Topic 4: Final Production

Question 1

Physical Properties of Materials

Answer 1

those that can be measured using non-destructive testing.

Question 2

Mass

Answer 2

amount of matter contained in a space. Mass is constant measured in kg.

Design Context:
From the perspective of ergonomics and performance, weight can be a very improtant factor. balancing of two factors often leads to innovative and technically complex design solutions.

Question 3

Weight

Answer 3

force and is measured in Newtons (N). Weight will change depending on the gravity.

Question 4

Volume

Answer 4

amount of 3-dimensional space a solid, gas, or liquid occupies.

Design Context:
can be explored from many different perspectives: as a container of space. Some designs context may specify specific volume considerations that are related to performance needs.

Question 5

Density

Answer 5

relationship between mass and unit of volume.

Design Context:
important property where mass and volume are important.

Question 6

Electrical resistivity

Answer 6

materials ability to conduct or resist electricity.

Design Context:
important material property when considering the design of an electrical component or safety equipment to be used around electricity. The Designer must know what the intended material will need to do

Question 7

Thermal conductivity

Answer 7

measures how fast heat moves through a material.
For objects that are to be heated, or used around heat, thermal conductivity is important for designers to consider.

Question 8

Thermal expansion

Answer 8

the degree to which a material increases its dimensions when heated. Different materials may expand at different rates. For designers, thermal expansion is important to consider when joining two different metals together.

Question 9

Hardness

Answer 9

the resistance of a material to scratching or penetration.

Question 10

Mechanical Properties of Materials

Answer 10

Compressive strength- ability of a material to resist pushing forces

Tensile Strength- ability of a material to resist pulling forces

Stiffness- ability to resist deflection (bending) by a force. the object can maintain its shape when a force is applied to it

Toughness- ability to deform (change shape) but resist cracking and not fracture under impact

Ductility- ability to be drawn or extruded into a wire-like form

Elasticity- ability for a material to bend and then return to its original shape

Plasticity- ability of a material to be formed into a new shape

Question 11

Design Context of Stiffness

Answer 11

For objects where the shape needs to be maintained under high forces, stiffness is an important performance consideration.

Question 12

Aesthetic Properties of Materials

Answer 12

those that are related to beauty and pleasure derived from a material.

Question 13

Form and shape

Answer 13

can influence how users interact and engage with it. different reactions to organic and geometric shapes. The material can also determine the form or shape of a product.

Question 14

Sound

Answer 14

sound a material makes when it is touched or manipulated can also be part of the user experience.

Question 15

Smell

Answer 15

very powerful connections with memory. The smell of a material is largely a concern for food, however product designers should consider it.

Question 16

Texture

Answer 16

how something feels or looks.

Question 17

Appearance

Answer 17

refers to the color or pattern of the material.

Question 18

Smart materials

Answer 18

reactive materials. change their properties when exposed to stimuli such as electrical charges, moisture, or temperature.

Question 19

Piezoelectricity

Answer 19

ability to release an electric charge when deformed. When an electric current is passed through a piezoelectric material its volume will increase or it will vibrate.

Question 20

Shape memory

Answer 20

have a pseudo-elastic property that allows them body to return to its original shape after deforming. Their shape changing property can be stimulated by either a change in temperature or the application of an electrical current. When the load is released, the body returns to its original shape.

Question 21

Photochromacity

Answer 21

ability to change color when exposed to light.

Question 22

Magneto-rheostatic

Answer 22

Fluids that undergo a change in their thickness when a magnetic force is applied. The change can change from a thick fluid to a solid almost almost instantaneously.

Question 23

Electro-rheostatic

Answer 23

Fluids that undergo a change in their viscosity when an electrical force is applied. The change can be almost instantaneous. The change can change from a thick fluid to a solid almost almost instantaneously.

Question 24

Thermoelectricity

Answer 24

Two different conductors, that when joined together generate electricity when heat is applied. The materials of the conductors determine the amount of electricity generated.

Question 25

METALS AND ALLOYS

Answer 25

Metals are typically found combined with other elements in localized areas. Rock that contains metals that can be economically extracted is called ore. Metals are crystalline structures made up of grains. The size of the grains has an impact on the physical and mechanical properties of a metal.

Question 26

Alloying

Answer 26

the mixture of one metal with another metal or non-metal. This combination creates a material that has unique properties than if the metal was just used alone. increases hardness and strength and reduces malleability and ductility.

Question 27

Work hardening

Answer 27

process of increasing the hardness of a metal through applying a process when the metal is cold. common method is the application of force to compress the grains through cold rolling.

Question 28

tempering

Answer 28

application of heat after work hardening. This reduces some of the hardness and stiffness and increase the toughness and ductility of the metal.

Question 29

Super Alloys

Answer 29

defined by a high resistance to creep and high oxidation and corrosion resistance.

Question 30

Creep

Answer 30

slow expansion or deformation of a material over time. can be exaggerated by high temperatures and prolonged forces

Question 31

Oxidation resistance

Answer 31

reaction of a metal with oxygen. most familiar of this type of reaction is rust. However, metals may also corrode in the presence of high temperatures and acids or alkalis.

Question 32

Recovery and disposal of metals and metallic alloys

Answer 32

Metals and metal alloys are easily recyclable. recycling metals uses less energy, produces less waste, and uses materials that have already been extracted. Metals can be indefinitely recycled, unlike plastics which can degrade in quality and properties through recycling.

Question 33

Metals and metal alloys

Answer 33

can be categorized into two categories, depending on whether or not they contain iron.

Question 34

Ferrous alloys

Answer 34

contain iron, which also makes them magnetic

Question 35

Non-ferrous alloys

Answer 35

do not contain iron.

Question 36

PLASTICS

Answer 36

derived from a non-renewable petroleum resource, such as crude oil, coal or natural gas. The social, environmental, and economic impacts of plastic production and disposal are of increasing concern for our global community. All plastics are a type of polymer. The different types of bonds determine the physical and mechanical properties of the material.

Question 37

Thermoplastics

Answer 37

linear chain molecules with weak secondary bonds between the chains. Due to the molecular structure of thermoplastics, they can be heated and reformed. They are ideal for processes that use heat to form the plastic over or around a mold. Thermoplastics have the following characteristics as group: low production cost easily injected into a mold low stiffness, making them ideal for uses requiring flexibility can be reshaped after heating

Question 38

Thermoset plastics

Answer 38

linear chain molecules with strong primary bonds between adjacent polymer chains. Once formed, they cannot be reheated or re-moulded. have a higher level of stiffness and strength than thermoplastics. tend to be more heat resistant and rigid than thermoplastics.

Question 39

TEXTILES

Answer 39

Fibers are the raw form. They are often used in the manufacture of other materials, called composites. They can be processed into long forms called yarns. Yarn is a long, continuous fiber Threads are thin yarns used in sewing, either by machine or hand. Fabric is created by cloth produced by weaving, knitting, or felting.

Question 40

Natural Fibers

Answer 40

Properties: High Absorbency Low Tensile Strength Low Elasticity Effect of high temperature: will burn but does not melt.

Question 41

Synthetic Fibers

Answer 41

Low Absorbency High Tensile Strength High Elasticity Effect of temperature : will burn and melt.

Question 42

One-Off Production

Answer 42

Only one or very few items are produced. This type of production is usually made to very specific needs and specifications by a client. higher cost. common for a one-off design to be designed and manufactured by the same person. Advantages: highly customizable to meet a specific consumer or client's needs Allows for development of high fidelity prototypes that can then be used to develop items for batch production or mass production. Disadvantages High production costs because cost of tools and machines are included in total cost Time consuming as production processes are often labor intensive

Question 43

Batch Production

Answer 43

refers to a set number of the item be manufactured. process are typically broken down into discrete steps, with each subsequent step dependent on the previous one. Advantages: lower unit costs Allows for some customization of parts, but not at the scale of one-off production Adjustable

Question 44

Mass Production

Answer 44

production at very large scale. Typically these are products that are needed in very large quantities that require little redesign. Advantages: Very low unit costs due to high rate of production Disadvantages: Little to no customization is possible because of the high initial investment and specialized equipment

Question 45

Continuous Flow

Answer 45

involves the large-scale production of goods. highly automated process that leverages automated and robotic production technologies to keep production going 24 hours a day/7 days a week. Advantages: Lowest per-unit costs High mechanized and automated processes Lower materials costs as raw materials are purchased in very high quantities.

Question 46

Mass Customization

Answer 46

aims to deliver a customized product using mass production methods. Such systems typically allow the consumer to select aspects of the design. The customized product is then produced using Computer Aided Manufacturing (CAM) systems. Advantages: Highly customized to users' needs and wants Integrates consumers into the value chain Highly responsive to changing consumer preferences and demands

Question 47

Design for Manufacturing

Answer 47

refers to the manufacturing process driving the some of the design design decisions. When designers are selecting processes for manufacturing they should consider: Material properties Cost Scale of production Cost associated for tooling, manufacturing machines and equipment Time required for processing Availability of material and cost of material Waste produced by the process

Question 48

Additive manufacturing techniques

Answer 48

Materials are added together to create a product or component

Question 49

Subtractive manufacturing techniques

Answer 49

Material is cut away to create a product or component

Question 50

Shaping Techniques

Answer 50

Methods that modify the shape of the material using heat, pressure, and other mechanical manipulation.

Question 51

Joining techniques

Answer 51

Methods that join two similar or dissimilar materials together

Question 52

Craft Production

Answer 52

small-scale production process centred on manual skills. Advantages: Highly skilled and specialized product Highly customizable to specific needs of client Disadvantages: time consuming and labor intensive high labor costs Environmental Impact: May not be designed for disassembly Typically use higher quality materials, and in lower quantities. Workforce Impact: Training and apprenticing may take much time.

Question 53

Mechanized Production

Answer 53

volume production process involving machines controlled by humans. The machines assist the workers in increasing their productivity, quality, and safety. Advantages: repetitive tasks carried out by machines increased productivity increased quality of product human error reduced Disadvantages: increased cost for training and machinery reduction in consumer choice Environmental Impact: increased pollution produced increased energy need Workforce Impact: repetitive work healthy and safety in factories can be an issue.

Question 54

Automated Production

Answer 54

a volume production process involving machines controlled by computers. Advantages: Higher quality Closer fidelity between CAD drawings and final product Higher productivity as machines can work 24/7 Disadvantages: High cost of equipment Environmental Impact: Less waste is produced as the production system can be optimized Workforce Impact: Lower labor costs as fewer workers are needed Improved health and safety as few workers are operating machines

Question 55

Assembly Line Production

Answer 55

volume production process where products and components are moved continuously along a conveyor. Advantages: Economy of scale High production volume of similar products is possible Disadvantages: Limited opportunity for customization Can be expensive to retool for new products Environmental Impact: Increased pollution due to higher levels of production Workforce Impact: Repetitive tasks can increase injury and decrease job satisfaction

Question 56

Mass Production

Answer 56

production of large amounts of standardized products on production lines, permitting very high rates of production per worker

Question 57

Mass Customization Production

Answer 57

manufactures products to individual customer orders.

Question 58

Robot Generations

Answer 58

Robots are classified into three generations. 1st Generation Robots- simple robots that do one task. They are programed to do one thing, and cannot respond to changes in their environment. do not have any sensors. (Singles tasked) 2nd Generation Robots- make use of sensors to respond to their environment. (Multi Task Robots) 3rd Generation Robots- make use of AI to process the world around them and to accomplish tasks. They are able to learn and operate without human supervision.

Question 59

Work Envelope and Load Capacity

Answer 59

The work envelope of a robot is the 3D space a robot can operate within, considering clearance and reach. The work envelop is defined by two factors: length of arm(s) determines the reach Range and number of axes. Each axis adds to a range of motion for the arm. Compare: 3D printers have 3 axes (X, Y, and Z).

Question 60

load capacity

Answer 60

refers to the maximum load (weight) that a robot can manipulate.

Question 61

Robot Teams

Answer 61

Production lines make use of teams of robots to perform tasks. Type: Multiple 1st Generation Robots working together.

Question 62

Machine to Machine (M2M)

Answer 62

refers to networking of robots together to share information and instructions.