Introduction To Manufacturing Technology Flashcards
(51 cards)
What is Carl Martin Dolezalek’s definition of production technology and how does it differ from manufacturing and process technology?
Carl Martin Dolezalek (1899–1984): Professor of manufacturing technology at the University of Stuttgart. Production Technology: Umbrella term encompassing manufacturing process, energy, and information technologies. Manufacturing Technology: Produces components with defined geometry dimensions and material properties. Includes joining components into final products. Process Technology: Produces formless materials (solid, liquid, gas) with defined properties (e.g., lubricants, fuel, powders)—energy & Information Technology: Also classified under production technology.
What is manufacturing technology, and how is it classified by DIN 8580?
Science of processes for forming/changing component properties.
DIN 8580 defines 6 main process groups:
Primary shaping, forming, separating, joining, Coating, changing material properties
Based on cohesive material behavior (creation, preservation, reduction, increase).
What aspects does manufacturing technology consider beyond physical processes?
Economic factors include production costs, quality (dimensional and surface accuracy, material properties)
strong link with materials science: materials’ properties affect final components.
Goals include balancing quality, quantity, performance, and cost.
What are the most common materials used in machine auto and aircraft manufacturing?
Steel (most common worldwide)
Light metals: Aluminum, Magnesium, Titanium
Plastics and composites: often fiber-reinforced
Must meet demands for strength,th toughn, corrosion, heat, and wear resistance
Considerations: processability, availability, cost
What is lightweight construction and why is it important?
Design goal: maximize weight reduction
Benefits:
Lower fuel & material usage
Reduced CO₂ emissions
Smaller drive systems & fuel storage
Improved load-to-weight ratio
Crucial in automobile and aerospace industries
What materials are typically used in lightweight construction?
Aluminum Magnesium Titanium alloys
Composites:
Carbon Fiber-Reinforced Polymers (CFRP)
Glass fiber-reinforced aluminum (GLARE)
Hybrid constructions (e.g. steel + plastic + aluminum)
Chosen for combining properties like low density high strength corrosion resistance
What materials are considered key in modern lightweight construction for automobiles and aircraft?
Fiber-reinforced composites (e.g. CFRP GFRP AFRP)
Aluminum alloys
Aluminum-lithium alloys
Offer high specific strength rigidity and significant weight savings.
Why are fiber-reinforced composites ideal for lightweight construction?
High bending tensile torsional rigidity
High strength-to-weight ratio
Enable new design and processing possibilities
Used in primary & secondary structures (e.g. Airbus A320 vertical stabilizer)
What are the main material requirements in auto and aircraft manufacturing?
High static & dynamic strength
Low density & thermal expansion
High corrosion oxidation and heat resistance
Low creep cost-effectiveness and availability
How do advanced materials like CFRP and aluminum-lithium impact weight and performance?
CFRP: Up to 25% weight reduction vs. aluminum
Aluminum-lithium: ~10% lighter 5% stronger than traditional aluminum
Fuel consumption can be reduced by ~10% in aircraft
Used in Airbus A350 Boeing 787
What are primary and secondary structures in aircraft manufacturing?
Primary structure: Load-bearing (fuselage wings etc.)
Secondary structure: Attachments (e.g. spoilers doors flaps)
CFRPs used in both for weight reduction and performance
What are some composite materials used in aviation and their functions?
GLARE: Glass fiber + aluminum for stiffening fuselage shells
CFRP: Used in wings tails and structural components
Aluminum-lithium: Self-supporting aircraft structures
What role do plastics and composite fibers play in composites?
Fibers (e.g. carbon glass aramid): absorb tensile forces
Matrix (plastic): positions fibers transfers shear forces
Common plastics: epoxy resins (thermosets)
What challenges are associated with using advanced lightweight materials?
Higher material & production costs
New manufacturing & design methods required
Maintenance complexity
Risk management needed for technology adoption
What is quantity performance in production and why is it important?
Economic efficiency depends on high flexibility and adequate automation. Flexibility = ability to produce varied components. Automation = how little manual activity is needed. High automation lowers unit cost but reduces flexibility. Balance between automation and flexibility is needed based on batch size.
What does flexibility and automation affect production scale?
Small batches need high flexibility
What is the REFA method and why is it used?
Determines allowed times for workers and equipment. Separates work order time (person) from occupancy time (equipment). Time analysis essential for planning
What other methods exist to determine allowed time?
Work Factor (WF) adds motion sequences from a catalog. Methods Time Measurement (MTM) uses motion elements and time measurement units (TMU). Both assume 100 percent performance of a skilled worker.
What defines quality in industrial production?
Quality = fulfillment of required characteristics (DIN EN ISO 9001). Must ensure defect-free products through optimized processes. Mass production needs automatic defect detection and correction. Quality is vital for reducing cost and boosting customer satisfaction.
Why is early defect detection important?
Based on the Rule of 10. Defect cost increases 10× at each later stage. Early detection = major cost savings. Tools like FMEA help avoid defects early in development. Recalls are very costly
What is a Quality Management System (QMS)?
Ensures consistent product and process quality. Central management task (ISO 9001). Required in industries like aerospace
What are the main quality standards in the automotive industry?
IATF 16949 is the global standard for mass production. VDA Volume 6 is the German guideline for OEMs and suppliers. Integrated with ISO 9001:2015. Covers cars
What role do production planning and control systems play in modern production management?
They support integration of suppliers and just-in-time production especially in industries like automotive and aerospace with complex data structures enabled by systems like SAP.
What major shift occurred in production management thinking due to Japanese practices?
The adoption of the Toyota Production System (TPS) and lean management emphasized customer value employee involvement and waste reduction leading to global success.
