Hog cycle Flashcards

1
Q

Chemical Etching

A

Definition:
A process that uses chemicals to remove material from the surface of a workpiece to create intricate designs or patterns.

Key Points:

Involves masking the areas that shouldn’t be etched.
Commonly used for thin metal parts.
Suitable for complex shapes and fine details.
No mechanical stress or heat is applied to the material.

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2
Q

Blanking

A

Definition:
A sheet metal forming process where a punch and die are used to cut out a piece of material from a larger sheet, producing a “blank.”

Key Points:

The blank is the desired part, while the remaining sheet is scrap.
Often used in mass production.
The process requires precise dies.
Common in manufacturing automotive parts, cans, and electronic components.

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3
Q

Chemical Machining

A

Similar to chemical etching, masking protects certain areas, but in chemical machining, the chemical solution removes material over a larger area or to a greater depth. It’s commonly used to lighten parts, create complex shapes, or produce variable thicknesses in metals.

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4
Q

Shaping

A

Definition:
A manufacturing process that involves removing material to form a desired shape, often using a cutting tool or press.

Key Points:

Suitable for creating parts with specific contours or forms.
Can be done manually or with machines.
Often used for metals, woods, and plastics.
Examples include forging, casting, and machining.

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5
Q

Spinning

A

Definition:
A metalworking process where a disc or tube of metal is rotated at high speed and formed into an axially symmetric part using a tool.

Key Points:

Ideal for making hollow, round shapes (e.g., cymbals, bowls).
Typically used with metals like aluminum, brass, or steel.
A cost-effective method for low-volume production.
Produces strong parts with excellent surface finish.

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6
Q

Pressing

A

Definition:
A process in which material (often sheet metal) is compressed or shaped by being forced into a die or mold under high pressure.

Key Points:

Can be used for mass production of components.
Common in forming, stamping, and punching operations.
Produces precise and repeatable shapes.
Frequently used in automotive, aerospace, and electronics industries.

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7
Q

Drawing

A

Definition:
A metal forming process in which a sheet, bar, or tube is pulled through a die to reduce its cross-section/diameter and increase length.

Key Points:

Used to produce thin-walled tubes, wires, and rods.
Can be done cold or hot, depending on material properties.
Produces high-strength, precision components.
Commonly used for making wires and long metal components.
Most failure due to misaligned tools/fitment

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8
Q

Hemming

A

Definition:
A metalworking process used to fold the edge of sheet metal onto itself to reinforce it or create a smooth edge.

Key Points:

Often used in automotive body parts to join metal sheets.
Creates a safe edge free of sharpness.
Can be done manually or by machine.
Provides additional strength and rigidity to parts.

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9
Q

High-speed steel

A

Description:
Cutting materials at high speed
Features:
Good for cutting harder materials.
Retains hardness even when heated.
Affordable and widely used in standard drills.

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10
Q

High rake angle

A

Key Features:
Reduces cutting resistance and improves efficiency - less force required.
Commonly used in tools for softer materials.
Promotes smoother cutting action.

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11
Q

Carbide cutter

A

Key Features:

Excellent for cutting tough or abrasive materials.
Carbide tips last longer than HSS tools.
More expensive but suitable for high-speed and high-performance applications.

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12
Q

Honing

A

Definition:
A precision machining process used to improve the surface finish or refine the shape of a bore.

Key Points:
Uses abrasive stones.
Achieves high dimensional accuracy and surface finish. Leaves cross hatched surface. Useful for retaining oil and lubrication.
Common in cylinder finishing and engine parts.

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13
Q

Broaching

A

Definition:
A machining process that uses a toothed tool (broach) to remove material, usually for making holes or cutting keyways.

Key Points:
Efficient for producing complex shapes.
High material removal rate.
Used for internal and external surfaces.

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14
Q

Reaming

A

Definition:
A finishing process that enlarges a hole to an exact diameter with a smooth finish using a reamer.

Key Points:
Ensures precise hole diameter.
Used after drilling.
Produces smooth, accurate holes.

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15
Q

Hobbing

A

Definition:
A gear manufacturing process using a hob (special cutting tool) to cut teeth into a gear blank.

Key Points:
Used for producing gears and splines.
Fast and efficient for mass production.
Provides accurate, repeatable results.

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16
Q

Lapping

A

Definition:
A machining process where two surfaces are rubbed together with an abrasive to achieve an extremely fine surface finish or precise flatness.

Key Points:
Ultra-fine finishing technique.
Commonly used for optical and precision components.
Achieves tight tolerances.

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17
Q

Slot drill

A

Definition:
A type of milling cutter with two or more cutting edges used to create slots or pockets in materials.

Key Points:
Can plunge directly into the material.

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18
Q

End Mill

A

Definition:
A cutting tool used in milling operations to cut in all directions.

Key Points:
Versatile tool for cutting, profiling, and slotting.

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19
Q

Bull Nose Mill

A

Definition:
A milling tool with a rounded edge, also called a corner radius end mill, used to create smooth contours or fillets in a workpiece

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20
Q

Fly Cutter

A

Definition:
A single-point cutting tool used in milling for producing a flat surface.

Key Points:
Efficient for machining large, flat surfaces.
Adjustable cutting diameter.

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21
Q

Material Extrusion (MEX)

A

Definition:
An additive manufacturing process where material is extruded layer-by-layer to build a part.

Key Points:
Common for thermoplastics like PLA and ABS.
Requires support structures for overhanging parts.
Inexpensive and widely accessible for hobbyists.

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22
Q

Photopolymerisation (VAT)

A

Definition:
An additive manufacturing process where liquid photopolymer is cured using light to create solid layers.

Key Points:
High accuracy and fine details.
Material only cures where exposed to light.
Ideal for intricate and precise parts.
Can use thermoset

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23
Q

Material Jetting MJT

A

Definition:
An additive process where droplets of material are deposited layer by layer and cured with UV light.

Key Points:
Allows full color and multiple materials.
High detail and surface finish.
Similar to an inkjet printer but for 3D parts.
Can use thermoset

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24
Q

Binder Jetting BJT

A

Definition:
A process similar to material jetting, but instead of material, a binder is deposited onto a powder bed.

Key Points:
Uses powder as both material and support.
Ideal for metals and ceramics.
Produces complex geometries with minimal material waste.

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25
Q

Powder Bed Fusion PBF

A

Definition:
An additive manufacturing process where powder is selectively fused using a heat source like a laser.

Key Points:
Used for both metals and polymers.
Support material is fused and can be difficult to remove.
Produces strong, high-quality parts.

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26
Q

Wave Soldering

A

Definition:
A bulk soldering process where a printed circuit board (PCB) is passed over a wave of molten solder to connect components.

Key Points:
Common in mass production of PCBs.
Fast and efficient for through-hole components.
Ensures consistent soldering of multiple joints.

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27
Q

Ultrasonic Soldering

A

efinition:
A soldering method that uses ultrasonic vibrations to break down oxides and bond materials without flux.

Key Points:
Ideal for difficult-to-solder materials (e.g., glass, ceramics).
No need for chemical flux.

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28
Q

Reflow Soldering

A

Definition:
A soldering process where solder paste is applied to a PCB, and components are attached and then heated in an oven to melt the solder.

Key Points:
Common in surface-mount technology (SMT).
Allows precise placement of components.

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29
Q

Low Rake Angle

A

Definition:
A low rake angle in a cutting tool means the angle between the tool’s face and the cutting surface is small, resulting in a more blunt edge.

Key Points:
Ideal for cutting tough, hard materials.
Requires more force to cut and may result in a rougher finish compared to tools with a high rake angle.

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30
Q

Extrusion

A

A manufacturing process where material is pushed through a die to create long parts with a consistent cross-section.

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31
Q

Rotational Moulding

A

Definition:
A moulding process where a hollow mold is filled with material and rotated in multiple axes to form hollow parts.

Key Points:
Produces large, hollow, lightweight parts.
Often used for plastic tanks, toys, and containers.
Low tooling cost, but slower cycle time compared to other molding methods.

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32
Q

Powder Metallurgy

A

Definition:
A process where metal powders are compacted into a desired shape and then sintered (heated) to create a solid part - has pores, metal infiltration can fill.

Key Points:
Suitable for materials that are difficult to machine.
Commonly used in producing gears, bearings, and filters - oil impregnation.

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33
Q

Shell Molding

A

Definition:
A casting process that uses a thin shell of sand and resin as the mold for producing metal parts.

Key Points:
Provides excellent surface finish and dimensional accuracy.
Used for complex shapes and thin-walled sections.

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34
Q

Die Casting

A

Definition:
A metal casting process where molten metal is forced into a mold cavity under high pressure.

Key Points:
Produces high-precision, smooth-surface parts.
Suitable for mass production of metal components.

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35
Q

Compression Moulding

A

Definition:
A moulding process where a preheated material is placed into a heated mold cavity and compressed into shape.

Key Points:
Commonly used for thermoset plastics and rubber.
Ideal for large, flat parts with simple geometries.

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36
Q

What gasses have RH thred on weld gas

A

Non Flammable (argon, oxygen, nitrogen)

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37
Q

What weld gas have LH thread

A

Flammable (Acetelyne, Hydrogen)

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38
Q

Thermoforming

A

Definition:
A process where a plastic sheet is heated until pliable and then formed into a shape using a mold and vacuum.

Key Points:
Commonly used for packaging, trays, and disposable cups.

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39
Q

Selective Laser Sintering

A

Definition:
Additive manufacturing process that uses laser to sinter small particles of powder into a solid structure. Can create items of plastics, metals, or ceramics.

Key Points:
No need for support but typically requires post-process machining to improve finish

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40
Q

Transfer Moulding

A

Definition:
A process where a pre-measured amount of material is heated in a chamber and then forced into a mold to form a part.

Key Points:
Used for thermosets and some elastomers.

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41
Q

Steriolithography (SLA)

A

Form of additive manufacturing (3D printing) that uses a photosensitive resin and an ultraviolet (UV) laser to create parts layer by layer. SLA works by curing liquid resin into solid objects.

fine detail, thermoset

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42
Q

Laser Cutting

A

A high-powered laser is used to cut precise and detailed cuts. It is used with a CNC machine and is good for small to medium runs.

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43
Q

Plasma Cutting

A

High-temperature electrodes are generated to cut materials. Can be hand-held or operated by CNC. Good for stainless steel

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44
Q

Oxyacetylene Cutting

A

Oxyfuel Gas cutting process good for cutting ferrous metals. Portable and cost-effective. Can cause heat damage.

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45
Q

DIE Swing EDM

A

Type of electron deposition cutting process that uses electron discharges to remove material and create precise cuts. Good for hard metals.

46
Q

Caste nut

A

Designed for safety-critical applications because they can be locked in place

47
Q

Explosion Welding

A

Solid-state welding process that uses controlled explosive energy to bond two metals together. Effective method for joining dissimilar metals over large surface area

48
Q

Deep Drawing

A

Metal forming process used to shape flat sheet metal into a hollow, cyclinder structure or other complex shapes by applying a mechanical punch. Seamless and airtight.

49
Q

Powder Metallurgy - Blending

A

Powders of the same chemistry but different particle sizes. The different particle sizes reduce porosity.

50
Q

Powder Metallurgy - Mixing

A

Powders of different chemistry combined. Can mix various metals to make alloys.

50
Q

Powder Metallurgy

A

The powder is compressed in a mould to create a green part. This is then heated to a temperature below the metling point bonding the particles and increasing the strength and density of the component.

51
Q

Laser Stereolithography (SLA)

A

Definition:
A 3D printing technology where a laser cures a liquid resin layer by layer to form solid parts.

Key Points:
Uses a laser to cure photopolymer resin.
Known for high accuracy and smooth surface finishes.

52
Q

Selective Laser Sintering (SLS)

A

Definition:
An additive manufacturing process where a laser selectively fuses powdered material, layer by layer.

Key Points:
Uses powdered materials such as nylon or metals.

53
Q

DLP Stereolithography (DLP)

A

Definition:
Digital Light Processing (DLP) is a variation of stereolithography where a digital light projector is used to cure an entire layer of resin at once.

Key Points:
Faster than traditional laser-based SLA.

54
Q

Roughing

A

First machining operation, removes bulk materials

55
Q

Dividing head

A

A dividing head is a crucial tool in machining, providing accurate control for operations requiring precise angular divisions

56
Q

Tig Welding

A

Tungsten Inert Gas welding is a welding process that uses a non-consumable tungsten electrode to produce the weld. Commonly used for precise and high-quality welding on thin materials like stainless steel, aluminium, and other non-ferrous metals.

57
Q

Powder Metallurgy Infiltration

A

Introducing a second typically liquid metal into the pores of the component. Done to increase density and improve mechanical properties

58
Q

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

A

to protect the weld pool from contamination from the atmosphere during the welding process, improving weld quality, stabilizing the arc, controlling heat transfer, and reducing spatter.

59
Q

Skill Saw

A

Circular power saw used for cutting wood.

60
Q

Cold Saw

A

Saw specifically designed for cutting metals with a circular blade. Typically operate at slower speeds with a blade made with carbide tipped or HSS that remains cold

61
Q

Rolling

A

Process used for making flat sheets with uniform thickness, not complex profiles.

62
Q

Ink Jet printer

A

Normal printer

63
Q

Silver Steel

A

High Carbon Steel with high strength, hardness and wear resistance. bright shiny finish, high cost. Not corrosion resistant.

64
Q

Poly Jet printer

A

Advanced 3D printing technology that uses inkjet-like print heads to deposit liquid photopolymer resins layer by layer, curing them with UV light for high-resolution, multi-material objects. It is widely used for rapid prototyping in industries like automotive and healthcare, allowing for intricate designs with smooth finishes and varying mechanical properties.

65
Q

Silver Steel

A

High Carbon Steel with high strength, hardness and wear resistance. Bright shiny finish and high cost.

66
Q

Heilcoil

A

A coil shaped insert used to repair or reinforce threaded holes in metal, plastic or other materials. Made to fit into damaged thereded hole to repair thread.

67
Q

Spot welding

A

Spot welding is a type of resistance welding used to join two or more metal sheets together at small, localized points, or “spots.” Works by pressing the sheets between two electrodes, then passing a high current through them to generate heat due to electrical resistance. This heat melts the metal at the contact point, fusing the sheets when they cool.

68
Q

Electron Beam welding

A

Electron Beam Welding (EBW) is a high-precision welding process that uses a focused beam of high-velocity electrons to join materials together by melding. Conducted in a vaccum.

69
Q

Ultrasonic welding

A

Ultrasonic welding is a solid-state welding process that uses high-frequency ultrasonic vibrations to join materials, typically thermoplastics or thin metals.

70
Q

Sand Blasting

A

surface preparation technique that uses a high-speed stream of abrasive particles propelled by compressed air or water to clean, smooth, or shape a surface.

71
Q

bead blasting

A

Bead blasting is a surface finishing process that uses small glass beads as abrasive material propelled by compressed air or water. It effectively cleans, polishes, and provides a uniform texture without removing significant material.

72
Q

Kerf

A

Measured as the width of a cut (the material removed). Teeth on blade have a set (the slight outward angle of the teeth) when worn down kerf becomes too narrow and dosent cut properly.

73
Q

Accuracy

A

How close a measure is the the true or accepted value

74
Q

Precision

A

Consistency or repeatability of measurements regardless if they are close to the true value

75
Q

MMC

A

Maximum material condition is a term used to describe the condition of a feature that contains the most material

76
Q

What is the primary purpose of limits and fits

A

Maximise interchangability

77
Q

Solid State welding

A

Solid-state welding is a group of welding processes that join materials without melting them. Instead, it relies on the application of pressure, heat, or both to create a solid bond at the atomic level.

78
Q

Surface Grinding

A

A grinding method where the workpiece is held stationary, and a rotating abrasive wheel removes material from the surface.
Applications: Commonly used for flat surfaces and for finishing large metal sheets.

79
Q

Cylindrical Grinding

A

Definition: Involves rotating the workpiece while grinding its outer surface or inside diameter with a rotating abrasive wheel.
Applications: Suitable for round or cylindrical parts, such as shafts, pins, and rods.

80
Q

Centerless Grinding

A

Definition: A method where the workpiece is held between two rotating wheels, with no center holding the part in place.
Applications: Used for mass-producing precise cylindrical components without clamping.

81
Q

Shaper

A

Definition: A shaper is a type of machine tool used to remove material from a workpiece to create flat surfaces, grooves, or keyways.
Operation: It works by moving a single-point cutting tool back and forth in a linear motion across the surface of the workpiece.

82
Q

Roll Forging

A

Definition: Roll forging is a metal forming process that reduces the cross-sectional area of a workpiece by passing it through two rotating rolls with shaped grooves.

Makes threads on bolts

83
Q

Swagging

A

Definition: Swaging is a metalworking process that uses compressive forces to shape or reduce the diameter of a workpiece by hammering it, often with a die

84
Q

Slotting Machine

A

Definition: A slotting machine is a vertical machine tool that uses a single-point cutting tool to create internal or external slots and grooves by moving the tool up and down.

85
Q

Anodizing

A

Anodizing is an electrochemical process primarily used for aluminum to create a corrosion-resistant oxide layer

86
Q

Maximum Material Condition (MMC)

A

Max amount of material on part within given tolerance

87
Q

HAZ

A

heat effected zone of weld

88
Q

Electrochemical Discharge (ECD)

A

ECD combines aspects of Electrochemical Machining (ECM) and EDM. It uses an electrolyte and electrical discharge to remove material. ECD provides flexibility for materials, including non-conductives, with less thermal damage.
For ceramics/glass

89
Q

Electrical Discharge Machining (EDM)

A

EDM is well-suited for precise machining of hard, conductive materials. Removes material with electrical discharge

90
Q

Electrochemical Machining (ECM)

A

ECM removes material through an electrochemical reaction. Ideal when a smooth surface finish and precision are essential, especially for complex geometries in very hard materials with no thermal effects.

91
Q

Accuracy vs Precision

A

Accuracy on target
Precision on same spot

92
Q

ISO fit system

A

later in alphabet means tighter fit. Capital leter for hole and lowercase for shaft.

93
Q

Circularity (Roundness)

A

How perfect circle is

94
Q

Cylindricity

A

measure of roundess and straighness - for shaft

95
Q

Tinning

A

Tinning is the process of coating a metal surface with a thin layer of tin to improve corrosion resistance and solderability, typically used for electrical components and food cans.

96
Q

Impregnation

A

Addition of oil or polymer to powder metallurgy part

97
Q

Fastest cooling rate for quenching

A

Brine

98
Q

Galvanizing

A

Galvanizing is a process that involves coating a metal (usually steel or iron) with zinc to prevent corrosion. It is widely used for marine and outdoor applications due to its durability and cost-effectiveness. (PROCESS - HOT DIPPING)

99
Q

Anodizing

A

Anodizing is an electrochemical process that thickens the natural oxide layer on metals, primarily aluminum, to improve corrosion resistance and surface hardness. It’s commonly used for aesthetic finishes and protection.

100
Q

physical vapor deposition (PVD)

A

Physical Vapor Deposition (PVD) is a coating process where a material is vaporized in a vacuum and deposited as a thin film on a target surface, commonly used to improve wear resistance, hardness, and aesthetic appeal of tools and components.

101
Q

Electroforming

A

Electroforming is a process where metal is deposited onto a mold via electrolysis to create precise, thin-walled components

102
Q

Age Hardening

A

Age hardening is a heat treatment process used to increase the strength and hardness of certain alloys, particularly aluminum, titanium, and some stainless steels. The process involves heating the alloy to a specific temperature to allow fine particles (precipitates) to form within the metal structure, followed by controlled cooling

103
Q

Upset Forging

A

Upset forging is a metalworking process that involves the deformation of a workpiece by compressing it along its axis, leading to an increase in its diameter and a decrease in its length. This method is often used to create components with uniform cross-sections, such as bolts, nuts, and various other fasteners, and is valued for producing parts with enhanced mechanical properties due to the work-hardening effect.

104
Q

Carburizing

A

surface hardening process for steels in which the metal is exposed to a carbon-rich environment at high temperatures. This allows carbon to diffuse into the surface layer, increasing hardness and wear resistance while keeping the core relatively soft and tough

105
Q

Nitriding

A

Nitriding is a surface hardening process that introduces nitrogen into the surface of steel or other ferrous alloys at high temperatures (typically 500–550°C). This creates a hard, wear-resistant surface by forming nitrides, which enhance hardness without requiring quenching - MINIMAL HEAT DAMAGE

106
Q

CNC pick and place

A

A CNC (Computer Numerical Control) pick and place machine is an automated device used in manufacturing and assembly processes to move components from one location to another with high precision and speed.

107
Q

Resistance Welding

A

Resistance welding is a process that joins metal pieces by applying heat from an electric current, generated through the resistance of the materials.spot welding, seam welding, projection welding, and resistance butt welding. Advantages include fast production rates, minimal distortion, and strong welds; limitations include suitability only for conductive metals, precise alignment, and high initial equipment costs.

108
Q

Investment Casting

A

ost-wax casting, is a versatile manufacturing process used for producing metal parts with high precision and excellent surface finishes. Good for low to medium production volumes.

109
Q

Punching vs Blanking

A

Punching is a metal working process that involves creating holes in a metal workpiece. Blanking is a metal fabrication process where the final product is removed out of the larger metal sheet, and the remaining material is discarded as scrap.

110
Q

Dovetail

A

The primary use of a dovetail cutter is to create dovetail joints to interlock parts

111
Q

Drop forging

A

metalworking process where a heated metal piece is shaped by being placed between two dies and then repeatedly struck with a hammer or ram to achieve the desired shape. It is used to create high-strength, durable components with precise dimensions