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Main Manufacturing Groups according to DIN 8580 Flashcards

(90 cards)

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1
Q

What is primary shaping according to DIN 8580?

A

Primary shaping is the process of producing a solid body from a formless material like gases liquids powders or fibers by creating cohesion

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2
Q

What are the main methods of primary shaping

A

Casting from liquid or pasty to solid
Powder metallurgy from solid or powder to sintered body
Additive manufacturing by layer-by-layer construction from polymers or metals

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3
Q

Why is casting technology important in manufacturing

A

It allows the economical production of complex or large components especially when other methods are inefficient or infeasible

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4
Q

What are the most common materials used in casting

A

Iron aluminum copper zinc tin ceramics and plastics

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5
Q

What are some disadvantages or challenges of casting processes

A

Shrinkage
Blowholes
Crystallization issues
Limited strength properties in some cases

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6
Q

What is the difference between lost and reusable molds or patterns

A

Lost molds or patterns are single-use made of sand or wax and destroyed during casting
Reusable molds or patterns are made of durable materials like metal or plastic and can be reused

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7
Q

What must be considered when designing casting molds

A

Shrinkage compensation
Thermal and mechanical stresses
Uniform wall thickness
Avoiding sharp corners or material accumulation

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8
Q

How does the casting cooling rate affect material properties

A

It impacts the microstructure which in turn affects mechanical properties
Controlled directional solidification is necessary for optimal results

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9
Q

What is sand casting and how does it work

A

A casting method where a pattern is molded in sand
Sand cores create cavities, and after pouring molten metal, the sand mold is broken to remove the cast part

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10
Q

What is investment casting and what are its advantages

A

Uses wax patterns and ceramic molds in the lost wax method Allows high precision and surface quality
Suitable for small complex parts
Minimal post-processing needed

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11
Q

What common defects or problems occur in casting

A

Poor mold filling
Solidification and solid shrinkage
Hot cracking
Gas absorption
Mold penetration especially in sand molds
Element segregation like phosphorus or sulfur separation

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12
Q

What is the benefit of replacing differential components with integral cast parts

A

Parts reduced from 296 to 64
Assembly time cut from 189 to 20 hours
Production cost reduced by nearly 50 percent

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13
Q

Despite newer technologies why is casting still widely used

A

It is still essential for producing large complex parts in industries like automotive aerospace and mechanical engineering where other methods are less effective or too costly

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14
Q

What is sintering technology in powder metallurgy?

A

Produces metallic bodies from metal powders (0.1–1.0 mm)
No melting of metal; particles remain solid
Allows mixing of incompatible metals (pseudo-alloys)
Powders pressed into mold → green compact → sintered at high temp
Density adjustable (50–99% volume fill)
Used in motors gearboxes drive systems

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15
Q

What are pseudo-alloys in sintering?

A

Solid-state mixture of metal powders
Not true alloys
Combine properties of different metals

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16
Q

What are common primary shaping methods for plastics?

A

Injection molding
Extrusion
Deep drawing
Calendering
Blow molding

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17
Q

What is injection molding used for in plastics processing?

A

Most common process
Heats and injects plastic granules into a mold
Used for complex shapes high-volume production
Expensive molds but reusable for millions of parts

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18
Q

How does extrusion differ from injection molding?

A

Produces continuous profiles (e.g. tubes sheets)
Also uses heated plastic granules
Common in film and profile manufacturing

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19
Q

What is blow molding used for?

A

Produces hollow plastic parts (e.g. bottles)
Inflates thermoplastic preform inside a mold

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20
Q

What are fiber-reinforced plastic composites used for?

A

Used in cars and aircraft for lightweight strong parts
Common materials: CFRP (carbon fiber), GFRP (glass fiber)
Used in bodies fuselage panels wing edges

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21
Q

What is GLARE and where is it used?

A

Glass Laminated Aluminum Reinforced Epoxy Layered composite: aluminum + adhesive + glass fiber
Used in Airbus A380 (skin fuselage tail units)

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22
Q

What are the benefits of fiber composites over metals?

A

Up to 30% lighter Up to 40% cost reduction
Superior strength stiffness vibration resistance
Used in high-performance structures

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23
Q

What is the prepreg method in CFRP manufacturing?

A

Uses pre-impregnated fiber layers
Molded and cured in an autoclave
High strength but labor-intensive and costly

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24
Q

How are textile and prepreg technologies different?

A

Prepreg: wet process coated mats
Textile: dry process resin injected or infused afterward

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25
What is forming technology in manufacturing?
Based on permanent plastic deformability of materials Shapes metals or thermoplastics into defined geometries Requires stress above yield strength (flow stress) Materials harden during forming increasing required force Common in automotive aerospace and other industries
26
What are the main types of forming processes?
Cold forming: Room temp higher stress material hardening Hot forming: Above recrystallization temp easier forming Sheet metal forming and solid forming are process categories
27
What are common forming methods and their uses?
Rolling (cold): Stringers frames panels Deep drawing (cold): Body parts flaps hollow components Stretch forming (cold): Aircraft paneling (large sheets) Extrusion (cold): High-stress components engines Forging (hot): Undercarriage drive components safety parts
28
What is drop forging and why is it used?
Hot forming with closed dies Preserves material fiber structure increases load capacity Used for safety-critical parts (crankshafts undercarriage parts) Requires high production volumes due to die tool costs
29
How does drop forging work?
Workpiece placed in closed dies Dies are engraved or milled then struck by hammers Workpiece heated and formed into die shape Produces strong durable components
30
What is stretch forming and where is it used?
Cold forming of large-format sheets Sheets clamped and drawn over a die Used in aircraft skin/panel shaping Suitable for low to medium quantities Dies are often wood or aluminum low cost
31
What is deep drawing?
Forms flat sheets into hollow shapes (e.g. cups) Uses punch die and blank holder Blank holder force must be controlled: Too low = wrinkles Too high = cracks Common in automobile body construction
32
Why is controlling the blank holder force important in deep drawing?
Too little force → Wrinkles in material Too much force → Material cracks Proper control is essential for defect-free components
33
What limits plastic deformability in materials during forming?
Deformability is not infinite Work hardening increases with deformation Cracks may form and are irreversible Must know the deformation limits of each material
34
What are the main separating manufacturing processes
Cutting (Punching) Machining (with geometrically defined or undefined cutters) Removal (spark erosion electrochemical chemical)
35
What is punching used for and where
Used in sheet metal processing (automotive aviation) Common for cutting contours and forming holes Being replaced by laser cutting in many areas
36
What processes use geometrically defined cutters
Turning milling drilling sawing broaching Has a defined cutting edge Tool wear is a concern so tools need replacement or sharpening
37
What are examples of undefined cutter machining
Grinding honing lapping Uses abrasive grains with varied geometries Grinding wheels are conditioned rather than replaced
38
What causes tool wear and its effects
Caused by heat pressure abrasion and diffusion Leads to dimensional errors and reduced surface quality Tool life defines how long a tool can remain in service
39
How is machining used in aircraft manufacturing
Used to make large integral components Components are up to 8m long with high precision CNC milling used to remove up to 95 percent of the material
40
What are the benefits of HSC in machining
Higher removal rates and faster feed speeds Lower cutting forces Ideal for thin-walled aluminum components
41
Why is laser inspection used in aircraft machining
Ensures high process reliability Reduces costly errors in expensive components Accurately measures component geometry
42
How does spark erosion work
Material removed using electric sparks in dielectric fluid Good for hard materials and complex shapes Common in toolmaking
43
How does electrochemical removal differ from EDM
Uses electrolyte and DC voltage Material dissolves via electrochemical reaction Reproduces tool shape on hard-to-machine parts
44
Where is chemical removal used and how
Uses acids to etch away material Unwanted areas are masked Used in aircraft to thin fuselage skins and reduce weight
45
What are the main types of assembly processes in automotive and aircraft manufacturing
Assembly welding soldering and adhesive bonding. Automobiles use automated assembly while aircraft rely more on manual processes due to component size and complexity.
46
How much value creation does assembly contribute in automobile and aircraft manufacturing
Around 50 percent in automobiles and 70 percent in aircraft manufacturing.
47
What are key automation trends in aircraft assembly
Use of large CNC riveting machines and flexible robots for riveting drilling milling and adhesive bonding.
48
Why is riveting widely used in aircraft manufacturing
It is reliable supports high loads and has strong fatigue resistance. It is used in aluminum and CFRP primary structures.
49
What are disadvantages of riveting
Requires many holes in load-bearing parts reducing strength. Less sophisticated than welding.
50
What is welding and how is it classified
A material-to-material joining process using heat or pressure. Divided into fusion welding and pressure welding.
51
What are problems caused by fusion welding in aircraft materials
Residual stress shrinkage gas absorption crystal formation and loss of strength especially in aluminum alloys.
52
Why is pressure welding preferred over fusion welding in some cases
It avoids molten material reducing shrinkage and structural degradation. Requires high joining force limiting use on thin parts.
53
What is Friction Stir Welding FSW
A pressure welding method using a rotating tool to create heat. Suitable for joining aluminum sheets in aircraft structures.
54
How is quality assurance handled in riveting vs welding
Riveting allows easy inspection and automation. Welding requires complex non-destructive testing to ensure integrity.
55
What are the key steps of the Friction Stir Welding (FSW) process?
1. A rotating tool is plunged into the joint generating heat through friction 2. Heat plasticizes the material allowing mixing at the seam 3. Tool moves along the joint line under pressure transporting the material to form a solid-state weld
56
What are the advantages of Friction Stir Welding (FSW)?
No fillers or shielding gas needed high seam strength low distortion can join dissimilar materials and avoids defects like hot cracks and pores found in fusion welding
57
Where is Friction Stir Welding (FSW) commonly used?
Primarily in aircraft manufacturing especially for aluminum alloy skin panels and large components
58
What is laser beam welding and how does it work?
A fusion welding process using high-intensity focused laser light to melt and join materials with a narrow and deep weld zone
59
What are the benefits of laser beam welding?
High power density low distortion small heat-affected zone high precision suitable for high-strength steel and aluminum in automotive and aircraft manufacturing
60
How is laser beam welding used in aircraft manufacturing?
Replaces riveting in skin-stringer joints enables weight and cost savings improves corrosion resistance and allows use of 6xxx aluminum alloys
61
What is Tungsten Inert Gas (TIG) welding used for in aerospace?
High-quality welding of complex aircraft piping systems made from titanium aluminum stainless steel and composite materials with minimal distortion
62
What are the strengths of TIG welding?
High seam quality low heat input small HAZ ideal for precision applications in demanding environments
63
How does Electron Beam Welding (EBW) work?
Uses high-velocity electrons in a vacuum to melt the material with extremely high power density and efficiency
64
What are the advantages of Electron Beam Welding (EBW)?
No shielding gas required very high-quality welds suitable for complex or thick materials used in aerospace engine and transmission production
65
What is soldering and how does it differ from welding?
A joining process where molten filler (solder) bonds parts without melting them; relies on diffusion and forms a low-strength cohesive bond
66
What is adhesive bonding and when is it used?
A joining method using adhesives to bond surfaces via adhesion and cohesion; used when low temperatures and material flexibility are needed
67
What are the limitations of adhesive bonding compared to welding?
Lower strength (40–50 N/mm²) and requires large bonding surfaces to handle stress ideally under shear not tension or peeling
68
What are key applications of adhesive bonding in aircraft manufacturing
Used for joining skin panels stringers frames and sandwich components like ailerons and rudders offers structural weight savings 15 percent and high fatigue strength with rigidity
69
What are the main advantages of adhesive bonding in aerospace
Homogeneous stress distribution large surface bonding vibration damping weight savings no heat distortion no optical changes joining dissimilar materials and sealing capability
70
What are major limitations of adhesive bonding
Difficult feasibility no easy nondestructive testing aging over time temperature sensitivity embrittles in cold softens in heat and demanding surface preparation
71
What is hybrid joining and its benefits for CFRP structures
Combines riveting and adhesive bonding to reduce rivet holes increase load capacity improve stress distribution and enable further weight reduction in wings fuselage and tails
72
How does automation benefit aircraft assembly processes
Transfers repetitive tasks from humans to machines increases efficiency ensures precision reduces physical strain and supports integration of novel materials and joining processes
73
What defines the degree of automation and flexibility in manufacturing
Degree of automation equals extent of human involvement 0 to 100 percent Flexibility equals ability to handle different parts or operations 0 to 100 percent High flexibility suits small batches high automation suits largescale production
74
What are essential conditions for automated aircraft production
Compact layout robotic loading or unloading flexible highprecision fixtures accurate machine positioning CNC control high speed and repeatability
75
What is the purpose of coating technology according to DIN 8580 (2003)
To apply firmly adhering layers of formless materials to improve a workpiece’s properties and appearance such as corrosion protection and visual aesthetics
76
What are the main types of coating processes according to DIN 8580
Chemical mechanical thermal and thermomechanical processes based on the coating material's state and method of application
77
Why is painting technology significant in automotive and aircraft manufacturing
It enhances corrosion resistance and achieves desired optical effects such as color and shine
78
What are the steps of the painting process in automobile manufacturing
Phosphate pre-treatment Anti-corrosion primer Filler (alkyd resin) Color coat (water-based) Clear coat (acrylic resin)
79
When is painting performed in aircraft manufacturing and why is it complex
It is the final step before delivery and is complex due to large surface areas strict quality demands and environmental control requirements
80
What are the surface areas painted on an Airbus A380
Approximately 3100 m² for the fuselage and 850 m² per wing
81
What painting method is used in aircraft manufacturing
Electrostatic spray guns using the airless method for an even high-quality finish
82
What are key challenges during aircraft painting
Short pot life and drying time under 2 hours per spray pass Only one section can be painted at a time Requires controlled temperature above 30°C Windowless hangars with glare-free lighting
83
How much paint and what thickness is typically used on a large aircraft like the A380
Nearly 1 ton of paint per aircraft with a total average thickness of 140 µm
84
What is the purpose of changing material properties in manufacturing
To enhance material performance for machine automobile and aircraft components especially under high dynamic stress
85
What are the main processes in the “changing of material properties” category (DIN 8580 2003)
Heat treatment thermomechanical treatment hardening by forming and less commonly sintering firing magnetization irradiation and photochemical processes
86
What is shot peening and where is it used
A surface hardening process where components are bombarded with small steel or glass balls to create residual compressive stress used in automobile and aircraft manufacturing
87
What are the effects of shot peening on material properties
Increases fatigue strength up to 100 percent Improves corrosion resistance up to 100 percent Enhances wear resistance up to 50 percent
88
What is the mechanism of shot peening
High-speed impact of small balls causes micro-deformations that generate a shallow residual compressive stress field improving resistance to cracks and corrosion
89
What materials are used in shot peening for different components
Steel balls for steel components and glass balls for aluminum or titanium components
90
What other hardening by forming processes exist besides shot peening
Hardening by rolling drawing or forging for components under high dynamic loads

Production Engineering (6 decks)

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