236 Flashcards

Learn 236 (56 cards)

1
Q

welding pros

A

-complex designs
-quick
-no limit to size
-can join dissimilar parts

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2
Q

welding cons

A

-time consuming to inspect
-skilled labour, disassembly hard
-heat distorts parts
-may need heat treating
- can change composition of metal

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3
Q

Adhesive pros

A

-can join dissimilar materials,
-uniform stress distribution
-low weight
-can seal
-thermally/electrically conductive/insulating
-fatigue/corrosion resistance
-low assembly time

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4
Q

adhesive cons

A

-Disassembly hard
-surface prep required
-accurate assembly required
-NDT hard
-affected by age/environment
-low creep strength

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5
Q

mechanical fastening pros

A

-no surface prep
-disassembly possible
-simple inspection

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6
Q

mechanical fastening cons

A

-stress concentration
-additional weight
-possible galvanic corrosion

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7
Q

causes of adhesive ageing

A

-mechanical-stresses
-chemical-humidity/oxygen etc
-physical-temp/ultraviolet etc

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8
Q

advatages plastics

A

-corrosion resistant
-good surface finish
-flexible/strong/light

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9
Q

thermoplastics pros

A

-recyclable
-tough/ductile
-crystalline or rubbery
-faster processing

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10
Q

thermoplastics cons

A

-more expenssive than thermosets
-lose shape if overheated (creep)
-less stiff than thermosets

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11
Q

thermoset pros

A

-resistant to high temps/chemicals
-higher tensile strength than thermoplastics
-good creep resistance
-simple processing
-dimensional/thermal stability

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12
Q

thermoset cons

A

-cant recycle/reshape
-harder to surface finish
-brittle at room temp

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13
Q

good plastic design practices

A

-constant wall thickness
-fillets for reducing corner stresses
-webs and ribs for strength
-tapers on verticle walls for demoulding
-only self tap screws <10 times assembly/dissasembly

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14
Q

plastic extrusion pros & cons

A

pros: cheap, complex cross-section, post-extrusion alterations.

cons: size variance, product limitations

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15
Q

plastic injection moulding pros

A

-fast productions
-high tolerances
-good finish, minimal post processing
-minimal scrap losses
-low labour cost

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16
Q

plastic injection moulding cons

A

-expensive equipment investment
-long time to make dies
-modifications tricky

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17
Q

rotational moulding pros (thermoplastic powder spun in heated mould)

A

-stress free moulding
-cheaper/quicker mould production
-very little polymer waste
-thick walls >12mm
-complex shapes

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18
Q

rotational moulding cons (thermoplastic powder spun in heated mould)

A

-slow process
-labour intensive
-can have non-uniform wall thickness

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19
Q

blow moulding pros

A

very fast rate of production at high machinery cost

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20
Q

compression moulding

A

-thermsoset powder heated and compressed
-low mould cost
-low strength parts

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21
Q

vacuum thermo-forming

A

sheet of thermoplastic heated and sucked into mould
pros: low cost and quick tool making, economical for small quantities.
cons: slow process, waste from offcut, sheets need to be preped

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22
Q

causes of errors

A

-insufficient knowledge
-ignorance, carelessness or negligence
-forgetfulness
-relying on others without sufficient control

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23
Q

avoiding failure

A

-get initial concepts/designs correct
-communicate
-argue and debate
-admit mistakes
-attention to details
-testing

24
Q

design defect

A

all similar products bear defective design feature, and unreasonably dangerous. if shown a safety feature could have feasibly been installed but wasn’t = defective design

25
3 types of liability
-strict: product unreasonably dangerous regardless of carefulness, dangerous beyond the expectation of ordinary consumer -negligence: designer/manufacturer didn't take adequate precautions in manufacturing/inspecting/testing product -warranty: product does not perform as intended, as stated by supplier or consumer guarantees act
26
Failure
"the degradation of the performance of a device or process outside of a specified value" and "non-performance or inability to perform its functions" defect: imperfection deficiency: lack of conformance to specifications fault: cause of failure malfunction: unsatisfactory performance
27
failure rate
Number of failures per unit hours of operating time
28
3 types of failure
1. early failure, initial kinks ironed out eg software 2. constant/random failures 3. wear out failures
29
reliability R(t) definition
probability a product will still be functioning at time t
30
how to assure quality of design
1. ensure conformance to standards 2. take corrective measures if there are faults 3. take preventative measures to eliminate faults
31
common causes and assignable causes
common - small random changes, background noise assignable - large variations in quality, process stopped
32
variable data
product characteristics that can be measured eg size, weight
33
Hydraulics pros and cons
pros: little energy absorption by fluid, higher forces cons: oil flammable, heavy components
34
Pneumatics pros and cons
pros: fewer shock loads, lightweight, air easily available cons: lower loads, explosion possible
35
Gear pump pros and cons
pros: low complexity/cost, compact cons: pressure and flow rate cannot be changed independently, abrasives wear teeth, sealing and losses
36
vane pumps pros and cons
pros: high pressures for low viscosity fluids, good intake suction cons: complex, pressure and flow rate not independant
37
piston pump - swash plate pros and cons
pros: large pressure range and viscosity range, pressure and flow rate can be controlled independently cons: complex, bulky, tight tolerances
38
cushioned lineae actuator
-flow restrictor on piston head -increases back pressure near end of stroke -reduces flow rate slows piston -less damage risk, smooth operation
39
positive contact clutch pros and cons
axial teeth engage with their opposite pros - high load capability, simple, cheap, long life cons - precise tooth alignment, cannot engage while running
40
overrunning clutch
one way transmission, ratchet mechanism
41
friction clutches pros and cons
pros - allow running engagement, more plates = more friction, normally engaged or disengaged cons - wear, axial load from clamping force, large diameter needed for large loads
42
different brake pad material
ceramic - most expensive, best performance, quietest metallic - good performance, loud, poor longevity organic - cheap, poor performance
43
disc vs drum brakes
disc offer superior stopping power and heat dissipation while drum brakes are cost-effective and durable
44
common causes of brake failures
disc: loss of hydraulic pressure, pads wearing too thin, disc warping drum brakes: contamination causing loss of friction, overheating of drum
45
Material Extrusion 3D printing process and pros/cons
extrudes plastic through nozzle and builds layers ontop of each other pros: affordable, cheap material, easy to use cons: weakness in z direction, poor surface quality
46
Vat Photopolymerisation 3D printing process and pros/cons
trace of UV beam on surface if liquid photopolymer solidifies a layer at a time and then pushes build down into liquid a little bit at a time pros: best surface finish, can make clear parts cons: brittle, messy and requires supports for overhangs
47
Material Jetting 3D printing process and pros/cons
droplets of photosensitive material put onto structure layer by layer and cured with UV light pros: best surface finish, clear parts, color parts cons: weak material, messy
48
Powder Bed Fusion 3D printing process and pros/cons
selectively melting layers of powder with laser pros: strongest AM parts, works with metal cons: metal PBF requires inert atmosphere, required support material for heat transfer, tricky to remove support structures
49
HP Multi Jet Fusion process
same as powder bed fusion but uses special ink that absorbs heat and melts powder only where ink is
50
Binder jetting 3D printing process and pros/cons
printhead selectively applies binding agent to thin layer of powder, can be used to make green parts for powder metallurgy pros: fast to produce green parts, cost effective for prototyping cons: green parts fragile, parts shrink while sintering, hard to use on large parts
51
Directed Energy Deposition 3D printing process and pros/cons
metal powder or wire is deposited from nozzle and melted by laser pros: can repair broken parts or add features to an existing part cons: surface requires milling
52
Hybrid AM pros and cons
combines directed energy deposition with multi axis cnc milling pros: can produce ready to use parts cons: difficult, high labour cost, high cost in general
53
cutting fluid coolant
reduce effects of heat in machining usually water based
54
cutting fluid lubricants
reduce friction of part with tool usually oil based can also reduce temps
55
CNC vs manual pros and cons
pros: high productivity, large volume of identical parts, complicated parts cons: more expensive upfront cost, alter labour force
56