Introduction to Manufacturing - Exam 1
The highest tensile strength plastic listed on table 14-1 when compared to the 36,000 PSI tensile strength of a low strength, low carbon steel is about what?
1/3 the strength of steel
A polymer contains at least how many mers?
100
What 300 series aluminum do we commonly melt in the foundry at UW-Platteville?
356
Advanced Composites usually have a fiber to resin ratio above _____%
50
What grade of hardened steel is commonly used to make gears?
8620
What are the two types of polymerization?
Addition and Condensation
Which of the following heat treatment processes would result in the lowest hardness of material: Annealing, Austempering, Carburizing, or Cyaniding?
Annealing
Kevlar fibers are also known as what?
Aramid fibers
Which of the following stainless steels is the most corrosion resistant: Austenitic, Ferritic, or Martensitic?
Austenitic
What is used when the location of features must be controlled from a common reference plane?
Baseline Dimensions
What are the rolls of a matrix in a composite?
Binder to Hold Fibers in Place, Protect Fibers from Damage, and Transfer Load to Fibers
Which of the following is the most severe [fastest cooling rate] quench media: Air, Brine, Oil, or Water?
Brine
A materials tendency to fail suddenly by breaking, without permanent deformation before failure.
Brittleness
What is the most important element for alloying steel?
Carbon
What do the last two digits of the AISI-SAE steel identification number denote?
Carbon Content
Which of the following metals contains the most amount of carbon: cast iron, plain iron, stainless steel, or steel?
Cast Iron
What is used when the tolerance between adjacent features is more important that the overall tolerance accumulation?
Chain Dimensions
The metal alloy in stainless steels responsible for its corrosion resistance.
Chromium
What alloying element is primarily responsible for the corrosion resistance in stainless steels?
Chromium
Polycarbonate is known for what properties?
Clarity/Transparency and Toughness
What is in location 7 in the house of quality?
Competition Assessment
Resistance of a material to a force that is tending to deform or fail it by crushing.
Compressive Strength
What is in location 1 in the house of quality?
Correlation Matrix [Roof]
Ceramics are known for what properties?
Corrosion Resistance, High Hardness, High Stiffness [Modulus of Elasticity], and High Temperature Resistance
Slow deformation of a material under a prolonged stress.
Creep
What is in location 6 in the house of quality?
Customer Requirements
Ability of a material to become permanently deformed without failure.
Ductility
The maximum stress a material can be subjected to without permanent deformation.
Elastic Limit
Ability of a material to return to it's original shape and dimensions after a deforming load has been removed.
Elasticity
What are the common uses for Polyvinylchloride?
Electrical Tape, Plumbing Fittings, and Wire Insulation
The stretching of a material by which any straight line dimensions increases.
Elongation
Maximum stress that a material will support indefinitely under variably and repetitive load conditions.
Endurance Limit
What is in location 2 in the house of quality?
Engineering Requirements or Design Characteristics
Where is First-Angle projection commonly used?
Europe
Red hot austenitic steel has what atomic structure
Face Center Cubic [FCC]
Austenite has what crystalline structure?
Face-Centered Cubic
FMEA is an acronym for ___________________ .
Failure Mode Effects Analysis
A "mer" is a complex chain of organic molecules, T/F?
False
Austenitic stainless steels are magnetic, T/F?
False
Finite Element Analysis [FEA] should be implemented as late as possible in the design process, T/F?
False
Glass is an inorganic substance that has cooled while forming a crystalline structure, T/F?
False
Heat treatment will always end in a material becoming stronger, T/F?
False
It is reasonable to produce a print without tolerances and expect that a part made from that print be exactly the dimensions listed, T/F?
False
PVC burns well, T/F?
False
Strain hardening is a type of heat treatment, T/F?
False
The liquidus temperature is the point at which a liquid metal completes its solidification process when cooling, T/F?
False
The process of annealing aluminum is the same as that of steels.
False
Cracking, breaking, or other failure of a material as a result of repeated or alternating stressing below the material's ultimate tensile strength.
Fatigue Failure
A material's resistance to repetitive or alternating stressing without failure.
Fatigue strength
What word is used to describe the graphite structure or grey iron?
Flakes
Ability of a material to resist indentation, penetration, abrasion, and scratching.
Hardness
Design for manufacture reduces cost of production by what?
Identifying the Best Material Process Combinations, Reducing Assembly Labor, Reducing Component Complexity, and Reducing Part Numbers
Ability of a metal to withstand a sharp, high velocity blow without failure.
Impact Strength
What is in location 5 in the house of quality?
Importance [Basement Two]
Amount of force applied to material or structure.
Load
Grey iron has what good properties?
Machinability, Vibration Dampening, and Thermal Conductivity.
Property of being permanently deformed by compression without rupturing; Ability to be rolled or hammered into sheets.
Malleability
What are all the reasons to use GD&T?
Manufacturing Costs Need to be Optimized, Repeatability is Important, Part Assembly is Critical, Part Manufacturing Happens in Multiple Locations, Part Verification is Required Though Functional Gauging
The prefix "poly" means what?
Many
What are common uses of polyethelyene?
Milk Jugs and Plastic Bags
Ratio of tensile stress to the strain it causes within that range of elasticity where there is a straight line relationship between stress and strain.
Modulus of elasticity
The sacrificial material used to prevent galvanic corrosion [e.g. used in water heaters to protect the steel] is _____ than the steel it is protecting.
More Anodic and More Active
Should all irons be classified as a brittle material?
NO!
Which of the following is not a case hardening process: Carburizing, Cyaniding, Nitriding, or Normalizing?
Normalizing
Resistance of a metal to adverse effects from the presence of notches or similar irregularities.
Notch Toughness
According to table 14-1 [page 122 in the textbook or slide 82 in the PowerPoint] what plastic has the highest ASTM D-638 tensile strength?
Nylon 6/6
The Solidworks® software that we use in class mainly uses what type of modeling?
Parametric Modeling
A material's color, magnetism, and melting temperature are examples of _____.
Physical Properties
Deformation of a material under the action of a force, and upon removal of the force, the material foes not return to its original shape.
Plasticity
The stress point beyond which an increase in stress is no longer proportional to an increase in strain.
Proportional Limit
What do the last two digits of the four digits wrought aluminum identification code denote?
Purity
Which of the following fits would require the most accurate process and cost the most to produce: RC3, RC5, RC7 or RC9?
RC3
What is in location 3 in the house of quality?
Relationship Matrix
What words are used to describe the graphite structure of ductile iron?
Round, Spherical
Physical effect of stress, usually evidenced by stretching or other material deformation.
Strain
What is in location 4 in the house of quality?
Target Values for Design Characteristics [Basement One]
Resistance of a material to a force that is acting to pull it apart.
Tensile Strength.
Polyethylene [PE], Polypropylene [PP], Polyvinylchloride [PVC] and Polyethylene Terphalate [PETE] are examples of what?
Thermoplastics
What category of plastics are solid at room temperature but when heated become soft and can be reformed, which also makes them easily recycled?
Thermoplastics
Phenolics, Urea-Formaldehydes, Epoxides, and Polyesters are examples of what?
Thermosets
This category of plastics are soft during processing but do not easily allow resoftening or reprocessing.
Thermosets
The ability of a material to absorb energy prior to failure.
Toughness
What is the term used to describe a material's ability to absorb energy prior to failure due to impact?
Toughness
Austenite has a face-centered cubic crystalline structure which allows for more carbon to dissolve, T/F?
True
Austenitic stainless steel can be hardened by coldworking, T/F?
True
Ceramics play a huge part in manufacturing in the roll of machine tooling to cut metal, T/F?
True
Design for manufacture allows the United States manufacturing facilities to compete and produce goods at similar prices of that of low cost labour countries, T/F?
True
Design for manufacture is a methodology that simultaneously considers all of the design goals and constraints for products that will be manufactured, resulting in simpler and less expensive products, T/F?
True
Ferrite contains almost no carbon, T/F?
True
Glass can be made from metal alloys, T/F?
True
Glass fiber can be added to thermoplastics including injection molded parts to make them stronger, T/F?
True
Quality function deployment is a technique for translating customer requirements into engineering characteristics, T/F?
True
The cost of requiring tighter tolerances grows in roughly an exponential manner, T/F?
True
The direction or orientation of the fibers can influence the strength of the composite, T/F?
True
The matrix of a composite must have a greater elongation at break than the fibers for maximum efficiency, T/F?
True
White iron is known for its wear resistance, T/F?
True
Where is Third-Angle projection commonly used?
USA
Maximum pulling force to which a material can be subjected to without failure.
Ultimate Tensile Strength [UTS]
Point at which a material will continue to elongate without an increase in stress.
Yield Point
Stress level corresponding with the yield point.
Yield Strength