Chapters 1,6,10,11

Question 1

The key point is that _____ adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly altered.

Answer 1

Manufacturing

Question 2

Manufacturing Industries can be classified into three industries.

Answer 2

Primary, Secondary, and Tertiary

Question 3

Most engineering materials can be classified into one of three basic categories

Answer 3

Metals, Ceramics, and Polymers

Question 4

_____ _____ which means it is a single step in the sequence of steps required to transform a starting material into a final part or product.

Answer 4

Unit operation

Question 5

Manufacturing operations can be divided into two basic types:

Answer 5

Processing and Assembly

Question 6

Most shape processing operations apply heat, mechanical force, or a combination of these to effect a change in geometry of the work material. There are four categories:

Answer 6

Solidification, Particulate, Deformation, and Material Removal

Question 7

Production systems can be divided into two categories:

Answer 7

Production facilities and Manufacturing support systems

Question 8

The _____ _____ of a unit operation is defined as the time that one work unit spends being processed or assembled.

Answer 8

Cycle time

Question 9

The cost of production equipment used in the factory is a fixed cost, meaning that it remains constant for any level of production output:

Answer 9

Fixed cost

Question 10

Overhead costs can be divided into two categories:

Answer 10

Factory and Corporate

Question 11

A _____ is a category of materials generally characterized by properties of ductility, malleability, luster, and high electrical and thermal conductivity.

Answer 11

Metal

Question 12

The following general properties possessed by virtually all of the common metals: high stiffness and strength, toughness, good electrical conductivity, and _____ _____ _____

Answer 12

good thermal conductivity

Question 13

An _____ is a metal composed of two or more elements, at least of which is metallic.

Answer 13

alloy

Question 14

The ferrous metals are based on _____

Answer 14

iron

Question 15

Together, _____ _____ constitute the vast majority of the metal tonnage used in the world.

Answer 15

steel and cast iron

Question 16

Steels produced by BOF or electric furnace are solidified for subsequent processing either as _____ _____ or by continuous casting.

Answer 16

cast ingots

Question 17

It often includes other allowing ingredients, such as manganese, chromium, nickel, and molybdenum; but the _____ is what turns it into steel

Answer 17

carbon

Question 18

_____ _____ are a class of (usually) highly alloyed steels designed for use as industrial cutting tools, dies, and molds.

Answer 18

Tool steel

Question 19

The _____ metals include metal elements and alloys not based on iron.

Answer 19

nonferrous

Question 20

The most important engineering metals in the nonferrous group are _____, copper, magnesium, nickel, titanium, and zinc, and their alloys.

Answer 20

aluminum

Question 21

As a production process, casting is usually carried out in a _____.

Answer 21

foundry

Question 22

Casting processes divide into two broad categories, according to type of mold used:

Answer 22

expendable mold casting and permanent mold casting

Question 23

Expendable molds are made of _____, _____ or similar materials, whose form is maintained by using binders of various kinds

Answer 23

sand, plaster

Question 24

In sand casting, the mold cavity is formed by means of a _____, which has the shape of the part to be cast and is made of wood, metal, plastic, or other material.

Answer 24

pattern

Question 25

The _____ _____ in a casting mold is the channel, or network of channels, by which molten metal flows into the cavity from outside the mold

Answer 25

gating system

Question 26

The _____ _____ is the temperature of the molten metal as it is introduced into the mold.

Answer 26

pouring temperature

Question 27

_____ is the measure of the capability of the metal to flow into and fill the mold before freezing.

Answer 27

Fluidity

Question 28

_____ involves the transformation of the molten metal back into the solid state.

Answer 28

Solidification

Question 29

_____ _____ _____ is the time taken between pouring and complete solidification.

Answer 29

Total solidification time

Question 30

Shrinkage occurs in three steps:

Answer 30

liquid contraction, solidification shrinkage, and thermal contraction

Question 31

_____ _____ are silica or silica mixed with other minerals

Answer 31

Foundry sands

Question 32

Five indicators used to determine the quality of the sand mold:

Answer 32

strength, permeability, thermal stability, collapsibility, and reusability

Question 33

Sand molds are often classified as _____, _____, or _____ molds.

Answer 33

green-sand, dry-sand, skin-dried

Question 34

_____ molding is a casting process in which the mold is a thin shell, typically 9mm (3/8 in) made of sand held together by a thermosetting resin binder.

Answer 34

Shell

Question 35

For certain geometries, sand molds can be produced and castings made at rates of _____ parts per hour and higher

Answer 35

400

Question 36

In making the mold, the grains of sand are held together by a mixture of _____ and _____ _____

Answer 36

water, bonding clay

Question 37

These molds are commonly made of steel and cast iron:

Answer 37

permanent

Question 38

With this permanent mold casting process, the pressure is maintained during solidification, after which the mold is opened and the part is removed.

Answer 38

Die casting

Question 39

In _____ _____ _____, molten metal is poured into a rotating mold to produce a tubular part.

Answer 39

true centrifugal casting

Question 40

There are five types of furnaces most commonly used in foundries are:

Answer 40

cupolas, direct fuel-fired furnace, crucible furnaces, electric-arc furnaces, and induction furnaces