Manufacturing 1

Manufacturing and Production Systems

Manufacturing is the ability to make goods to satisfy societal needs Different Manufacturing processes work together to create a manufacturing system (MS)

Toughness

Mechanical property of a material that indicates the ability of the material to handle overloading before it fractures.

sand old must possess this property

Must allow hot air and gases to pass through voids in sand

fatigue

extreme tiredness

In vacuum molding, the mold is made of sand and sand particales are held together by vacuum pressure

smaller

What does gamma (γ) represent

γ = shear strain

stiffness

ability of a tissue to resist a load

impact

(n) the striking of one object against another; the shock caused by a collision; (v.) to affect especially forcefully

For which one of the following values of chip thickness before the cut to would you expect the specific energy in machining to be the greatest: a) 0.010 inch, b) 0.025 inch, c) 0.12 mm, or d) .50 mm?

12 mm, smallest chip thickness would have greatest specific energy in machining

Hardness

A measure of how easily a mineral can be scratched

Which one of the following metals would usually have the lowest unit horsepower in a machining operation: a) aluminum, b) brass, c) cast iron, or d) steel?

Aluminum would have the lowest unit horsepower in a machining operation

Identify some of the reasons why machining is commercially and technological important.

Applicability to most materials; it can produce a variety of geometries to a part; it can achieve closer tolerances than most other processes; and it can create good surface finishes

Which one of the following stamping dies is the most complicated: a. blanking die, b. combination die, c. compound die, d. edge-bending die, e. progressive die, or f. V-bending die?

Compound die

What are the three basic categories of material removal processes?

Conventional machining, abrasive processes, and nontraditional processes

What are the parameters of a machining operation that are included within the scope of cutting conditions?

Cutting conditions include speed, feed, depth of cut, and whether or not a cutting fluid is used.

Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material: a) continuous, b) continuous with bue, c) discontinuous, or d) serrated?

DISCONTINUOUS

In sand casting, the size of the final part is ........... than the pattren due ti shrinkage

Decrease in power and increase in shear plan

Name and briefly describe the four types of chips that occur in metal cutting.

Discontinuous—chip is formed into separated segmentsContinuous—chip does not segment and is formed from a ductile materialContinuous with built-up edge (BUE)---same as continuous above, except the friction at the tool-chip interface causes adhesion of a small portion of work material to the tool rake faceSerrated---semi-continuous in the sense that they possess a saw-tooth appearance that is produced by a cyclical chip formation of alternating high shear strain followed by low shear strain.

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut t corresponds to which one of the following cutting conditions in turning: a) depth of cut d, b) feed f, or c) speed v?

Feed rate f

Which of the following manufacturing processes are classified as material removal processes (two correct answers): a. casting, b. drawing, c. extrusion, d. forging, e. grinding, f. machining, g. molding, h. press working, and i. spinning.

GRINDING and MACHINING are material removal processes

According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers): a) decrease in friction angle, b) decrease in power requirements, c) decrease in shear plane angle, d) increase in cutting temperature, and e) increase ins hear plane angle?

INCREASE in rake angle would result in a DECREASE in power requirements and increase in shear plane angle.Merchant equation:Phi = 45 + α/2 - β/2phi: shear plane angleα: rake angle of cutting toolβ: friction angle

Which of the following descriptions applies to a V-bending operation as compared to an edge-bending operation: a. costly tooling, b. inexpensive tooling, c. limited to 90 degree bends or less, d. used for high production, e. used for low production, and f. uses a pressure pad to hold down the sheet metal. (2 best answers)

Inexpensive tooling and used for low production

casting process in which pattren is destroyed along with mold

Investment casting

What is Manufacturing?

It is the process of converting raw materials into products..........the designed products

A roughing operation generally involves which one of the following combination of cutting conditions: a). high v, f, and d, b). high v, low f and d, c). low v, high f and d, d). low v, f, and d, where v=cutting speed, f=feed, and d=depth?

LOW cutting speedHIGH feed rate and depth of cut

A lathe is used to perform which one of the following manufacturing operations: a. broaching, b. drilling, c. lapping, d. milling, and e. turning.

Lathes are used to perform TURNING

What is an orthogonal cutting operation

Orthogonal cutting involves the use of a wedge-shaped tool in which the cutting edge is perpendicular to the direction of speed motion into the work material

Which of the following are characteristics of the orthogonal cutting model (three best answers): a) a circular cutting edge is used, b) a multiple cutting edge tool is used, c) a sing-point tool is used, d) only two dimensions play an active role in the analysis, e) the cutting edge is parallel to the direction of cutting speed, f). the cutting edge is perpendicular to the direction of cutting speed, and g) the two elements of tool geometry are rake and relief angle?

Orthogonal cutting model:Only two dimensions play an active role in the analysisThe cutting edge is perpendicular to the direction of cutting speedThe two elements of tool geometry are rake and relief angle

Manufacturing and Production Systems

Production system is the total company and includes manufacturing systems

With which one of the following geometric forms is the drilling operation most closely associated: a. external cylinder, b. flat plane, c. round hole, d. screw threads, or e. sphere.

ROUND HOLE

Which of the following cutting conditions has the strongest effect on cutting temperature: a) feed or b) speed?

Speed

Ductility

The ability to be pulled into thin wires

Identify the four forces that act upon the chip in the orthogonal metal cutting model but cannot be measured directly in an operation

The four forces that act upon the chip are friction force, normal force to friction, shear force, and the normal force to shear force.

casting process are performed

True

strength

the ability to maintain shape under the application of force

creep

the slow downhill movement of weathered rock material