Sign-In
Register
Please choose an option to Register
Register as Freelancer
Register as Client
Close
Bellgigs
Bridging Skills and Opportunities
Sign-In
Register
☰
Back To Interview Q & A
Back To Interview Q & A
Home
About Us
Apply for Jobs
Build Resume
Interview Questions & Answers
Contact Us
Help
Suggested Certification for Tool Design Engineer
Certifications - citdindia.org
Recommended Book 1 for Tool Design Engineer
★★★★☆
Check Amazon for current price
View Deal
On Amazon
Recommended Book 2 for Tool Design Engineer
★★★★☆
Check Amazon for current price
View Deal
On Amazon
Recommended Book 3 for Tool Design Engineer
★★★★☆
Check Amazon for current price
View Deal
On Amazon
Recommended Book 4 for Tool Design Engineer
★★★★☆
Check Amazon for current price
View Deal
On Amazon
Recommended Book 5 for Tool Design Engineer
★★★★☆
Check Amazon for current price
View Deal
On Amazon
Note:
*Check out these useful books! As an Amazon Associate I earn from qualifying purchases.
Interview Questions and Answers
1. How does a tool design engineer work with other departments, such as manufacturing and quality control?
Tool design engineers collaborate closely with manufacturing and quality control to ensure that tools are designed for manufacturability, meet quality standards, and are properly maintained.
2. What is the difference between a jig and a fixture?
A jig guides the cutting tool, while a fixture holds the workpiece in a fixed position during machining or assembly.
3. What are the ethical considerations in tool design?
Ethical considerations include ensuring the safety of operators, designing tools that minimize waste, and complying with environmental regulations.
4. What are the key considerations when designing an injection mold?
Key considerations include gate location, runner design, cooling channels, venting, ejection system, and material shrinkage.
5. How do you determine the optimal cooling strategy for an injection mold?
By performing thermal analysis to identify hot spots and designing cooling channels to maintain a uniform temperature distribution throughout the mold.
6. What are the common challenges in tool design?
Challenges include meeting tight tolerances, minimizing tool wear, optimizing tool life, reducing costs, and accommodating design changes.
7. How does a tool design engineer stay up-to-date with the latest technologies and trends?
By attending industry conferences, reading technical publications, taking continuing education courses, and networking with other professionals.
8. What is FEA (Finite Element Analysis) and how is it used in tool design?
FEA is a computer-based simulation technique used to analyze the structural integrity and performance of tools under various loading conditions. It helps identify potential weaknesses and optimize the design.
9. How do you calculate the cutting forces involved in a machining operation for tool design?
Cutting forces depend on the material being machined, the cutting tool geometry, the cutting speed, the feed rate, and the depth of cut. Empirical formulas and software tools can be used to estimate these forces.
10. How does a tool design engineer contribute to improving manufacturing efficiency?
By designing tools that reduce cycle times, improve accuracy, minimize waste, and automate processes.
11. What is the importance of ergonomics in tool design?
Ergonomics is important for ensuring that tools are comfortable and safe to use, reducing the risk of repetitive strain injuries and improving operator productivity.
12. How do you select the appropriate manufacturing process for a specific tool?
Consider the complexity of the tool, the required tolerances, the material properties, the production volume, and the cost of manufacturing.
13. What is GD&T and why is it important in tool design?
GD&T (Geometric Dimensioning and Tolerancing) is a symbolic language used to define and communicate manufacturing tolerances. Its crucial for ensuring proper fit, function, and interchangeability of parts.
14. What is the design process for creating a new tool?
The process typically involves understanding the manufacturing requirements, creating preliminary designs, performing simulations and analysis, selecting materials, detailing the design, and overseeing the fabrication and testing of the tool.
15. How does a tool design engineer ensure a tool meets the required specifications?
By performing thorough simulations and analysis (e.g., FEA), considering tolerances, using appropriate materials, and conducting rigorous testing and inspection.
16. What are the different types of tools that a tool design engineer might design?
Tool design engineers design a wide variety of tools, including cutting tools, forming dies, injection molds, jigs, fixtures, gauges, and automated assembly equipment.
17. What materials are commonly used in tool design?
Common materials include tool steels (e.g., high-speed steel, carbide), alloy steels, cast iron, aluminum, and polymers, depending on the application and performance requirements.
18. What is the role of a tool design engineer?
A tool design engineer designs and develops tools, dies, molds, jigs, fixtures, and other specialized equipment used in manufacturing processes.
19. What skills are essential for a tool design engineer?
Essential skills include proficiency in CAD software (e.g., AutoCAD, SolidWorks, CATIA), knowledge of manufacturing processes (e.g., machining, casting, molding), materials science, GD&T, and problem-solving abilities.
20. What software is commonly used for tool design?
Common software includes AutoCAD, SolidWorks, CATIA, NX (Siemens), Creo Parametric, and specialized CAM software for generating toolpaths.
21. What are the various phases of the tool design process?
Problem definition, Design exploration, Design optimization, and Design communication.
22. What are the different types of loads that can act on machine components?
The five types of loads that can act on a structure are tension, compression, shear, bending and torsion.
23. What are the factors affecting endurance strength?
Endurance limit is affected by many factors such as surface finish, reliability, temperature, size etc.
24. Describe an experience where a system malfunction was eliminated by your design modification?
Explain with examples that sync with the job description.
25. What is Ductility, fatigue, Machinability, S-N Curve, Curved Beam, Goodman & Soderberg diagrams, Factor of safety, endurance limit, and impact load?
Ductility:- Ductility is the ability of a material to be drawn or plastically deformed without fracture. the ability of a material to have its shape changed (as by being drawn out into wire or thread) without losing strength or breaking.
fatigue:- Material fatigue is a phenomenon where structures fail when subjected to a cyclic load. Fatigue is the most common source behind failures of mechanical structures.
Machinability:- Machinability is the ease with which a metal can be cut (machined) permitting the removal of the material with a satisfactory finish at low cost. Materials with good machinability (free machining materials) require little power to cut, can be cut quickly, easily obtain a good finish, and do not wear the tooling much.
S-N Curve:- A SN-Curve (sometimes written S-N Curve) is a plot of the magnitude of an alternating stress versus the number of cycles to failure for a given material.
Curved Beam:- Beam having its neutral axis curved in unloaded condition is known as curved beam. Neutral axis and centroidal axis of a curved beam do not coincide. Neutral axis of curved beams is shifted towards the centre of curvature.25
Goodman & Soderberg diagrams:- Within the branch of materials science known as material failure theory, the Goodman relation (also called a Goodman diagram, a Goodman-Haigh diagram, a Haigh diagram or a Haigh-Soderberg diagram) is an equation used to quantify the interaction of mean and alternating stresses on the fatigue life of a material.
Factor of safety:- A factor of safety is the load carrying capacity of a system beyond what the system actually supports.
Endurance limit:- It is defined as maximum value of the completely reversed bending stress which a polished standard specimen can withstand without failure, for infinite number of cycles (usually 107 cycles).
Impact Load:- Machine members are sometimes subjected to abrupt loads as a result of falling or colliding with another object. The impact load is the force created as a result of these actions. The Impact stress is the stress created in the machine members as a result of the impact load.
26. Differentiate between repeated stress and reversed stress?
Repeated stress is stress varying from zero to a maximum value of same nature. Reversed stress of cyclic stress varies from one value of tension to the same value of compression.
27. Share an experience where you have been able to create a new design or modify an existing design to better serve your customers needs?
Answer appropriately.
28. Explain size factor in endurance strength?
The rotating beam specimen is small with X mm diameter. Now if the size of the standard specimen is increased, then the endurance limit of the material will decrease.
29. What are the factors to consider in material selection?
Self-weight of the machine.
Energy Transmitted.
Change of temperature.
Frictional resistance.
The inertia of reciprocating parts.
Unbalance of Moving parts.
30. What software do you use?
Computer-aided design (CAD) is one of the most ubiquitous software design tools.
31. Explain Griffith theory and State the condition for crack growth?
The growth of a crack, the extension of the surfaces on either side of the crack, requires an increase in the surface energy. Griffith found an expression for the constant. in terms of the surface energy of the crack by solving the elasticity problem of a finite crack in an elastic plate.