Top Questions Asked in CADFEM Interview for CAE Engineers | Engineer’s Interview Blueprint

For CAE engineers, landing a job in the highly competitive world of FEA (Finite Element Analysis) and simulation can be a daunting task.  

You've spent years building technical expertise, mastering simulation tools, and solving complex engineering problems, but interviews still feel like a hurdle. It's not uncommon to feel anxious about the types of questions that might be thrown your way—questions about software, analysis methods, or even intricate details of your past projects. 

The key challenge? Knowing what interviewers really want to hear and how to showcase your skills effectively.  

For many candidates, the unknown is the hardest part. If you’ve ever found yourself wondering, "What are the specific questions asked in a CAE engineer interview?" or "How do I prepare for real-time, company-specific technical questions?", you’re not alone. 

This blog is here to help. We’ve gathered real-time interview questions from CADFEM, a company that frequently recruits CAE engineers.  

Let’s get started 

1. What’s the difference between explicit and implicit analysis? 

• Explicit analysis: Typically used for dynamic events (e.g., crashes) with short timescales, where small time steps are required for accuracy. 

• Implicit analysis: Used for static or slowly changing events where larger time steps are allowed, making it computationally more efficient. 

2. What is the MAT 24 card in LS-DYNA? 

MAT 24 is a material model used in LS-DYNA for modeling isotropic elastic-plastic materials with strain rate effects. It's commonly used for metals in crash simulations. 

3. What is the difference between engineering stress and true stress? 

• Engineering stress: Calculated based on the original cross-sectional area. 

• True stress: Accounts for the actual cross-sectional area as it changes during deformation. True stress is more accurate for high strain applications. 

4. What is quasi-static analysis? 

Quasi-static analysis refers to simulations where loads are applied slowly enough that inertia effects can be neglected, but not so slowly as to be considered purely static. It’s used for situations where dynamic effects are minimal but still relevant. 

FEA Simulation Engineer-Specific Questions 

5. What is ANSA used for? 

ANSA is a pre-processing tool used to prepare models for FEA/CFD analysis, including geometry cleanup, meshing, and assigning boundary conditions. 

6. Is morphing possible in ANSA? 

Yes, ANSA allows for morphing, which is the process of modifying a mesh or geometry while maintaining the quality of the elements. This is useful in optimizing designs. 

7. What are under-defined and fully defined elements? 

• Under-defined elements: Have incomplete constraints, meaning their position or shape can change. 

• Fully defined elements: Have all necessary constraints applied, ensuring that they are fixed in their position and geometry. 

8. What is a time step in FEA? 

A time step is the increment of time over which the numerical solution progresses in dynamic simulations. It determines how frequently the solver updates the solution. 

9. What is mass scaling? 

Mass scaling artificially increases the mass of elements to improve computational stability by allowing larger time steps, especially in explicit analysis. 

10. What is element formulation 16 in LS-DYNA? 

Element formulation 16 refers to solid elements using reduced integration in LS-DYNA, which helps to avoid hour glassing and improves computational efficiency.

General FEA and Material Knowledge 

11. What is FEM (Finite Element Method)? 

FEM is a numerical method used to solve complex engineering problems by breaking down a structure into smaller, simpler parts (elements), solving for each, and combining the results. 

12. What are the types of stress? 

• Tensile stress: Stretching force. 

• Compressive stress: Squeezing force. 

• Shear stress: Sliding force parallel to the surface. 

13. What is Poisson’s ratio? 

Poisson’s ratio is the ratio of lateral strain to axial strain in a material when subjected to stress. It indicates how much a material contracts or expands in the perpendicular direction when stretched or compressed. 

14. Can you explain the stress-strain curve? 

The stress-strain curve shows how a material deforms under stress. It typically includes an elastic region (where the material returns to its original shape) and a plastic region (where permanent deformation occurs), leading to failure. 

15. What is fatigue? 

Fatigue refers to the weakening or failure of a material caused by repeated loading cycles, even if the applied stresses are below the material's yield strength. 

Thermal and Structural Analysis 

16. What is modal analysis and why is it important? 

Modal analysis identifies the natural frequencies of a structure, which are important to avoid resonance during operation, where vibrations could cause failure. 

17. What is the SN curve? 

An SN curve (stress-number of cycles curve) shows the relationship between the cyclic stress a material can endure and the number of cycles to failure, helping predict fatigue life. 

18. What is the difference between static and dynamic analysis? 

• Static analysis: Assumes loads are applied slowly, and inertial effects are ignored. 

• Dynamic analysis: Takes into account the inertia and damping effects, critical for problems like impacts or vibrations. 

Mesh and Element Knowledge 

19. How do you define mesh for 2D and 3D components? 

• 2D components: Use shell elements for thin structures, focusing on aspect ratio and mesh size for accuracy. 

• 3D components: Use solid elements for thicker structures, ensuring good quality by minimizing skewness and maintaining regular element shapes. 

20. What is contact thickness? 

Contact thickness refers to the virtual thickness of elements in contact during an FEA simulation. It ensures that the surfaces interact properly without penetrating each other. 

 Additional Key Concepts 

21. What is resonance? 

Resonance occurs when a structure is exposed to vibrations at its natural frequency, causing amplified oscillations, which can lead to structural failure. 

22. What is natural frequency? 

Natural frequency is the rate at which an object vibrates when it is disturbed. Understanding natural frequency is critical in designing structures that avoid resonance. 

23. What is buckling, and when does it occur? 

Buckling is the sudden deformation of a structure under compressive loads. It typically occurs when the load exceeds a critical threshold, leading to structural failure. 

Conclusion 

Now that you’re equipped with real-time questions that have been asked by CADFEM, take the time to refine your answers, revisit your past projects, and strengthen your knowledge of key concepts.  

This preparation can be the difference between walking out of the interview with a job offer or with uncertainty. Your next step toward securing your role as a CAE engineer starts now! 

With Skill-Lync's Post Graduate Programs, you'll build a rock-solid foundation in all these critical concepts, making you interview-ready in no time. Plus, our Career Experts offer hands-on support through mock interviews, resume workshops, LinkedIn profile optimization, and much more! 

Sign up for a FREE course demo today, and let’s start your journey toward landing that dream job!