon if car is taking a turn?

Ans. Buoyancy in a balloon is not affected by the car taking a turn due to the principle of relative motion.
Buoyancy is a force exerted by a fluid that opposes the weight of an immersed object.

The balloon and the air inside it are both moving with the car, so the buoyant force remains constant.
The buoyant force is determined by the displaced fluid, not the motion of the object.

Therefore, the balloon will continue to float in the same manner regardless of the car's movement.
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Q57. What are the different pros and cons of isometric view and parametric view?
Ans. Isometric view and parametric view have different advantages and disadvantages.

Isometric view provides a 3D representation of an object, making it easier to visualize and understand.

Parametric view allows for easy modification of dimensions and parameters, saving time and effort.

Isometric view can be misleading in terms of proportions and distances.

Parametric view can be complex and difficult to set up initially.

Isometric view is commonly used in engineering and architecture.

Parametric view is commonly used in CAD software and product design.

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Graphics

Q58. 1. How to calculate transformer size?

Ans. Transformer size is calculated based on the load requirements and voltage levels.

Determine the load requirements in kVA or amps

Determine the primary and secondary voltage levels

Calculate the required turns ratio

Select a transformer with a suitable kVA rating and voltage levels

Consider factors such as efficiency, temperature rise, and insulation class

Consult relevant standards and regulations

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Q59. How much do you know about CHS?

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Ans. CHS stands for Circular Hollow Section, a type of steel tube used in construction and engineering.

CHS is commonly used in the construction of buildings, bridges, and other structures.

It is known for its strength and durability.

CHS is often used in applications where weight is a concern, as it is lighter than solid steel.

It is available in a range of sizes and thicknesses to suit different applications.

CHS can be used in both compression and tension applications.

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Q60. Sheet metal component for CAD test

Ans. A sheet metal component needs to be designed using CAD software for testing purposes.
Understand the specifications and requirements of the component

Choose the appropriate sheet metal material and thickness

Create a 2D sketch of the component

Use sheet metal tools to add bends, flanges, and other features

Add necessary cutouts and holes

Check for interference and collisions

Export the design in the required file format

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Q61. What is difference between simulation and modeling?

Ans. Simulation is the imitation of a real-world process or system, while modeling is the creation of a simplified representation of a system.

Simulation involves running a model to observe its behavior in different scenarios.

Modeling involves creating a simplified representation of a system or process.

Simulation is used to predict the behavior of a system under different conditions.

Modeling is used to understand the behavior of a system and make predictions about its future behavior.
Simulation requires a detailed model of the system being simulated.

Modeling can be done at different levels of detail, depending on the purpose of the model.

Examples of simulation include flight simulators, weather forecasting models, and traffic flow models.

Examples of modeling include financial models, climate models, and population growth models.
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Q62. Which ASME codes do you used in previous organization?

Ans. I have used ASME B31.1 and B31.3 codes in my previous organization.

ASME B31.1 for Power Piping

ASME B31.3 for Process Piping

Used for design and construction of piping systems

Ensured compliance with safety standards
Reviewed and interpreted code requirements

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Q63. which method are used to plastic manufacturing?

Ans. Various methods such as injection molding, blow molding, extrusion, and rotational molding are used in plastic manufacturing.
Injection molding: molten plastic is injected into a mold to create a part
Blow molding: air pressure is used to expand molten plastic into a mold

Extrusion: plastic is melted and forced through a die to create a continuous profile
Rotational molding: powdered plastic is rotated in a mold until it coats the entire surface

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Q64. why kaplan turbine is used for low head?

Ans. Kaplan turbines are used for low head because they are designed to operate efficiently in low head conditions.
Kaplan turbines have adjustable blades that allow for optimal performance in low head situations

They have a higher specific speed compared to other turbine types, making them suitable for low head applications
Examples of low head applications include run-of-river hydroelectric plants and irrigation systems
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Q65. what is A3 paper sheet size in mm?

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Ans. A3 paper sheet size is 297 x 420 mm.
A3 paper size is commonly used for drawings, diagrams, and posters.
It is part of the ISO 216 standard paper sizes.

The dimensions of A3 paper are 297 x 420 mm or 11.7 x 16.5 inches.

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Q66. what is diff b/w PFMEA & DFMEA?

Ans. PFMEA focuses on potential failures in the manufacturing process, while DFMEA focuses on potential failures in the design process.

PFMEA stands for Process Failure Mode and Effects Analysis, while DFMEA stands for Design Failure Mode and Effects Analysis.
PFMEA is used to identify and prioritize potential failure modes in the manufacturing process, while DFMEA is used to identify and prioritize
potential failure modes in the design process.
PFMEA helps in improving the manufacturing process by addressing potential failure modes, while DFMEA helps in improving the design by
addressing potential failure modes.

An example of PFMEA could be identifying a potential failure in a specific manufacturing step that could lead to defects in the final product,
while an example of DFMEA could be identifying a potential failure in a design feature that could lead to safety hazards.
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Q67. Minimum reinforcement for RCC columns , beams , slabs

Ans. Minimum reinforcement for RCC columns, beams, slabs is specified in codes and depends on various factors.

Minimum reinforcement is specified in codes such as IS 456 for Indian standards and ACI 318 for American standards.
The minimum reinforcement depends on factors such as the size of the member, the type of loading, and the exposure conditions.
For example, the minimum reinforcement for a column may be 0.8% of the cross-sectional area for mild exposure conditions.

Similarly, the minimum reinforcement for a beam may be 0.85% of the cross-sectional area for moderate exposure conditions.
The minimum reinforcement for a slab may be 0.12% of the cross-sectional area for mild exposure conditions.

The minimum reinforcement is provided to ensure that the member can resist the applied loads and maintain its shape and integrity.
The actual reinforcement provided may be higher than the minimum reinforcement depending on the design requirements and detailing
considerations.
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Q68. What is a stress and strain Different b/w 1 st angle and 3 rd angle Detail of drowning Details in Solidworks command
Ans. Answering questions related to stress and strain, drawing, and Solidworks commands.

Stress is the force per unit area applied to a material, while strain is the deformation caused by stress.
First angle and third angle projection are two methods of representing a 3D object in 2D drawings.

Drawing is the process of creating a visual representation of an object or idea.

Solidworks is a computer-aided design software used for creating 3D models and drawings.
Examples of Solidworks commands include extrude, revolve, and fillet.

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Q69. Do you know autocad software & how it is used?

Ans. Yes, AutoCAD is a widely used software for creating 2D and 3D designs in various industries.
AutoCAD is used for creating precise technical drawings and models.

It is commonly used in architecture, engineering, and construction industries.

Users can create detailed floor plans, blueprints, and 3D models using AutoCAD.

The software allows for accurate measurements, annotations, and layering of designs.
AutoCAD files can be easily shared and edited by multiple users.
Proficiency in AutoCAD is often a requirement for design engineering roles.

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Q70. 1)What is Renloyds number? 2) What is degree of freedom?

Ans. Renloyds number is a dimensionless number used in fluid mechanics to characterize the flow of a fluid over a surface.
Renloyds number is defined as the ratio of inertial forces to viscous forces in a fluid flow.

It is used to determine the type of flow (laminar or turbulent) that occurs over a surface.
Renloyds number is calculated using the formula: Re = (ρ * V * L) / μ, where ρ is the density of the fluid, V is the velocity of the fluid, L is a
characteristic length, and μ is ...read more
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Q71. What is K factor and Bend allowance

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Ans. K factor and bend allowance are important factors in sheet metal bending.

K factor is a ratio that determines the location of the neutral axis in relation to the thickness of the material.
Bend allowance is the amount of material that is required to make a bend.

K factor and bend allowance are used to calculate the length of material needed for a bend.
K factor and bend allowance vary depending on the material being used and the type of bend being made.
K factor and bend allowance are important for ensuring accurate and consistent bends in sheet metal.

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Q72. 2. what is shutt off angle in molding?

Ans. Shut off angle in molding refers to the angle at which the mold halves meet and close to form a complete part.
Shut off angle is crucial for ensuring proper part ejection and preventing flash formation.

It is typically between 0.5 to 3 degrees, depending on the material and part design.
A larger shut off angle may be required for parts with deep cavities or complex geometries.

Improper shut off angle can lead to part defects like flash or incomplete filling of the mold.
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Q73. What are the types of welds you have used? and on what basis will you select the type of weld?
Ans. Types of welds include fillet welds, groove welds, plug welds, and slot welds. Selection is based on joint design, material thickness, and strength
requirements.
Fillet welds are used for lap joints and T-joints

Groove welds are used for butt joints and can be V-groove, U-groove, or J-groove
Plug welds are used to fill holes in one of the parts being joined
Slot welds are used to join overlapping parts with a slot cut in one of the parts

Selection is based on joint design, material thickness, and strength requirements

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Q74. How to justify plastic & sheet metal?

Ans. Plastic and sheet metal are justified based on factors like cost, durability, weight, and design flexibility.

Plastic is often chosen for its low cost, lightweight properties, and design flexibility.
Sheet metal is preferred for its strength, durability, and ability to be easily formed into complex shapes.

Plastic is commonly used in consumer products like electronics casings, while sheet metal is often used in automotive and aerospace industries.
The choice between plastic and sheet metal depends on the specific requirements of the project, such as budget, strength, and aesthetics.
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Q75. How to use DFMEA actual practices?

Ans. DFMEA is used to identify and prioritize potential failure modes in a design process.
Identify potential failure modes in the design process
Prioritize the failure modes based on severity, occurrence, and detection

Develop actions to mitigate or eliminate the identified failure modes

Monitor and update the DFMEA throughout the design process

Collaborate with cross-functional teams to ensure comprehensive analysis

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Q76. What is k factor in sheet metal?

Ans. K factor in sheet metal is a constant representing the ratio of the location of the neutral axis to the material thickness.

K factor determines how much a sheet metal part will stretch during bending.
It is used in calculating the bend allowance to determine the flat pattern length of the sheet metal.
Different materials and thicknesses have different K factors.

Typical K factor values range from 0.3 to 0.5.

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Q77. What is plastic shrinkage & draft angle?

Ans. Plastic shrinkage is the reduction in size of a plastic part during cooling, while draft angle is the taper applied to vertical surfaces to aid in mold
release.
Plastic shrinkage occurs as the molten plastic cools and solidifies, causing it to contract in size.

Draft angle is the slight taper given to vertical surfaces of a mold to allow for easy removal of the part.

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Plastic shrinkage can lead to warping or distortion if not properly accounted for in the design.
Draft angles are typically between 1-3 degrees, depending on the material and geometry of the part.
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Q78. How many types of defects in plastic?

Ans. There are three main types of defects in plastic: surface defects, physical defects, and chemical defects.
Surface defects include scratches, sink marks, and flow marks.
Physical defects include bubbles, voids, and warping.

Chemical defects include discoloration, degradation, and contamination.

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Q79. Tell me which component used in the frame ?

Ans. Various components used in the frame include tubes, joints, brackets, and fasteners.
Tubes: provide structural support and can be made of materials like steel or aluminum
Joints: connect tubes together at different angles
Brackets: used to reinforce joints or provide additional support
Fasteners: such as bolts and screws are used to secure components together

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Q80. what is draft angle in plastic?

Ans. Draft angle in plastic is the degree of taper or slope applied to the vertical walls of a plastic part to facilitate its ejection from the mold.
Draft angles are typically recommended to be between 1-3 degrees for most plastic parts

Draft angles help prevent the part from getting stuck in the mold during ejection
Examples of draft angles include adding a slight taper to the sides of a plastic cup or the walls of a plastic housing
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Q81. What is gate & runner in molding? &

Ans. Gate & runner in molding are channels through which molten material is injected into the mold cavity.
Gate is the opening through which molten material enters the mold cavity
Runner is the channel that connects the gate to the sprue or main injection point
Proper design of gates and runners is crucial for ensuring even distribution of material and preventing defects
Examples: Submarine gate, edge gate, hot runner system

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Q82. What is work of npd in industry?

Ans. NPD in industry refers to New Product Development, which involves the process of designing, creating, and bringing new products to market.
NPD involves identifying market opportunities and customer needs

It includes concept development, design, prototyping, testing, and commercialization

NPD teams often collaborate with various departments such as marketing, engineering, and manufacturing
Successful NPD can lead to increased revenue, market share, and competitive advantage
Examples of NPD in industry include the development of new smartphones, automobiles, and consumer electronics
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Q83. If you have 1000 KVA Transformer then LT side breaker size and cable size?
Ans. The LT side breaker size for a 1000 KVA transformer would typically be around 800A and the cable size would be around 400mm2.
LT side breaker size is usually around 80% of the transformer rating, so for a 1000 KVA transformer, it would be around 800A.
Cable size for the LT side would depend on the current carrying capacity required, typically around 2 times the breaker size, so around 400mm2.

It is important to consult with electrical standards and regulations to determine the exact breaker size and cable size needed.
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Q84. How to Control plastic defects?

Ans. Plastic defects can be controlled through proper material selection, process optimization, and quality control measures.
Selecting the right type of plastic material for the specific application can help prevent defects.
Optimizing the manufacturing process parameters such as temperature, pressure, and cooling time can reduce defects.
Implementing quality control measures like regular inspections and testing can help identify and address defects early on.
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Q85. CELL BALANCING, PROTECTION IN BATTERIES, HOW BLDC MOTOR DRIVER WORK
Ans. Cell balancing ensures equal charge distribution in batteries. BLDC motor driver controls the operation of brushless DC motors.
Cell balancing is the process of equalizing the charge levels of individual cells in a battery pack to maximize performance and lifespan.
It is achieved by transferring charge between cells or by adjusting the charging/discharging rates of individual cells.
Cell balancing prevents overcharging or over-discharging of cells, which can lead to reduced capacity, overheating, or even safety hazards.

Battery management systems (BMS) often incorporate cell balancing functionality to ensure optimal battery performance.
BLDC motor driver controls the operation of brushless DC motors by providing the necessary power and control signals to the motor's windings.
It uses electronic commutation to switch the current flow in the motor's windings, resulting in smooth and efficient motor operation.
BLDC motor drivers can vary in complexity, from simple integrated circuits to more advanced microcontroller-based systems.
They are commonly used in applications such as electric vehicles, drones, and industrial automation.

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Q86. What do you know about solar industry

Ans. Solar industry involves the production and distribution of solar energy through various technologies.
Solar industry is a rapidly growing sector globally

It includes the production of solar panels, solar cells, and other related equipment
Solar energy is used for various purposes such as electricity generation, heating, and cooling
The industry is heavily dependent on government policies and incentives
Major players in the industry include companies like SunPower, First Solar, and Canadian Solar
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Q87. What GD and T What are material you are taking Kind of weldments Mmc and lmc Cad test must Earlier experience related
questions mostly Basic calculations for weldments Sheet metals related
Ans. Geometric Dimensioning and Tolerancing (GD&T) is a system for defining and communicating engineering tolerances. It is essential for design
engineers to understand GD&T for accurate manufacturing.
GD&T is used to specify the allowable variations in form, size, and orientation of features on a part.
Materials selection is crucial for design engineers to ensure the desired mechanical properties, corrosion resistance, and cost-effectiveness of
the final product.
Different types of weldments include fillet welds, groove welds, plug welds, and spot welds.
Maximum Material Condition (MMC) and Least Material Condition (LMC) are GD&T symbols used to specify the maximum and minimum allowable
sizes of a feature.

CAD testing is essential for design engineers to validate the design, check for interferences, and optimize the product for manufacturing.
Experience-related questions may focus on previous projects, challenges faced, and solutions implemented.
Basic calculations for weldments include determining weld size, throat thickness, and weld length.
Sheet metal design involves considerations such as bend allowances, bend deductions, and minimum bend radii.
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Q88. Does the Neutral Axis change its position?

Ans. Yes, the Neutral Axis changes its position based on the shape and loading of the beam.
The Neutral Axis is the line within a beam where there is no stress or strain.
The position of the Neutral Axis depends on the shape of the beam and the distribution of loads.

For example, in a simply supported beam with a uniform load, the Neutral Axis will be at the centroid of the beam's cross-section.
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Q89. What is the similarity of circularity and circular run out?

Ans. Circularity and circular run out are both measurements of how well a circular object conforms to its intended shape.

Circularity measures the overall roundness of a circle, while circular run out measures the variation in the center point of the circle as it rotates.
Both measurements are important in ensuring the proper functioning of rotating parts in machinery.
For example, in a car engine, circularity ensures that pistons move smoothly within cylinders, while circular run out ensures that the crankshaft
rotates without wobbling.

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Q90. How many kind of plastic category?

Ans. There are seven main categories of plastics based on their chemical structure and properties.
Polyethylene (PE)

Polypropylene (PP)
Polyvinyl Chloride (PVC)

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Polystyrene (PS)
Polyethylene Terephthalate (PET)

Polyurethane (PU)
Polycarbonate (PC)
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Q91. Do you know the symbol of position tolerance?

Ans. Yes, the symbol for position tolerance is a circle with a horizontal line through the middle.

The symbol for position tolerance is a circle with a horizontal line through the middle
It is used in engineering drawings to specify the allowable deviation in the location of a feature
Position tolerance controls the location of a feature relative to a specified datum
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Q92. How sheet metal thickness are decided

Ans. Sheet metal thickness is decided based on the application, material, and manufacturing process.
The application determines the required strength and durability of the sheet metal.
The material being used affects the thickness needed for the desired properties.
The manufacturing process also plays a role in determining the appropriate thickness.

Factors such as cost and weight may also be considered.

Thickness can be measured in gauge or millimeters.
For example, automotive body panels typically range from 0.6mm to 1.5mm in thickness.
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Q93. If you dropdown end of pipe in the bucket, whether discharge will increase, decrease, same,
Ans. The discharge will increase when the end of pipe is dropped down in the bucket.
Dropping the end of pipe in the bucket will increase the head pressure and hence the discharge.
The height of the water column above the end of the pipe will increase, resulting in higher pressure.
This is similar to the concept of a siphon, where the height difference between the two ends of the pipe determines the flow rate.

However, if the end of the pipe is completely submerged in the water, the discharge will remain the same.
This is because the pressure at the end of the pipe will be equal to the atmospheric pressure, which is not affected by the height of the water
column.
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Q94. What factors are you consider when you going to start concept design
Ans. Factors considered for concept design
Client requirements and specifications
Market research and analysis

Feasibility and technical constraints

Budget and resources
Design trends and innovation
User experience and ergonomics
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Q95. why are use draft angle in plastic?

Ans. Draft angles are used in plastic to facilitate easy ejection of the molded part from the mold.
Draft angles help prevent the part from getting stuck in the mold during ejection
They reduce friction between the part and the mold walls

Draft angles improve the overall quality and consistency of the molded part
Common draft angles range from 1 to 3 degrees, depending on the material and design
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Q96. How many types of tolrence and Full form of Autocad. and what is the use of autocad like this. And basic questions of
measuring instruments. like micrometer and caliper.
Ans. Types of tolerance include bilateral, unilateral, and limit. AutoCAD stands for Automatic Computer Aided Design. It is used for creating 2D and
3D designs. Measuring instruments like micrometers and calipers are used for precise measurements.

Types of tolerance: bilateral, unilateral, limit

AutoCAD full form: Automatic Computer Aided Design

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AutoCAD is used for creating 2D and 3D designs
Measuring instruments like micrometers and calipers are used for precise measurements
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CAD Software

Q97. Explain machining operations of given job?

Ans. Machining operations involve using various tools and techniques to shape and cut raw materials into the desired shape and size.
The job may involve using lathes, milling machines, grinders, or other specialized equipment.
The machinist must carefully measure and mark the material before cutting or shaping it.
The machinist may need to use different cutting tools or techniques depending on the material being worked on.
Examples of machining operations include drilling holes, turning cylindrical shapes, and cutting threads.

The machinist must also ensure that the finished product meets the required specifications and tolerances.
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Q98. How to prevent plastic defects?

Ans. Preventing plastic defects involves proper material selection, design optimization, and quality control measures.

Selecting the right type of plastic for the specific application

Optimizing the design to minimize stress concentrations and molding issues
Implementing quality control measures during manufacturing process
Regular maintenance and inspection of molds and equipment
Training staff on proper handling and processing techniques

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Q99. No. of tonnage molding machine you are used?

Ans. I have experience working with various tonnage molding machines, including 50-ton, 100-ton, and 200-ton machines.
50-ton molding machine

100-ton molding machine

200-ton molding machine
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Q100. How is a bolted connection design

Ans. A bolted connection design involves selecting appropriate bolts, nuts, and washers to join two or more components together.
The design must consider the loads and stresses that the connection will experience
The bolt size, grade, and material must be selected based on the required strength and corrosion resistance
The number and spacing of bolts must be determined to evenly distribute the load
Proper tightening torque must be applied to ensure the connection remains secure

Washers may be used to distribute the load and prevent damage to the components being joined
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