Design and Manufacture

Question 1

What is the purpose of limits and fits?

Answer 1

Max interchangeability

Question 2

Which process can most readily achieve a 0.2 Ra surface finish?

Answer 2

Dimond Machining

Question 3

What letter and number represents a tight fit?

Answer 3

p6

Question 4

ϕ8 +0.036 -0.000. What is the
MMC?

Answer 4

8.036

Question 5

Blow moulding is used for what products?

Answer 5

Hollow containers

Question 6

Identify what DFMA solution would be appropriate for eliminating threaded
fasteners.

Answer 6

Clips

Question 7

What is not a solid state welding process?

Answer 7

MIG

Question 8

What is the kurf? related to cutting.

Answer 8

Width of the cut

Question 9

What process is used for creating a ultra smooth surface?

Answer 9

Lapping

Question 10

How do you repair a stripped thread?

Answer 10

Use a helicoil

Question 11

What process is best used for an internal keyway?

Answer 11

Broaching

Question 12

Name a method of brazing

Answer 12

Vacuum

Question 13

What process should be used for long lengths that need to be cut for heat sinks in electronics?

Answer 13

Rolling

Question 14

What process for mass producing carburetor bodies?

Answer 14

Hard metal die casting

Question 15

TIG and MIG welders use inert gas around the weld pool. Why?

Answer 15

Protect from environment

Question 16

What welding technique is good for thin sheets

Answer 16

TIG

Question 17

What is an ideal solution to prevent loosening?

Answer 17

Nylock nuts

Question 18

A frame sits on metal skids, what are these made of?

Answer 18

Hot rolled channels

Question 19

What process is used to make metal sheets spherical?

Answer 19

Spinning

Question 20

What protection is used for exposer to environment?

Answer 20

Galvanization

Question 21

What is the most likely method of cutting a thin sheet with lots of cutouts?

Answer 21

CNC turret punch

Question 22

What is the most efficient and easy type of welding?

Answer 22

MIG

Question 23

What does CNC stand for?

Answer 23

Computer numerical control

Question 24

What does CAM stand for?

Answer 24

Computer aided machining

Question 25

What is the rule of 10 in DFMA?

Answer 25

Costs 10 x more to fix a defect at each stage of assembly

Question 26

What is concurrent engineering?

Answer 26

Design development in parallel with manufacturing process

Question 27

What is top down assembly?

Answer 27

Start building from a base and adding things on top

Question 28

What material is often used for round bar, plate, sheets, rectangular bar, hex bar? (Hint: Will rust)

Answer 28

Cold rolled steels

Question 29

What material is often referred to as Black due to its oxide scale?

Answer 29

Hot rolled steels (I beam and channel steel)

Question 30

What are the carbon % of low, medium, high and ultra high carbon steel?

Answer 30

0.05-0.25, 0.3-0.5 (balances with ductility, durable, large parts), 0.6-1 (very strong, springs shafts and tools) and 1.25-2 (tempered, special uses like punches and knives) respectively

Question 31

What caron content is silver steal?

Answer 31

high - ultra high carbon, 0.8-2%

Question 32

Drills, taps and dies are made from....

Answer 32

High speed steal (medium to high carbon content)

Question 33

hydraulics, rams are usually made from....

Answer 33

Hard chrome bar (steel with chrome painting, non-corrosive)

Question 34

What material is used for domestic plumbing?

Answer 34

Copper

Question 35

Pots, pans, hospital equipment are made from....

Answer 35

stainless steel (corrosion resistant)

Question 36

What tool is used to make sure cap screws are flush?

Answer 36

Counter boring tool

Question 37

What are 2 visual features of an oxygen gas bottle?

Answer 37

Black with a right-hand thread

Question 38

What is the likely process for making a mould cavity in steel?

Answer 38

Spark erosion

Question 39

What is the process for making cans?

Answer 39

Reverse extrusion

Question 40

What kind of soldering used to attach terminals onto an Arduino micro-controller circuit board?

Answer 40

Wave

Question 41

A 12mm diameter stainless steel tube must be welded to a brass threaded fitting. What process used?

Answer 41

Vacuum brazing

Question 42

Are left or right-hand threads more common.

Answer 42

Right

Question 43

what are the 3 types of welding?

Answer 43

Fusion (melting the 2 parts), diffusion (1-part melts then diffuses into the next) and solid state (heat or pressure used but no melting)

Question 44

Arc and resistance welding are....

Answer 44

Fusion welds

Question 45

Gas metal ARC welds are also known as...

Answer 45

MIG

Question 46

Gas tungsten ARC welding is also known as...

Answer 46

TIG