Commonly Asked Interview Questions

Topics to prepare for Mahindra & Mahindra Body system engineer interview:
● Design
● CATIA
● Sheet Metal
● strength of material
● Stamping
● gd &t
● Materials

Q. CATIA FULL FORM

Computer Aided Three Dimensional Interactive Application

Q. CATIA ACCURACY
There are many ways to manage the performance of CATIA V5 & accuracy of models. To

improve performance & increase productivity, we need to configure the settings properly. Some

of these options are discussed in detail in this document. These will immensely benefit CATIA

users.

1. Undo Stack

Undo ➞ Stack size ➞ change from 10 to 5

Stack Size defines the maximum number of commands which can be undone for each document.
Lower the value better the performance. More the stack value, more will be the memory
consumption.
Tools ➞ Options ➞ General ➞ PCS ➞ Undo stack size

2. Virtual Memory Setting

Virtual memory of the system should be set to recommended value.

Set trigger memory from 70% to 90%.
A warning message gets activated when the application detects that the memory consumption
exceeds the given threshold.

3. Set 2D and 3D Accuracy for Display

2D and 3D Accuracy settings can be controlled at:

Tools ➞ Options ➞ Display ➞ Performance
Set 2D and 3D Accuracy to maximum value (0.5 or 1.0).

1. 3D Accuracy Settings for Display

The 3D Accuracy Setting controls the tessellation of surfaces.

Proportional:
Calculating tessellation according to object size. The larger the object, the coarser will be the
tessellation. For the same accuracy value, the tessellation on small objects will always be finer
than on the larger objects.
Fixed:
It sets a fixed accuracy value for calculating tessellation on all objects which does not vary with
object size.
In Fixed settings option, user can set a sag value (from 0.01 to 10) for calculating tessellation on
all objects which does not vary with object size. The sag value defines the chordal deviation for
curves and surfaces.
4. Pixel Culling

○ The minimum object size in pixels technology is used to define the size

in pixels of objects to be displayed or hidden in the geometry.

○ Setting a high value enables to quickly move large parts.

 ○ Setting a low value displays more details. For example, setting a value of

2 means that objects whose size on screen is lower than 2 pixels are

static.

5. Anti-Aliasing

○ This technology is used to smooth out the uneven edges of objects.

○ For better performance, anti-aliasing should be disabled.

Tools ➞ Options ➞ General ➞ Display ➞ Visualization

6. Level of Detail (LOD)

○ The Level of Detail technology or LOD adjusts the polygonal

representation of an object to the distance of the user. The idea is that it is

not always necessary to view a high level of detail in the geometry

because some objects are far away, enough to make the detail

meaningless.

○ Set a high value to remove details.

○ Set a low value to see all details.

Q. DIFFRENCE BETWEEN GDnT SYMBOL
GD&T is a symbolic language. It is used to specify the size, shape, form, orientation,
and location of features on a part. And its basically a design tool. To apply GD&T
properly one must have a good understanding of parts functional requirement in an
assembly. Let us start learn the language of symbols.
There are fourteen geometric characteristic symbols used in the language of GD&T.
They are divided in to five categories namely form, orientation, location, runout, and
profile.
In addition to above symbols there are five more modifying symbols used in GD&T.

We will discuss each of these symbols in detail on future chapters.

Let us now familiarize the feature control frame

Geometric dimensioning and tolerancing is applied on a drawing via these feature

control frames. It’s a rectangle which is divided into compartments within which
geometric characteristic symbol, tolerance value, modifiers, and datum references
are placed. These feature control frames may attached below dimensions or to a
datum reference or to a feature with a leader.

Let us now familiarize some of the common terms used in GD&T.

Basic Dimension
A basic dimension is a numerical value used to describe the theoretically exact size,
profile, orientation, or location of a feature or datum target. Basic dimensions are
used to define or position tolerance zones.
Datum
A datum is a theoretically exact point, line, or plane derived from the true geometric
counterpart of a specified datum feature. A datum is the origin from which the
location or geometric characteristics of features of a part are established.
Datum feature
A datum feature is an actual feature on a part used to establish a datum.
Feature
A feature is a physical portion of a part like hole, flat surface, ribs etc.
Feature of Size
A feature with size dimension, hole with diameter dimension is an example of
feature of size.
Least Material Condition (LMC)
The least material condition of a feature of size is the least amount of material within
the stated limits of size. For example, the minimum shaft diameter or the maximum
hole diameter.
Maximum material condition (MMC)
The maximum material condition of a feature of size is the maximum amount of
material within the stated limits of size, for example, the maximum shaft diameter or
the minimum hole diameter.
True position
True position is the theoretically exact location of a feature established by basic
dimensions. Tolerance zones are located at true position.
Virtual condition
The virtual condition of a feature specified at MMC is a constant boundary generated
by the collective effects of the MMC limit of size of a feature and the specified
geometric tolerance. Features specified with an LMC modifier also have a virtual
condition.

Rule #1

Rule #1 states that where only a tolerance of size is specified, the limits
of size of an individual feature of size prescribe the extent to which
variations in its geometric form, as well as its size, are allowed. No
element of a feature shall extend beyond the MMC boundary of perfect
form. The form tolerance increases as the actual size of the feature
departs from MMC toward LMC. There is no perfect form boundary
requirement at LMC

Let us now discuss rule #1 in detail. The simplest meaning of rule #1 is at

MMC the feature is on perfect form. For example consider a shaft with
diameter Ø5.000-Ø5.040. Then its MMC is Ø5.040. Now assume we have
this part produced at Ø5.040 then according to rule #1 the part should be
in perfect form. That is it should have perfect straightness, circularity
and cylindricity.

Rule #2

Rule #2 states that RFS automatically applies, in a feature control frame,

to individual tolerances of size features and to datum features of size.
MMC and LMC must be specified when these conditions are required.

Now examine rule #2, here also lets assume a stepped shaft with Ø5.000
and Ø3.000-Ø3.004. The bigger diameter is assigned as datum (Say C)
and the smaller diameter Ø3.000 is controlled by a concentric geometric
tolerance and this tolerance is applied without any dimensional size
constraints ie regardless of feature size (RFS)

Q. DENSITY OF MATERIALS

Item Grade Density（

g/mm³)

Aluminum Plate A1100 0.00272

Aluminum Foil 0.00272

Aluminium Alloy A5052-H32 0.00272

Brass Sheet (Hard) C2680R 0.0085

Brass Sheet (Soft) C2680R 0.0085

PH.Bronze C5191 0.00878

Pure Copper C1100 0.009

Beryllium Copper C1720-1/2H 0.0083

Stainless Steel (Hard) SUS 304 0.0078

Stainless Steel AISI 430 0.0078

Stainless Steel SUS 301 0.0078

Stainless Steel (Soft) SUS 304 0.0078

Secc/Electro-Galvanized T1/T2/EW/EL 0.0078

Steel

PVC Laminated Steel Sheet 99033 0.00645

99033-3(Black) Anti-Finger 99033-3(Korea) 0.00645

Coating
C010R : B200 0.00645

ZINC PLATE/Galvanized Steel JIS G3303 SGCC 0.00803

CR-Steel 0.00785

Black Steel 0.0077

SPCC/Cold Rolled Steel JIS G3141 0.0078

SPCC-SD

Cold Rolled Steel-1/4Hard JIS G3141 0.0078

SPCC-4B

Cold Rolled Steel-Hard JIS G3141 0.0078

SPCC-1B

Cold Rolled Steel Net 0.0078

Tin Plate JIS G3303 0.0079

 Tin Plate Coating 2.8/2.8 JIS G3303 0.0079

Silicon Steel (with no 0.00738

direction)

Silicon Steel – Zll (with direction) 0.00738

FAQ about metal density

What is the density of mild steel (ms)?

The density of ms is 7.85g/cm3, or 7850kg/m3

What is the density of galvanized steel (gi)?

The density of galvanized steel is 7.8g/cm3 for

Secc/Electro-Galvanized Steel and 8.03g/cm3 for ZINC
PLATE/Galvanized Steel

What is the density of aluminium sheet?

The density of aluminium sheet is 2.72g/cm3, or 2720kg/m3

Q. STRESS STRAIN CURVE

In engineering and materials science, a stress–strain curve for a material gives the
relationship between stress and strain. It is obtained by gradually applying load to a
test coupon and measuring the deformation, from which the stress and strain can be
determined (see tensile testing). These curves reveal many of the properties of a
material, such as the Young's modulus, the yield strength and the ultimate tensile
strength.

GD&T SYMBOL & THEIR MEANING

what kind of material is used in the BIW panel

Can you explain the 3-2-1 principle

The 3-2-1 Locating Principle

What is it?

A fundamental concern in metalworking is locating the part to be machined,

punched, bent, or stamped relative to the work platform (fixture). For example, a
CNC machine tool starts its process at a specific point relative to the fixture and
proceeds from there. Hence, the accuracy with which a part is machined is quite
dependent on the accuracy with which it is positioned in the fixture.

Accurate locating of not just one part, but each and every part that is loaded into
the fixture is crucial. Any variation in part location on the fixture adds to the
dimensional tolerance that must be assigned to the finished parts.

Additionally, the method of supporting and securing the part in the fixture affects
not only dimensional tolerances, but surface finishes as well. This is true because
improper supporting or clamping can temporarily or permanently deform the part.
Hence, techniques for supporting and clamping must be considered together with
the method of locating in order to assure repeatability from part-to-part.

Locating of a part to be machined is a three-step process:

1. Supporting

2. Locating (positioning)

3. Holding (clamping)
The Locating Process: Degrees of Freedom

In order to completely specify the position in space of a three-dimensional

object (such as the cube that’s shown), we refer to six coordinates:

1. Translational position along the X-axis

2. Translational position along the Y-axis
3. Translational position along the Z-axis
4. Rotational position about the X-axis
5. Rotational position about the Y-axis
6. Rotational position about the Z-axis

These six coordinates are known as the six degrees of freedom of a

three-dimensional object. As the double-headed arrows indicate, the translational
and rotational positions can vary in either direction with respect to each of the three
axes.

To completely prevent movement, all six degrees of freedom must be restricted.

draw the profile section used in the rocker area

Q. tell about dfmea and what you have done

What Is DFMEA?
Design failure mode and effect analysis (DFMEA) is a systematic group of activities
used to recognize and evaluate potential systems, products, or process failures.
 DFMEA identifies the effects and outcomes of these failures or actions. It eliminates or
mitigates the failures and provides a written history of the work performed.

Figure 1. Failure mode and effective analysis (FMEA) is an important part of the design
cycle, hence the creation of DFMEA.

With such a broad application, it sounds like DFMEA could be all things to all people.
However, it is not the best analysis tool for every challenge. So, is it the best solution for
you? Read on to find out.

The Industries Served by DFMEA

In essence, DFMEA determines what might go wrong, how bad the effect may be, and how
to prevent or mitigate it.

DFMEA helps engineers detect failures at the earliest possible moment so they can be
corrected early, without significant cost. It is especially useful for disciplines in which risk
reduction and failure prevention are crucial, including:

● Manufacturing.
● Software.
● Business processes.
● Healthcare.
● Service industries.
● Regulated industries.
 Figure 2. Many industries can benefit from DFMEA.

The DFMEA Process

DFMEA drills into failure from several angles to determine why the expected or intended
function didn’t occur under the stated conditions. There are four areas of analysis:

● Failure mode — the way in which a failure is observed,

● Failure effect — the immediate consequences of a failure on the operation, function,
or functionality.

Figure 3. A DFMEA risk priority number (RPN) distribution

 ● Failure cause — the underlying cause of the failure, or things which initiate
processes that lead to failure (such as a defect in design, system, process,
quality, or part application).
● Severity — the consequences of a failure mode, framed in the worst-case
outcome, degree of injury, property damage, or harm.

The results are then taken to a more granular level with the calculation of a risk priority
number (RPN) based on several variables:

● Severity of the failure effect (SEV): A value applied on a scale of 1 (low) to 10

(high).
● Frequency of failure occurrence (OCCUR): A value applied on a scale of 1
(infrequent) to 10 (frequent).
● Detectability/preventability (DETEC): A value assigned on a scale of 1 (very
detectable) to 10 (not detectable).

RPN is determined by multiplying SEV, OCCUR, and DETEC. Therefore, the RPN can
have a value anywhere from 1 (low risk) to 1,000 (high risk). Users are then able to
define what is acceptable and unacceptable for the failure being analyzed.

Common DMFEA Mistakes

Like any process, DFMEA is subject to some degree of user error. Some obvious lapses
include never referencing or updating DMFEA documentation or applying the analysis
inconsistently. Procedurally, there are a number of missteps that can also occur:

● Misunderstanding the DFMEA scope and objective

● Skipping the process of design control
● Skipping failure mode and cause and effect separation
 Figure 4. Avoid common mistakes in the DFMEA process

● Ranking criteria too closely.

● Identifying only problems, not solutions.
● Having no control plan in place when a solution exists.

Q. what is the difference between stress and strain

Q. how will you calculate the strain and stress in different material

Q. Questions from favourite subjects. Important *