For Sheet metal design engineer position in sheet metal product design or sheet metal manufacturing company, interviewer may ask questions on    For Sheetmeta sheet-metal manufacturing and design. To clear sheet-metal design engineer interview you should be aware of basic fundamentals of sheetmetal design . You can learn the basics of sheet-metal design here

Some of the basic sheetmetal interview questions are given below:

What is the standard bending radius followed during sheet metal fabrication?

This is commonly asked question in sheet-metal interviews. For hard materials (like CRCA and stainless steel) minimum inside radius is 0.7 times of sheet thickness  and for soft material (like Aluminium) it is equal to sheet thickness.

What is the Minimum Flange Length in Sheet-Metal Bend?

The minimum flange length should be kept 4 times of sheet thickness plus inside radius

Minimum Flange length = 4 X T (sheet thickness) + R (Inside Bend Radius)

What is minimum Hole/Slot distance from Edge?

Minimum Distance = 3 X Sheet Thickness + R (Inside Bend Radius)

What are the general Tolerance followed in sheet-metal Design?

What is meant by bending allowance or bend Deduction in sheet metal fabrication? How to calculation bending allowance?

When sheet-Metal bending is done, metal is deformed plastically to change its shape. Material is stressed beyond its yield strength but below ultimate tensile strength to achieve desired shape. This results in the change of surface area. After bending there is some increase in the total length e.g. (Length + Height) is not equal to Flat Length.

Flat Length = Length + Height - Bend Deduction

You can check more in detail about bending allowance here:

What is K-factor in sheet metal fabrication?

This is the commonly asked interview question for the position of sheet-metal development and design engineers.

K-Factor is a constant factor that is used to calculate the flat pattern in cad software’s. Value of K-Factor depends on material used, Bend radius, sheet thickness and machines used

When sheet metal is bent, the inside surface of the bend is compressed and the outer surface is stretched. Somewhere in between the thickness of material lies neutral axis: Line with-in thickness that is neither compressed nor stretched

Mathematically K-Factor is a ratio of position of neutral axis and sheet thickness.Value of K-factor is always less than 0.5

What is Y-Factor in Sheet metal?

There is a direct relationship in between k-Factor and Y-Factor in sheetmetal.

What are the commonly used surface finish operations on sheet metal parts?

Following are surface finish operations done on sheet-metal parts:

• Pre-Treatment : Phosphate Conversion Coating, Chromate Conversion Coating, Derusting, Descaling
• Anodising
• Plating: Zn Plating/Galvanising, Tin plating, Silver plating

What are some common design parameters need to be considered while material selection for sheet metal parts is done?

This question is most commonly asked interview question to sheet metal design engineers. Following are the commonly parameters need to consider:

What is some common reinforcement techniques used to improve the strength of the sheet metal parts?

This question is asked to sheet metal design engineers. Generally following Techniques are used

• Bending: normal bend, hem bend
• Forming tools: sheet-metal rib, louver, lance & Tab

What is a press tool?

Press tool is commonly used in hydraulic, pneumatic & mechanical presses to produce sheet-metal parts. Press tools can be classified based on operation done by them like: blanking, piercing, bending and forming.

What is the difference between progressive, compond & combination tool?

What do you mean by stampings?

Stamping is a process of giving desired shape to sheet-metal parts with press tool. Blanking, punching, pressing, piercing, bending and forming operations are done with stamping dies.

What are commonly used sheet metal operations?

• Sheet-Metal Cutting operations: Punching, Piercing,Perforation, Cutting off, Parting off, Dinking, Trimming, Shaving, Shearing, Notching (Click Here To Know More About Cutting operations)
• Material Removal: Deburring, Grinding
• Sheetmetal Forming: Straight bend, Angle bend, Hem bend
• Material Joining: Welding (Tig, MIG, GAS Welding), Riveting, Folding, Screws
• Final Finish: Passivation, Chromate Conversion Coating, Plating, powder Coating

What are commonly used sheet-metal assembly process?

Following are the some of sheet metal parts joining Techniques:

• Screws: Self tapping Screws, Machine Screws
• Welding : Arc Welding, TIG Welding, MIG Welding
• Folding Techniques: Lap Joint, Hem Joint
• Riveting
• Press Fitting: PEM Inserts

What is the application of dowel pins?

Dowel Pins are generally used to align two parts for assembly.

What is the effect of grain direction in sheet metal bending?

When Sheetmetal is manufactured with cold rolling process, Grain structure of sheetmetal is aligned in the direction of rolling. for the softer materials if bending is done in rolling direction it will result in cracks. It is always prefered to do bending in the direction perpendicular to rolling direction.

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