Manufacturing Midterm

is also known as chain growth polymerization monomers joined together in a manner that leaves no byproducts

Polymerization

what is composed of a bed, a headstock, tailstock, carriage, and a quick change gearbox

a lathe

is a reservoir connected to the mold cavity

a riser

Channel through which the metal enters the mold

a runner

the holding portion of the tool

cutting shank

r highly crystalline polymers high mechanical strength and rigidity natural loop city highest deflection temperature excellent toughness and resistance to creep repeated impact also resistant to moisture gasoline and solvents

Acetal

Two part like your adhesive with high strength durability and fast setting times

Acrylics

occurs when two surfaces are brought together under high pressure and high temperature welding occurs between the chip and tool face well

Adhesion or attrition

high performance thermoset or thermoplastic resin matrix reinforced with high strength high modulus arrangement of carbon , aramid, and boron fibers

Advanced Composites

Specialty adhesives designed to cure on metals in the absence of oxygen. Primarily used to anchor threaded joints and shafts against breaking free due to vibration. Can eliminate the need for lock washers and press fitted metal joints. Often known as "locking compounds." Based on synthetic acrylic resins.

Anaerobics

having different properties in different directions

Anisotropic

Restoration of cold worked or heat treated metal to its original properties

Annealing

-Quenching a hardenable steel from the austenizing temp to slightly above temo where martensite starts to form (Ms temp) and below temp where annealing type structure would result (AC3). -held at temp until transformation is complete, them quenched or air cooled -done in steps -for thin pieces -put in bath of molten salt then dumped in water -Bainite is produce

Austempering

or Y-iron is a solid solution containing up to 2.11% carbon Exhibits good formability, starting point for virtually all heating treatment processes

Austenite

typically non magnetic do not Harden by treatment corrosion resistant due to high nickel content

Austenitic stainless steels

An austenitic transformation product found in some steels and cast irons. It forms at temperatures between those at which pearlite and martensite transformations occur. The microstructure consists of a-ferrite and a fine dispersion of cementite.

Bainite

sheared slug or part is saved the remainder of scrapped

Blanking

Computer Aided Manufacturing

CAM

Materials have extreme hardness and work systems

Carbides

It is a case hardening process by which the carbon content of the steel near the surface of a part is increased.

Carburizing

Process in which molten metal is poured or injected into a cavity and allowed to solidify taking on the shape of the cavity

Casting

sand metal depending on the process or placed into the cavity to form the inner surfaces of the casting

Cores

acts primarily as a coolant and secondly as a lubricant, reducing the friction effects as tool/chip interface and the work/flank regions. also carry away the chips and provide friction (and force) reductions in regions where the bodies of the tools rub against the work piece

Cutting Fluids

One part adhesive that quick cures quickly by reacting with moisture combine too many materials

Cyanoacrylates

the process or product of forcing molten metal into a metallic mold or die under hydraulic pressure to give it a particular shape or form.

Die Casting

Remove some of the hardness but not all of it typically for applications requiring high wear resistance acquiring high toughness

Tempering

removes material and produces a narrow kerf by the cutting action by a high pressure stream of water

Waterjet Machining

Is a flange that has been bent 180 degrees or more primarily used for parents before attachment of a one sheet to another

a hem

high strength to weight ratio, corrosion resistance ,high thermal and electrical conductivity, appearance ,machinability ,formability

aluminum

Lead is cathode and Al is anode. Surface is converted from metallic Al to aluminum oxide.

anodizing process

process where metal is pulled to shape through a die

drawing

defined as the ability of a material to become permanently deformed without failure determined by the tensile test

ductility

good flexibility solvent resistance good electrical insulation however both susceptible too movie light in oxidation

polystyrene

The material processing technique used to consolidate particular matter both metals or and or nonmetals into discrete shapes

powder metallurgy (P/M)

uses a long endless band with many teeth traveling over two or more wheels, too cut in one direction

power Band sawing

Gas tungsten arc welding

slag

A forming technique used for some ceramic materials. A slip, or suspension of solid particles in water, is poured into a porous mold. A solid layer forms on the inside wall as water is absorbed by the mold, leaving a shell (or ultimately a solid piece) having the shape of the mold.

slip casting

occurs when two dissimilar metals are electrically connected in place in a common electrolyte

Galvanic corrosion

An arc welding process where the arc is between a tungsten electrode (non-consumable) and the weld pool. The process is used with an externally supplied shielding gas. also known as TIG welding

Gas Tungsten Arc Welding (GTAW)

machining characterized by a high cutting speed , but lighter cuts

High speed Machining

Are capable of maintaining hardness at a higher temperature better than carbon and medium alloy steel

High speed steels

A metastable iron phase supersaturated in carbon that is the product of a diffusionless (athermal) transformation from austenite. hard needle like structure harder than find pearlite

Martensite

contain small Mount nickel have high carbon content heat treatable are magnetic exhibit high strength hardness fatigue resistance and ductility moderate corrosion resistance

Martensitic stainless steels

it holds fibers in place, protects the fibers, under a applied force deforms and distributes the stress

Matrix

Used for cutting tools and grinding wheels also ceramic ball bearings hot surface igniters there's a low coefficient of friction against steel

Nitrides

For ferrous alloys, austenitizing above the upper critical temperature, then cooling in air. The objective of this heat treatment is to enhance toughness by refining the grain size.

Normalizing

The process of mechanically cutting sheet metal with the application of shear force

Shearing

Type of molding that offers a higher degree of accuracy in surface finishing insane casting but not as much as permanent bold or precision casting

Shell casting

An arc welding process that produces an arc between a consumable, coated electrode and the workpiece, creating a weld pool.

Shielded Metal Arc Welding (SMAW)

Are semi crystalline materials with high strength stiffness and heat resistance

nylons

number of teeth per inch in a bandsaw

pitch

By stressing the metal beyond its yield strength not exceeding its tensile strength create a shape

A bend

American Society of testing and manufacturing

ASTM

appearance of hairline cracking

Thermal cracking

are plastics that often soften during original processing but once finished they cannot be easily reprocessed

thermosets

Used in the construction of hollow products such as bottles and containers. The molten plastic enters around a tube that also forces air inside the material, which forces it against the interior surface to mold to create the shape desired.

Blow Molding Process

machining process generating internal cylindrical forms by removing metal with single point tools

Boring

the process of joining metal with a filler rod that melts at a temperature below the metal being joined

Brazing

uses a long multi-tooth cutting tool that forms a shape in a single pass of the workpiece. pulls or pushes across the workpiece

Broaching

Part heated athigh temperature and causes the oxide particles the ceramic to bond, reduces porosity, increases strength and hardness

Ceramic firing

Include high hardness and brittleness , low impact strength, no plastic deformation before reaching tensile strength high modulus

Ceramic properties

cutting tool material. Ceramic material in a metal binder.

Cermets

describe how substance forms or substance through chemical change reaction

Chemical properties

Consider the catastrophic failure that occurs when a small piece breaks away from the cutting edge of the tool

Chipping

Typically produced by selectively etching the copper

Circuit traces

Process used manufacture of clay pipe-drainage tiles, auger or ram forces clay through it tubing die

Clay extrusion

Forming done below the crystallization point is :

Cold Forming

produces holes by the relative motion of a rotating cutting toll and workpiece

Drilling

nodule iron contains carbon in the form of times nodules or spheres gives the iron good ductility high tensile strength

Ductile Iron

highly accurate elastic impression materials that have qualities similar to rubber; they are used extensively in indirect restorative techniques, such as crown and bridge procedures

Elastomers

A process by which an electrode spark is used to erode small amounts of material from a work piece.

Electrical Discharge Machining (EDM)

Direct electric current is used to speed up the rate at which the material dissolves using a chemical etchant

Electrochemical machining

the metal to be welded is heated by the impingement of a beam of high-velocity electrons

Electron Beam Welding (EBW)

an electrolytic process in which a metal ion is reduced and a solid metal is deposited on a surface

Electroplating

is uniform removal of metal from a part to produce a smooth surface by using electrochemical techniques.

Electropolishing

A manufacturing process plastic deformation process that forces material through a die opening.

Extrusion

a-iron is a soft and ductile body centered cubic phase of iron the solid solution contains only 0.008% carbon at room temperature

Ferrite

Forming operation in which a narrow strip at the edge of a sheet is bent down along a straight or curved line

Flanging

force across the width of the grinding wheel measured in lb/in

Force Intensity

A process by which metal is heated and shaped by plastic deformation by suitably applying compressive force.

Forging

the heat required to produce the joint is generated by friction heating at the interface (spin welding)

Friction Welding (FRW)

An arc welding process where the arc is between a continuous filler metal electrode and the weld pool. Shielding from an externally supplied gas source is required.

Gas metal arc welding GMAW

attach the runners to the mold cavity

Gates

Process of removing unwanted residual stress from glass

Glass Annealing

Process of floating a sheet of viscous glass into a bath of liquid tin to eliminate surface imperfections

Glass rolling

Mold compacted around pattern with a sand clay water mixture that may contain other additives

Green Sand Casting

An operation that removes material by rotating an abrasive wheel or belt against the work.

Grinding

the degree in depth of hardness possible depends on the composition in cooling rate

Hardenability

- IBM combines injection molding and blow molding - A parison is injection molded and then blown - Better control over material distribution in preform - 2 molds are required (preform & blow mold)

Injection Blow Molding

2 stages of cooling -Molten salt bath with lower temp than austempering -cool in water

Martempering

glassy material contains rubber additives also known as Styrofoam good insulator but brittle

polystyrene

combines cutting forming in one step creates whole without completely separating the middle, creates tabs

Lancing

a welding process producing coalescence with the heat from a laser beam impinging on the joint

Laser Beam Welding (LBW)

high cost process for large parts

Plastic casting

is a machining process for removing material by relative motion between a workpiece and a rotating cutter having multiple edges

Milling

A chemical change in which a substance combines with oxygen, as when iron oxidizes, forming rust

Oxidation

an advanced ceramic currently produced synthetically it allows control of impurities particle size and except blending

Oxides

A type of welding that uses heat from the combustion of a mixture of oxygen and a fuel gas, such as acetylene, methylacetylene-propadiene (MAPP), propane, natural gas, hydrogen, or propylene.

Oxyfuel Gas Welding (OFW)

engineering thermoplastic transparent extrude ability and impact resistance makes polycarbonate strong competitor acrylic sheet replacing flat glass plexiglass

Polycarbonate

A mixture of ferrite and cementite phases in parallel plates produced by the euctectoid decomposition of austenite. softest on the iron carbon diagram

Pearlite

the arc is maintained between a non consumable electrode and either the welding gun or the work piece

Plasma Arc Welding (PAW)

a method of forming items by injecting molten plastic into a die.

Plastic Extrusion

Will the hardest materials available high temperature and pressure bond cubic boron crystals together has high resistance to oxidation good hot harness thermal shock resistance high speeds not as tough

Polycrystalline cubic boron nitride

Consistent micro size diamond crystals in the carbide substrate compacted and bonded together, for greater precision and smoothness

Polycrystalline diamond

important in injection molding and blow molding susceptible too degradation in damage from ultraviolet light

Polypropylene

two part adhesive better flexibility in pill strength at low temperatures

Polyurethanes

Flexible for vinyl upholstery material rigid is found in pipes and plumbing fittings solve resistance burning flame retardant good insulator

Polyvinyl Chloride (PVC)

acetate forms and emotion commonly used to join materials such as wood paper

Polyvinyl acetate (PVA)

porous weld

Porosity

Continuous fiber reinforcement preimpregnated with a polymer resin that is then partially cured.

Prepreg

A continuous manufacturing process used to create composite materials that have a constant cross-section. Reinforcing fibres are saturated with a liquid polymer resin and then pulled through a heated die to form a part.

Pultrusion

also known as piercing used primarily for making holes

Punching

iron contains up to 0.008% carbon

Pure iron

Liquid reactants monomers are mixed and then pressurized into a mold.

Reaction Molding

Heat treating process by which the grains of the strain hardened or work hardened metal reform or recrystallize into an unstrained condition

Recrystallization

heat treating process where the grains of a strain hardened material reform into an unstrained condition.

Recystallization

a solder paste (a mix of solder and flux particles) is applied onto the surface of the parts to be joined and then are heated to a temperature above the melting point of the solder. The process is conducted in a continuous furnace.

Reflow Soldering

Curving of metal into cylinders or cylindrical segments is carried out on machines using two or more rolls rotate in bend the metal as it passes between them

Roll bending

A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.

Rotational Molding

Provide a blend of oil and detergency in one package vantages are good lubrication in rust control longer soaplife solid oils cleaner shop

Semi-synthetic fluids

Adhesive that is flexible good ceiling capabilities heat resistance but low strength

Silicones

fusion of ceramic particles at their borders by heating them to the point that they just start to melt

Sintering

Process of joining two metallic surfaces to make an electrical contact by melting solder (usually tin and lead) across them.

Soldering

product of austenitic transfomation; formed when steel alloy with either pearlitic or bainitc microstructures is heated to and left at temperature below eutectoid for 18-24 hours; sphere-like particle

Spheroidite

Sheet metal is stretched and simultaneously bent to achieve shape change

Stretch Forming

Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold.

Thermoforming

plastics that are solid at room temperature but when he did this often can be recorked

Thermoplastic

process used to cut thread and refers to the manufacture of threads on external diameters. Lathes are sometimes used to cut the threads.

Thread Cutting

Component leads are placed through holes in the board and soldered on the other side

Through Hole Technology

Defined as a period of cutting time that the tool can be used

Tool life

is a solid-state process in which coalescence is produced by the localized application of high-frequency shear vibrations to surfaces that are held together under rather light normal pressure

Ultrasonic Welding (USW)

a raw workpiece to be forged

blank

strength is a point at the curve for this specimen fails

breakingor rupture strength

a formation on the cutting tool, is associated with a variation of the continuous chip, often encountered in machining ductile materials.

built-up edge (BUE)

nin crease in grain size will increase toughness but reduce the hardness and wear resistance of the tool

carbides

alloy of iron and carbon contains 2.0-6.67% carbon very brittle easy to pour and cast

cast iron

Have good wear resistance and maintain their hardness at high temperatures but they're not tough at high speeds

cast-colbalt alloys

the intermetallic compound Fe3C, a hard and brittle substance 6.67% carbon

cementite

Removes enough moisture to prevent the ceramic part from cracking in the firing kiln

ceramic Drying

presses powder from all directions at room temperature

ceramic Isostatic Pressing

Can be operated at higher cutting speeds and coated carbide tools run hotter and longer with less wear low coefficient of friction high wear resistance chemical inertness

ceramic cutting tools

Improves appearance and strengthen makes the ceramic part impermeable forms a smooth glassy coating after firing

ceramic glazing

lathes are sometimes used to cut the threads by this name

chasing

requires use of a Potter's wheel mechanical device spins clay that is hand shaped

clay Throwing

Process that forms one side of a clay product with a plaster mold and the other side using a metal template

clay jiggering

Process applies pressure on the material inside matched metal tooling

composite compression molding

the upper half of the mold in a cast

cope

polymers formed from two different monomers

copolymers

Gradual tool wear on the rake face of the tool

crater ware

regular geometric pattern of particles in most solids, giving a solid a definite shape and volume

crystalline structure

is a portion of the face edge that separates the chip from the workpiece

cutting edge

Green parts are then heated to drive off the polymer binder in the process known as

debinding

powder is electrostatically charged and sprayed into the ground work piece

electrostatic spraying

Are all droplets suspended in water by blending the oil with emulsifying agents and other minerals

emulsifiable fluid

adhesive are one or two par Have good chemical and heat resistance

epoxy

Method of making metal castings by the use of expanding polystyrene from patterns that eliminate the need for traditional mold cavities that evaporate after casting

evaporative casting

two-stage plastic forming process in which (1) a tube or parison is first extruded and then (2) it is clamped into a mold with a cavity much larger than the tube diameter, (3) it is blown outward to fill the mold cavity

extrusion blow molding

are magnetic and have good corrosion resistance let's duck tile cannot be hardened by heat treatment contain small amount of nickel

ferric stainless steels

process for producing fiber reinforced composites in which continuous fibers are wrapped around a form or mandrel the fibers may be prepregged or the filament wound structure may be impregnated to complete the production of the composite

filament winding

Surface or surface below and adjacent to the cutting edge

flank

Gradual tool wear on the relief face of the tool, cased by plastic deformation of the cutting edge

flank ware

Consist of heating the steel to proper temperature and then cooling slowly through the transformation range

full annealing

The art of heating and shaping glass.

glass blowing

usually involves matching molds that press a blob of viscous glass into a desired shape using mechanical centrifugal forces

glass pressing

edge where one boundary meets another

grain boundary

particle size of the abrasive grains, which influence the stock removal rate and surface finish

grain size

material loose powder

green compact (powder metallurgy)

carbon content in Free State flake or graphite most commonly used cast iron due to its machinability and high shear strength

grey iron

made but heat treating white iron high strength ductility in machinability

malleable iron

high pressure fluid surrounds the work piece and applies the force necessary to extrude through the die

hydrostatic extrusion

a shape in wax is created, and then covered with plaster or ceramic material (investment). When investment has hardened, the wax is melted out, then molten metal is poured in

investment casting

when extremely complex shapes are desired, the powder is generally encapsulated in a flexible mold and immersed in a pressurized gas or liquid process

isostatic compaction

laser machining

laser beam machining (LBM)

Smallest radius that can be formed without part cracking

maximum bend radius

stress to which material can be subjected without permanent deformation is known as the last elastic limit

maximum stress

also known as powder injection molding, powder is injected and then melted in the mold

metal injection molding (MIM)

Specialized metal forming process used for hollow products that can be turned to produce the desired shape

metal spinning

is the indication of the stiffness of a material

modulus of elasticities

the corner arc or sham for joining the side cutting in cutting edges

nose

Single groove that occurs simultaneously on the face and flank the tool but the depth of cut

notching ware

the most common thermal cutting, commonly flame cutting. in some cases the metal is merely melted by the flame of the oxyfuel gas torch and blown away to form a gap or kerf

oxyfuel gas cutting

process for producing a large number of castings using a single reusable mold. Casting process simply involves pouring molten metal into a mold where it cools and solidifies (most commonly used to cast ingots where are then processed into components)

permanent mold casting

a tool for understanding the phase changes of a metal

phase diagram

adhesive good sheer and peal strength with good heat resistance

phenolic

do not involve a change in composition

physical properties

submersion of material in chemical bathe to remove oxides

picking

thermoset molding compounds placed in mold heated and compressed under pressure to a shape

plastic Compression Molding

plastic melted in a pot and pumped into mold

plastic Transfer Molding

a thin board made of fiberglass or other laminate material on which conductive pathways are "printed", connecting different components on the PCB, such as transistors, resistors, and integrated circuits.

printed circuit board (PCB)

Substances that have a relatively high melting point and tend to exist in solid form.

refractory materials

welding in which the heat is generated by an electric current passing through the join

resistance welding

continuous hot or cold forming process

rolling

Multiple layer structural materials containing a low density core between thin faces of composite laminates

sandwiches

Process of cold forming a flat pre cut metal blank into a hollow vessel without the occurrence of excessive wrinkling thinning or fracturing

sheet Drawing

refers to a condition in which two metals are each completely soluble in the other while the in the other state

solid solubility

Or made from mineral oil provides excellent lubrication good rest control and long life yeah can be cause fire

straight cutting fluids

increased density for component population compared to that through whole technology paste it with soldering paste using a stencil printed operation

surface mount technology

Surface of glass is rapidly cooled after it has been formed some layers of compression in tinsel forces

tempered glass

the maximum stress developed by the material based on the original cross sectional area

tensile strength

base with a flat surface on the tool Shank parallel perpendicular to the tool plane

the cutting base

Lower half of a mold

the drag

is inclination of the face with respect to the side cutting edge angle

the side-rake angle

Channel through which the metal enters the mold

the sprue

extremely old process in which superheated molten metal and slag are produced from an exothermic chemical reaction between a metal oxide and a metallic reducing agent

thermit welding (TW)

Transfer of atoms across the interface between the workpiece and the cutting tool

tool diffusion

cutting point is the part of the tool shape to produce the cutting edges face in plank

tool point

he ability of material to absorb energy prior to failure, failure found by impact test

toughness

process used to solder wire ends, such as the multiple connecters that protrude through holes in electronic circuit boards,

wave soldering

A process that combines welding and adhesive bonding, combine in a way that compliments one another and cancels out each other's negative effect

weld bonding

Particles of molten metal produced during welding and thrown onto the surface adjacent to the weld

weld splatter

Fusing two pieces of material using a heat process; most commonly used with metal and plastics

welding

casting Gray iron against a metal sheet heat sink it's hard abrasion resistant soft iron core

white iron

A type of soda lime glass contains about 75% silica 14% soda and 10% lime

window glass

point of a ductile material defined as the point at which a permanent deformation continues without an increase in stress

yield point

the point at which a material begins to deform permanently

yield strength