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IE 302 > Chapters 1 & 2 > Flashcards

Chapters 1 & 2 Flashcards

1
Q

________ is the cornerstone of a solid

economy.

A

Manufacturing

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2
Q

Countries with innovation in manufacturing are capable

A

of reducing the effects of economic crises leading to a faster return to economic stability

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3
Q

Manufacturing represents a significant part of overall

A

product cost (often stated to be ca. 40%)

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4
Q

Selection of suitable process(es) has big influence on

A

overall cost

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5
Q

In order to select suitable manufacturing process -> engineers need to

A

be aware of available techniques and their pros & cons

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6
Q

After a selection / design was made and production started,

A

a switch is often very costly

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7
Q

It is important to determine the best manufacturing process

A

for given requirements

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8
Q

The goals may be different:

A
  • Focus on QUALITY (“cost not important”)
  • Focus on COST
  • Focus on SUSTAINABILITY
  • Etc.
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9
Q

manufacturing is a term that incorporates

A

a multitude of definitions that, even though they have different meanings; they refer to one of the aspects that leads a design to become a physical tangible product

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10
Q

What is Advanced Manufacturing?

A
  • The use of innovative technology to improve products or processes.
  • Relevant technology can be described as “advanced”, “innovative”, or “cutting edge”, etc.
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11
Q

Impacts of Advanced Manufacturing:

A

Increased level of quality
Boost productivity
Gives way to innovation
Reduced production time and cost

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12
Q

One of the main advantages

of advanced manufacturing technology is

A

quality enhancement

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13
Q

Advanced manufacturing

technologies help boost

A

operational productivity in various ways. …

 Small batch production  Rapid prototyping

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14
Q

digital manufacturing helps to

A

Reduce production time and cost

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15
Q

What is a manufacturing process?

A

Manufacturing as a transformation process, manufacturing does not equal production

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16
Q

Multiple manufacturing processes are needed to

A

produce a product in most cases

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17
Q

A simple classification of manufacturing processes into three categories:

A

Deformative
Subtractive
Additive

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18
Q

Polymers manufacturing is a

A

subset of Deformative Manufacturing

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19
Q

Deformative manufacturing represents processes where

A

where we transform the material from Form A to Form B without the addition or subtraction of material

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20
Q

The fundamental concept of Deformative manufacturing is

A

is that the volume of materials remains unchanged throughout the process

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21
Q

Forging, Rolling, Casting are examples of

A

Deformative Manufacturing

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22
Q

Subtractive manufacturing represents processes where

A

we transform the material from Form A to Form B by subtraction of material

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23
Q

The fundamental concept of Subtractive manufacturing is

A

that we reduce the volume of materials throughout the process

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24
Q

Milling, Drilling, Turning are examples of

A

Subtractive Manufacturing

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25
Q

Additive manufacturing represents processes where

A

we transform the material from Form A to Form B by addition of material

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26
Q

The fundamental concept of Additive manufacturing is

A

is that we augment the volume of materials throughout the process

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27
Q

SLS, SLA, FFF, DED are examples of

A

Additive Manufacturing

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28
Q

We obtain products (and sub-products) by performing

A

assembly operations on individual parts

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29
Q

Mechanical joining, welding and bonding are examples of

A

Assembly Operations

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30
Q

Manufacturing enable a progression of materials from an

A

initial shape to a net shape

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31
Q

The different processes transforms the

A

initial shape into multiple intermediate shapes

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32
Q

Only when the shape is ‘almost’ as intended we classify it as a

A

near net shape

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33
Q

Final output is the

A

net shape or the finished part

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34
Q

Industry 1.0

A

18th century

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35
Q

Industry 1.0 stands for the

A

mechanization of production in contrast to manual processing

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36
Q

The transformation of energy sources to produce goods

A

highlights the first era in manufacturing evolution

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37
Q

Industry 2.0

A

19th century

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38
Q

Industry 2.0 stands for

A

the mass production of products

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39
Q

This has been particularly encouraged by the arming race between countries

A

Industry 2.0

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40
Q

It led mass production of airplanes, transportation vehicles in parallel to civil goods

A

Industry 2.0

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41
Q

Industry 3.0

A

’70s in the 20th century

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42
Q

Industry 3.0 stands for

A

the introduction of automation, robotics and computers into manufacturing

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43
Q

Computer Aided Manufacturing is one of the direct results of this era as well as the replacement of humans in hazardous working conditions by robotic arms

A

Industry 3.0

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44
Q

Industry 4.0

A

Apply information and communication

technologies to industry

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45
Q

Industry 4.0 stands for

A

the integration of cyber- physical systems and the digital transformation of industries

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46
Q

integration of cognitive manufacturing

A

smart systems that analyze and interpret data– is offering new insights and abilities for next generation industries

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47
Q

The development of materials and man’s ability to process them is linked to

A

the history of man
(Stone Age (8700 BC and 2000 BC)
 Copper and Bronze Age (3000 BC and 1200 BC)
 Iron & Steel Age (1200 BC and 600 BC))

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48
Q

The current age is that of

A

plastics, composite materials, and exotic alloys

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49
Q

Alloys are

A

-Materials composed of two or more different elements -Major component is a metal, not a chemical compound

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50
Q

Ferrous metal alloys:

A
  • Cast Iron > 2% Carbon

- Steel < 2% Carbon

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51
Q

Plan carbon steel

A
  • Low-carbon (< 0.2% C)
  • Medium-carbon (0.2%~0.5% C)
  • High-carbon (>0.5% C)
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52
Q

Alloy steel

A
  • Stainless steel (low-carbon steel with 4% to 6% chromium) -Tool Steel
  • Others
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53
Q

Non-Ferrous metals and alloys:

A
  • Copper alloys
  • Titanium alloys
  • Aluminum alloys
  • Zinc based alloys
  • Etc.
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54
Q

Non-ferrous metals and alloys have properties that are not available in the ferrous metal alloy, such as:

A
  • Easy to fabricate
  • High electrical and thermal conductivity
  • Light weight
  • Resistance to corrosion
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55
Q

Blast Furnace ——>

A

includes: - Iron Ore
• Limestone, Coke • Hot Gases

goes to: Pig Iron

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56
Q

Basic Oxygen Furnace ———>

A

includes; -Jet of oxygen, -Usage of scrap iron

goes to: Steel/cast Iron

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57
Q

——> Molding

A

-Ingots

• Continuous Casting

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58
Q

Polymers are

A

chains of monomers grouped together

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59
Q

We identify three categories of polymers:

A

Thermoplastics, Thermosets and Elastomers

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60
Q

Thermoplastics are

A

commercially the most important and have over 70% of the polymer market share

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61
Q

There is a wide range of

A

natural and synthetic polymers

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62
Q

Natural polymers

A

exist in flora and fauna

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63
Q

Natural polymers include

A

proteins, cellulose, and natural rubber

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64
Q

Synthetic polymers ______

A

are derived mainly from mineral oil, natural gas, and coal. They include among others nylon, polyethylene, phenolics, and epoxies.

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65
Q

General common term for a wide range of synthetic or semi-synthetic organic amorphous solid materials.

A

Plastic

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66
Q 
-Light weight
 Corrosion resistance
 Electrical resistance
 Low thermal conductivity
 Variety of optical properties
 Surface finish
 Comparatively low cost (in material manufacturing and processes)
A

Characteristics of plastics

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67
Q

A polymer with both viscosity and elasticity and
with weak intermolecular forces
-Rubber

A

Elastomer

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68
Q

Thermoplastics (Thermoplastic materials)

A 
-Tend to be flexible and tough
 Soften with increasing temperature
 Become harder and stronger when cooled
 Can be cast, injected into a mold, or forced into (through) dies to produce a desired shape 
 Scrap can be re-melted and reused
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69
Q

Thermosets (Thermosetting materials)

A

-Significantly stronger and more rigid
 Have lower ductility and poorer impact properties
 Elevated temperature promotes irreversible reaction
 Additional heating do not produce softening
 “Set under heat and cannot be re-melted.”

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70
Q

A ceramic is

A

an inorganic, non-metallic solid prepared by action of heating and subsequent cooling

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71
Q

Crystalline ceramics and glass constitutes

the

A

two categories of Ceramics

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72
Q

Crystalline ceramics includes

A

traditional ceramics such as pottery, and advanced ceramics such as tungsten carbide

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73
Q

Glass is a

A

non-crystalline amorphous solid with widespread usage

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74
Q

General Properties of Ceramics

A 
-Hard, brittle, high melting point
 Low electrical and thermal conductivity 
 Low thermal expansion
 Good chemical and thermal stability
 High elastic modulus
 High compressive strength
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75
Q

A composite material is composed of

A

two or more different materials

-These two or more different materials form a new material with enhanced properties

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76
Q

Composites consists typically of two phases:

A

Forming and Strengthening

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77
Q

The forming phase,

A

labeled as matrix/resin, provides the formability and ductility property

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78
Q

The strengthening phase,

A

labeled as reinforcement/fibers, provides the strength to the final part

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79
Q

Fiber/Filament

Reinforcement:

A

-High Strength
 High Stiffness
 Low density
 Carbon, Glass, Aramid, etc.

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80
Q

Matrix:

A

-Good shear properties
 Low density
 Thermoset & thermoplastic
 Epoxy, Polyester, Nylon, etc.

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81
Q

Composite:

A 
-High Strength
 High Stiffness
 Good shear properties 
 Low density
 Anisotropic!
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82
Q

General properties of composites

A

-Two or more constituent materials
 Can be stronger than steel, lighter than aluminum, and stiffer than titanium;
 Low thermal conductivity, good heat resistance
 Good fatigue life
 Low corrosion rates
 Adequate wear resistance

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83
Q

is one of the earliest manufacturing

processes used by humans

A

Forging

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84
Q

is also one of the earlier manufacturing

processes

A

Casting

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85
Q

Types of forging:

A
  • Cold working (CW)
  • Warm working (WW)
  • Hot working (HW)
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86
Q

Shaping of material at room temperature (below recrystallization temperature)

A

Cold working (CW)

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87
Q

What is the Positive effect of cold working?

A

Work hardening (strain hardening) strengthens metal through plastic deformation (but, material becomes more brittle)

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88
Q

Shaping of material elevated above room temperature but below recrystallization temperature

A

Warm working (WW)

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89
Q

Trade-off between hot and cold working

A

Warm working (WW)

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90
Q

Shaping of material above the recrystallization temperature but below melting temperature

A

Hot working (HW)

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91
Q

What is the Positive effect of hot working?

A

Properties (e.g., toughness, ductility, elongation) improve / less force required to transform ingots

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92
Q

Shaping of material above the recrystallization temperature and melting temperature

A

Casting

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93
Q

Types of Recrystallization:

A
  • Recrystallization
  • Recrystallization temperature
  • Energy
94
Q

The process in which grains of a crystal structure come in a new structure or new crystal shape

A

Recrystallization

95
Q

Dislocations in metal material move to grain boundaries and/or move to the material surface

A

Recrystallization

96
Q

Material becomes “strain-free”

A

Recrystallization

97
Q

Temperature at which 95 percent of recrystallization is complete within one hour

A

Recrystallization temperature

98
Q

Different metals have different

A

recrystallization temperatures (e.g., Al 300°F, Fe 840°F & Ni 1,100°F)

99
Q

Recrystallization is a function of the

A

total energy

100
Q

Total energy =

A

strain energy + thermal energy

101
Q

Whats the effect of energy?

A

the more strain energy is induced, the less thermal energy is required (the more cold working is performed, the lower recrystallization temperature)

102
Q

Hooke’s Law (one dimensional):

A

σ = Ee

103
Q

E =

A

Young’s modulus (stiffness of material)

104
Q

Permanent change of shape

A

Plastic Deformation

105
Q

Stress in material larger than yield strength

A

Plastic Deformation

106
Q

Plastic Deformation is where ______

A

Where Manufacturing Happens

107
Q

Flow stress

A

Stress needed to achieve a plastic deformation (strain) on a material

108
Q

Flow stress of material is influenced by:

A

Strain rate, temperature, etc.

109
Q

Metals with low yield strength and high ductility are best suited for

A

forging

110
Q

Yield strength _______ with higher temperatures

A

decreases

111
Q

Ductility _______ with higher temperatures

A

increases

112
Q

Shape undergoing deformation have influence on the

A

‘next’ force needed to pursue the operation

113
Q

The influence of shape is captured via

A

different experimental trials and relevant to the manufacturing process

114
Q

Force =

A

Flow Stress x Area

115
Q

In extrusion, the shape factor is trying to compare

A

the shape to a theoretical circular shape Cc having the same area as the extruded shape

116
Q

In forging, we are further integrating

A

the coefficient of friction

117
Q

As you further continue the forging operation,

A

your shape factor increase: the shape is more flat and thus D is bigger and h is smaller

118
Q

Forging operations induce

A

-shape changes on the work piece
 by plastic deformation
 under forces applied (hammering or pressing)
 by various tools and dies

119
Q

Different classifications used for forging:

A

-Material: Bulk (most common) vs. Sheet
 Operating temperature: Hot (vs. Warm) vs. Cold
 Mode: Steady vs. non-steady state vs. mixed
 Gas turbine engine (870 oC) vs internal combustion engine (Cyclic Temp.)
 Type of stress: Compression vs. Tension vs. Bending, etc.
 Flow: Homogeneous vs. Semi-homogeneous vs. Inhomogeneous
 Succession/Operation: Primary vs. Secondary

120
Q

Biggest forging hydraulic press in the world:

A

-80,000 ton closed-die hydraulic press

 Shanghai Electric Group, Shanghai, China

121
Q

Open Die Forging is the

A

simplest form of (industrial) forging

122
Q

No specialized tooling required for ____

A

Open Die Forging due to high flexibility

123
Q

Work piece deformed between two flat (or simple shaped) dies

A

Open Die Forging

124
Q

Process of choice when in Open Die Forging:

A

Work piece very large or Small batch size

125
Q

Open Die Forging is

A

Often used as primary shaping process to pre- form the work piece for subsequent closed-die forging

126
Q

Bulging of work piece is (undesired) side effect of this forging process

A

Open Die Forging

127
Q

Safety issue in Open Die Forging:

A

flash occurs

128
Q

Impression Die (or Closed Die) Forging is

A

a more complex form of (industrial) forging

129
Q

Work piece is shaped under high pressure between two

dies with cavity in form of desired design

A

Impression Die (or Closed Die) Forging

130
Q

Enables close dimensional tolerance (e.g., for coins)

A

Impression Die (or Closed Die) Forging

131
Q

____________ is expensive (Only economical for larger batch sizes)

A

Impression (or closed) dies

132
Q

Flash gutter:

A

Small amount of material forced out of impression die cavity, forming flash

133
Q

Process of choice when in Impression Die (or Closed Die) Forging;

A

Complex shape or Large batch production

134
Q

Impression die may contain

A

recesses allowing work piece to transform into 3D shapes with complex surfaces

135
Q

Upset forging describes

A

deformative transformation of shape by changing the diameter by compressing the length

136
Q

Most common application of Upset forging:

A

Fasteners of various kind (-> thus widely used)

137
Q

Both hot and cold ______ forging possible

A

upset

138
Q

Upset forging is ______

A

Generally, high throughput operation

139
Q

Applicable work pieces range from

A

wires with small diameter to bars with large diameters (~ 10in) (Upset forging)

140
Q

Main rule of upset forging:

A

Length of to-be-deformed material restricted to max. 3x diameter (without adapted/special tooling) to prevent buckling

141
Q

Common defects in forging:

A

-Incomplete die filling
 Die misalignment
 Forging laps
 Incomplete forging penetration
 (Material) Property variation (due to micro structural differences)
 Pitted surface (due to oxide scales, occurring at high temperature, sticking on die(s) )
 Buckling (mainly common in upset forging) (due to high compressive stress)
 Surface cracking (due to temperature differential between surface and center, and/or excessive working of surface at too low temperature)
 Micro-cracking (due to residual stress)

142
Q

Design guidelines for Forging:

A

-Rib height to rib thickness ratio not to exceed 6:1
 Part must be designed with an appropriate draft angle (standard degree: 1 +/- 0.5)
 Add additional material for secondary (machining) processes and plan the parting line (where dies meet)
 No sharp corners – plan with appropriate radii
 Minimum (~0.2in) / maximum (~10in) wall
thickness (varies to some extent)
 Consider achievable surface finish (and plan
for secondary processing if necessary)

143
Q

Extrusion is

A

a deformative manufacturing process (compression forming) by which metal billet is reduced in cross-section and/or formed in different cross-sectional shape by forcing it to flow through a (or multiple) die orifice(s) under high pressure

144
Q

Metal (hot) extrusion is mainly used to

A

produce cylindrical bars, hollow tubes or as intermediate shapes for drawn rod, cold extrusion or forged products

145
Q

Most metals are hot extruded due to

A

required forces

146
Q

Complex shapes can be extruded from

A

softer metals such as aluminum

147
Q

Direct Extrusion:

A

Material is forced forward by a punch through the die orifice, producing a smaller cross-section (diameter decreases, length increases) than the initial blank

148
Q

Direct extrusion is also known as

A

Forward Extrusion

149
Q

Friction increases the

A

extrusion force

150
Q

~75% area reduction is possible with using

A

direct extrusion

151
Q

Indirect Extrusion:

A

Material is formed around the punch by being forced backward around the punch within the die, producing hollow parts with solid bottoms

152
Q

Die is mounted on the ______

A

punch (also referred to as ram) (Indirect Forging)

153
Q

For Indirect Extrusion, ________

A

The bottoms of the hollow parts should be thicker than the walls

154
Q

Indirect Extrusion is also known as

A

Backward Extrusion

155
Q

Area reductions of ~20-75% are possible

with

A

indirect extrusion

156
Q

Combined Extrusion:

A

Material is formed around the punch by being forced backward around the punch within the die and forced forward by the punch

157
Q

Many designs in combined extrusion include:

A

both extrusion forms therefore, both forms are applied simultaneously to minimize production cost

158
Q

There are a wide variety of different combinations possible depending on

A

the creativity of the design and manufacturing engineer

159
Q

What is the shape factor of a circle?

A

1

160
Q

Rolling is

A

a deformation process where shape of a (continuous) work piece is transformed using (one or multiple) pairs of rolls without changing the volume

161
Q

Generally, rolling processes produces

A

constant cross-sectional shapes (exception: thread rolling)

162
Q

Hot-Rolling (e.g., ring) and Cold-Rolling (e.g., thread) can be used ______

A

in rolling processes

163
Q

Multi-stage processes are very common due to

A

max. deformation in one step

164
Q

Bearings (e.g., force) and surfaces of rolls (e.g., temperature) are

A

highly stressed

165
Q

Rolling is a multi-stage process that can

A

produce a large variety of different products

166
Q

Succession is reflected in work piece terminology:

A
  1. Ingots
  2. Bloom (square cross-section)
  3. Slab (rectangular cross section)
  4. Billet (Bar w/ cross-section smaller than 6in x 6in)
167
Q

Typical products stemming from the various rolling processes are:

A
  • Sheet metal products (e.g., Plates, Sheets, Large diameter pipes)
  • Constant cross-sectional products (e.g., Seamless pipes, Train rails, various profiles (e.g., H, T), Wires, Bars)
  • Misc. products (e.g., Rings, Bolts, Train wheels)
168
Q

Rolling Mills:

A

Shaping material by forcing it through two rotating rolls on both sides of the work piece

169
Q

in Rolling mills, parts of _____

A

uniform cross sectional areas can be produced

170
Q

Parts are generally longer than those produced by

A

extrusion and larger than those produced by wire drawing

171
Q

Structural shapes, such as I-beams, and railroad rails are produced by

A

rolling

172
Q

Thread rolling ______

A

deforms the material by rolling it between two threaded dies to imprint external threading on a round bar/wire material

173
Q

The threaded dies can be

A

plane or round depending on the process

174
Q

Thread rolling is a

A

cold forming process

175
Q

Thread rolling produces external threads with desirable properties like

A

-Strong
 Precise
 Uniform
 Smooth

176
Q

Ring rolling is

A

a deformation process which increases diameters of rings by reducing the radial thickness of the work piece between a set of rollers

177
Q

Work piece volume is maintained which leads to

A

diameter increase and requires rollers to adjust with work piece throughout the ring rolling process

178
Q

Driver roll is fixed in most cases while

A

idle roll, rolling pins and guiding rolls adjust to the changing dimensions of the work piece

179
Q

Two, often conical shaped rollers maintain

A

the upper and lower boundary of work piece (= height)

180
Q

Ring rolling is generally a

A

hot working process

181
Q

Ring rolling results in

A

desirable circumferential grain structure achieving better mechanical properties

182
Q

Casting is a

A

prehistoric technology enabled by the fire-using technologies

183
Q

Casting is a

A

primary manufacturing processes that transforms shape of a material by changing its state to allow it to fill a mold cavity and take the shape represented without changing its volume

184
Q

Casting is applicable for

A

all material groups: Metals, Ceramics and Polymers

185
Q

Polymers most famous casting processes

A

are Injection and Blow molding

186
Q

Metal casting is classified based on

A

the mold material

187
Q

If the mold material is a solid material (e.g., stone, metal, ceramic) and is reused in the casting process, we refer
to

A

permanent mold processes

188
Q

If the mold material is sacrificed to obtain the final shape of the work piece (e.g., sand, wax) and we have to
create a new mold every time we manufacture a new part, we refer to

A

expendable mold processes

189
Q

The fundamental concept of casting is by

A

(1) melting the material into a highly plastic (polymers) or liquid (metals) state, (2) designing a mold (and cores if applicable) to contain the molten material, (3) pouring the material into the designed mold, and, finally (4) waiting for the material to solidify/cool

190
Q

Advantages of casting

A

-Suitable for mass production (selected processes)
-Ability to create complex components
-Ability to create small to large components
(such as nuclear reactor pressure heads of
60+ tons)
-Versatile process
-Ability to design both internal and external contours
-Variety of materials can be manufactures (incl. special alloys)

191
Q

Disadvantages of casting

A
  • Limited mechanical strength and lifecycle fatigue
  • Often requires a ‘next’ process due to poor dimensional accuracy and surface finish
  • Ergonomics of the process are challenging especially with respect to safety of operators
192
Q

Main Function of a parting line

A
  • Drag is the bottom half of the mold
  • Cope is the upper half of the mold
  • They are split along the parting lines - Molds have multiple internal cores
193
Q

Main Function of cavity

A
  • Cavity is the void in the mold
  • This will be filled to create the final shape
  • Often it includes cores to create internal shapes
194
Q

Main Function of gating and runner

A
  • Gating includes the pouring location and the downsprue
  • The main function is to regulate the flow into a laminar flow so that the mold is not eroded
  • The runner has the function to transfer the poured metal to the cavity
195
Q

Main Function of riser

A
  • Metals exhibit shrinkage during solidification
  • The riser main function is to act as a reservoir to supply molten metal and fill the shrinkage voids
  • A rule of thumb: Risers should never solidify, by design, before the cavity
  • A common practice is to use riser solidification times of 1.2 to 1.3 the cavity solidification time
196
Q

What is a process parameters?

A

Computing the amount of heat needed to pour the metal

197
Q

A conventional pouring temperature is

A

100 degrees Celsius above the melting temperature

198
Q

To facilitate the design of the mold,

A

following thoroughly the Design for Manufacturing and

Assembly (DFMA) guidelines is necessary

199
Q

Regulation of flow:

A

ensure a laminar flow that will not erode the walls of the mode

200
Q

After the metal is poured into the mold cavity,

A

it requires a certain amount of time to

solidify tST

201
Q

Having a bigger contact area for the same volume enables

A

faster solidification

202
Q

Chvorinov developed a rule that is dependent on:

A

-Mold Material
 Molten Material
 Volume/Area ratio of the cavity

203
Q

The area represents the

A

contact area from all sides

204
Q

Mold constant Cm and mold exponent n are

A

experimentally derived

205
Q

Volume V and Area A are computed based on

A

the geometry

206
Q

Design guidelines for Casting:

A

-Design uniform sections when possible
 Include draft angle
 Plan ejection pins & parting line (die casting)
 Avoid sharp corners / angles and use rounded corners
 Include buttresses / ribs to support material flow
 Design wall thickness uniformly (uniform cross-
section)
 Reflect shrinkage in casting design
 Add additional material for secondary (machining) processes

207
Q

Permanent mold casting is a process for

A

producing a large number of castings using a single reusable mold

208
Q

The mold is made from

A

a high-temperature metallic material, such as cast iron or hot work die steel

209
Q

Advantage of permanent mold casting:

A

produces metal with better dimensional tolerance, superior surface finish, and higher and more uniform mechanical properties

210
Q

Disadvantages of permanent mold casting:

A

high cost of the reusable mold

211
Q

Most common application of permanent mold casting is:

A

the aerospace industry for the casting of aluminium, titanium and steel ingots

212
Q

The fundamental difference in expendable mold processes is that

A

the mold is sacrificed for the creation of each part

213
Q

The great advantage of expendable mold processes is:

A

The creation of internal shapes

214
Q

There are plenty of expendable mold processes:

A

-Sand Casting where the mold is made of Sand
 Lost Wax Process where the pattern is made of
Wax
 Lost Foam Process where the pattern is made of polystyrene

215
Q

Lost wax process is primarily used in

A

the jewelry manufacturing industry

216
Q

The expendable mold process is as follows:

A 
-Making patterns of wax
 Assembling the patterns in a tree
 Placing the assembly in a plaster mold
 Heating the mold with pattern to loose the wax  Filling the void with molten metal
 Breaking the mold
217
Q

Sheetmetal deformation describes

A

the change of shape of a material in sheet form with no or little change in thickness

218
Q

Generally, the sheetmetal deformation is

A

two-dimensional (2D)

219
Q

In sheetmetal processing,

A

the modulus value of the material does not change

220
Q

The elastic recovery of the material has to be

A

considered as it is usually larger than in other deformation processes

221
Q

The sheetmetal blanking process describes

A

the process of remove the work piece from the blank by forcing a shaped punch through the sheet into a shaped die

222
Q

Sheetmetal blanking is

A

Fast process and considered rather economical for medium and large batches

223
Q

In sheetmetal blanking,

A

Different shapes are possible to be manufactured

224
Q

The sheetmetal punching process describes

A

the process of removing material from the blank which remains as the desired work piece via shearing

225
Q

The punch often passes through

A

a die to ensure a precision shearing of the material

226
Q

In sheetmetal punching,

A

a variety of differently shaped holes can be realized

227
Q

The sheetmetal punching process,

A

is very cost effective and fast on larger batches

228
Q

Sheetmetal bending processes are

A

plastic deformation processes around a linear axis while not (or only slightly) changing the surface area

229
Q

Bending processes entail

A

a certain elastic recovery from the combined tension and compression that needs to be accounted for

230
Q

Parameters influencing the elastic recovery include

A

material type and thickness

231
Q

Sheetmetal (deep) drawing describes

A

a process of forming a material through plastic deformation using a punch and die, typically creating cylindrical or rectangular containers

232
Q

There are two common types of sheetmetal drawing processes,

A

deep drawing (depth > diameter) and shallow drawing (depth < diameter)

IE 302 (1 decks)

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