Manufacturing

Question 1

Product Creation Cycle

Answer 1

Design → Material Selection → Process Selection → Manufacture → Inspection → Feedback (repeat)

Question 2

Manufacturing Engineer

Answer 2

Select and coordinate specific processes and equipment

Question 3

Industrial Engineer

Answer 3

Responsible for the manufacturing system design

Question 4

Materials Engineer

Answer 4

Develop and select materials based on desired material properties and manufacturing processes

Question 5

Job Shop

Answer 5

Small quantities of produces. Large variety of products. Products move through the shop to various machines. General-purpose machines

Question 6

Flow Shop

Answer 6

Larger quantities of products. Production line. Special purpose machines.

Question 7

Linked-Cell Shop

Answer 7

Manufacturing and subassembly cells connected to final assembly. Lean production system. One piece flow system.

Question 8

Project Shop

Answer 8

Product being manufactured cannot be easily moved during production. Production processes are brought to the product. Examples: Bridges, ships, large airplanes, locomotives, large machinery.

Question 9

Continuous Process

Answer 9

Large Plants. Utilized in the manufacture of liquids, oils, gases, and powders.

Question 10

Lean Manufacturing

Answer 10

100% “good” units flow from process to process. Integrated quality control (IQC). All employees are inspectors.

Question 11

Casting and Foundry Processes

Answer 11

In one step raw materials are transformed into a desirable shape. Parts require finishing processes. Excess material is recyclable.

Question 12

Forming and Metalworking Processes

Answer 12

Utilizes material that has been cast. Modify the shape, size, and physical properties of the material. Hot and cold forming.

Question 13

Rolling

Answer 13

Material passes through a series of rollers, reducing its thickness with each pass

Question 14

Forging

Answer 14

Material is shaped by the controlled application of force (blacksmith)

Question 15

Extrusion

Answer 15

Material is compressed and forced through a die to produce a uniformed cross section. A rotating screw forces plastic through a heating chamber and then through a heated die. Produces long plastic parts with uniform cross sections.

Question 16

Wire, rod, and tube drawing

Answer 16

Material is pulled through a die to produce a uniformed cross section

Question 17

Cold forming and forging

Answer 17

Slugs of material are squeezed into dies

Question 18

Machining Processes

Answer 18

Controlled removal of material from a part to create a specific shape or surface finish.
Cutting element is used.
Movement must exist between the part and cutting element.

Question 19

Turning Processes

Answer 19

Operations that create cylindrical parts.

Work piece rotates as cutting tool is fed into the work.

Question 20

Milling Processes

Answer 20

Operations that create flat or curved surfaces by progressively removing material.
Cutting tools rotate as the work piece is secured and fed into the tool.

Question 21

Drilling Processes

Answer 21

Operations that create holes.

Cutting tools rotate and are fed into nonmoving secured work pieces.

Question 22

Shearing Processes

Answer 22

Operations that break unwanted material away from the part.
A material is placed between a stationary and movable surface. The movable surface (blade, die, or punch) applies a force to the part that shears away the unwanted material.

Question 23

Abrasive Machining Processes

Answer 23

Operations in which small particles of materials (abrasives) remove small chips of material upon contact.

Question 24

Thermal and Chemical Processes

Answer 24

Operations that cut and shape materials through chemical means.
No mechanical force is used.
Electrical discharge, electrochemical, chemical, laser, electron beam, flame-cutting, and plasma-arc cutting.

Question 25

Heat Treating Processes

Answer 25

Controlled heating and cooling of a material to alter its properties while maintaining its shape

Question 26

Mechanical Fastening

Answer 26

Use physical force to hold parts together. Ex: screws, bolts, nails

Question 27

Welding

Answer 27

Operations that use heat, pressure, or both to permanently join parts.

Question 28

Adhesive bonding

Answer 28

Bonding of adjoining surfaces by filling the gap between each surface with a bonding material.
Glue, cement, thermoplastic, thermosetting, and elastomers.

Question 29

Soldering and Brazing

Answer 29

Operation in which metal surfaces are bonded together by an alloy.
Heated molten alloy flows between the adjoining surfaces.
When the heat is removed, the molten metal solidifies and the metal surfaces are bonded.

Question 30

Rapid Prototyping

Answer 30

Additive process. Parts are produced directly from software applications. Common rapid prototyping systems include: stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM).

Question 31

Injection Molding

Answer 31

Heated plastic is forced by a movable plunger through a nozzle and then into a mold. The material fills the mold and then is cooled. Most widely used high-volume production process

Question 32

Casting

Answer 32

Plastic is melted and poured into a mold–No pressure of fillers are required.

Question 33

Rotational Molding

Answer 33

A closed mold is filled with a predetermined amount of plastic. The mold is heated, rotated, and then cooled to create a hollow plastic object with uniform wall thickness.

Question 34

Blow Molding

Answer 34

A solid bottom hollow tube is placed between two mold halves and heated. The heated tube is then expanded into the sides of the mold with compressed air.

Question 35

Thermoforming

Answer 35

Plastic sheets are heated over an open mold to a working temperature. Once workable, a vacuum is applied to the mold, forcing the plastic sheet to take the shape of the mold

Question 36

Reaction Molding

Answer 36

Liquid reactants are mixed and then pressurized into a mold.

No heat is needed. Curing time is typically less than 1 minute.

Question 37

Crystalline Ceramics

Answer 37

Material is shaped and then heated to produce a permanent solid.