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Manufacturing Technology > Manufacturing Technology - Part B > Flashcards

Manufacturing Technology - Part B Flashcards

1
Q

What are the 5 types of permanent mold casting?

A
  • Slush Casting
  • Pressure casting
  • Die casting
  • Centrifugal casting
  • Continuous casting
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2
Q

What is SLUSH casting and where is it used? how is thickness determined?

A
  1. Molten metal is poured into the metal mould.
  2. When desired thickness of solidified skin is
    obtained
  3. mould is inverted and remaining liquid metal
    is poured out.
  4. Mould halves are then opened.
  5. Casting is removed.

-hollow castings with thin walls
-decorative/ornamental objects
-Very common in theatre/film industry for
making latex/silicone props and costumes

-Thickness is a result of the cooling time, solidifies from the outside in

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3
Q

What is PRESSURE casting and where is it used?

What are the advantages & disadvantages?

A

-Molten metal is forced upward by
Gas pressure into a graphite or metal mould
-A vacuum removes gases and gives
the casting a lower porosity
-Pressure is maintained until the metal has
completely solidified in the mould

-Used for high quality casting of components, such as car wheels

Advantages)
-avoids rapid oxidation, solidifies from top down

Disadvantages)
-long cycle time

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4
Q

What is DIE casting and what are the two types?

how is it different from pressure casting?

A

-Molten metal is injected into a closed metal
die under high pressure
-Pressure is maintained during solidification
-Die is separated and casting ejected

  • Hot chamber process
  • Cold chamber process

-No vacuum present in die casting

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5
Q

What is the HOT chamber die casting? where is it used, what materials? what are the advantages?

A
  • Significant difference is that metal is melted in a reservoir joined to the die, no transfer
  • Dies are cooled by circulating water/oil through passageways in the die block

-zinc tin & lead based alloys (low melting point metals, Cornish metals..)

  • No transfer process of the molten metal
  • Fast cycling times
    -Good strength
    -Excellent dimensional precision and surface
    finish
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6
Q

What is COLD chamber die casting? where is it used, what materials? what are the disadvantages?

A

-Metal is melted in a separate furnace and is
transported to the die casting machine
-Molten metal is fed into an unheated chamber
-A mechanical plunger forces the molten metal
into the die cavity where the metal solidifies

-Employed for die casting of materials that are
not suitable for hot chamber design (high melting point metals) e.g aluminium, magnesium and copper (shiny’s)

  • Expensive dies
  • Requires high production rate to justify the usage
  • The need to transport molten metals
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7
Q

What is CENTRIFUGAL casting? what are the three types?

A
  • Pour molten metal into rotating mould
  • Utilises inertial force caused by rotation to distribute molten metal into mould cavities
  • Metal is held against the mould wall by centrifugal force until it is solidified

1) True Centrifugal Casting
2) Semi-Centrifugal Casting
3) Centrifuging

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8
Q

what is TRUE Centrifugal Casting and where is it used?

A
  • mold made of steel with refractory lining for longevity
  • mold rotates as a barrel would
  • used to create pipes with external geometries
  • molten metal is distributed uniformly

-Pipes

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9
Q

what is Semi-centrifugal Casting?

A
  • Used to cast parts with rotational symmetry

- the mold cavity rotates perpendicular to gravity

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10
Q

what is Centrifugal Casting and where is it used?

A
  • similar to Semi-centrifugal casting only the molten metal is spun by a device that sprays it onto the mold
  • Bushes, bearing housings etc, high precision cylindrical parts
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11
Q

What are the possible steps in the production of steel?

A

1) Recylced steel - An electric arc furnace is used (EAF) this melts steel and the molten steel is then rolled and continuosly cast
2) Blast furnace method - Iron is produced in a blast furnace, the molten iron then goes to a basic oxygen steel maker (BOS) where oxygen is added and the carbon content is altered; producing steel. The molten steel is then continuously cast

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12
Q

What are the possible faults in continuously casting steel? how is steel quality increased?

A
  • prone to bubble entrapment which make the steel porous
  • fluxes are added that can:
    prevent oxidation, stop solidification of the surface
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13
Q

What are the benefits of using cutting fluids during machining? what is coolant made of?

A
  • Allow for cutting speed to be increased
  • Chips are removed
  • extend tool life

-oil and water to lubricate & avoid rust

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14
Q

explain the different types of turning can be achieved using a lathe?

  • Straight turning
  • Form turning
  • Facing / Parting
  • Boring
  • Thread cutting
  • Knurling
  • Drilling
A
  • Straight turning - cut in just the z direction x constant
  • Taper turning - cut in the z & x direction
  • Form turning - A specific tool is used that cuts a profile of the final shape
  • Facing / Parting - The end of a work-piece is flattened off
  • Boring - internal features are cute using an ‘L’ shaped tool
  • Thread cutting - Produces external or internal threads in a work-piece
  • Knurling - regularly shaped roughness is achieved on the surface of a component
  • Drilling - the drill bit is kept stationary whilst the work piece is rotated
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15
Q

What are the advantages of using non-traditional methods of machining?

A

-No chips produced
-Complex geometries can be achieved
-Delicate components can be machined (brittle)
achieves a high surface finish

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16
Q

What are the four branches of Non-traditional machining?

A
  • Chemical machining
  • Electro-chemical machining
  • Mechanical methods (water jet & abrasive flow)
  • Thermal machining
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17
Q

what is CHEMICAL machining and what are its advantages & disadvantages?

A

-Material is removed from a work-piece by selectively
exposing it to a chemical reagent or etch-ant
-the material is masked using masking agents or photo-resist backing
-etch rate is proportional to chemical concentration

advantages)
-Induces no stress in the material
-Thin section (e.g. honey comb) can be machined as no
mechanical forces are involved

disadvantages)
- Very slow process
- Dangerous chemicals

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18
Q

what is ELECTRO-CHEMICAL machining and what are its advantages & disadvantages?

A
  • It is a de-plating process where the tool is the cathode and the work-piece is the anode
  • electrolyte is pumped through a hole in the tool
  • metal ions are removed from the work-piece and washed away
  • work-piece takes the form of a negative of the tool

advantages)

  • Well suited for machining complex shapes
  • materials that cannot withstand high machining forces
  • No tool wear developed
  • No thermal damage

Disadvantages)

  • Costly
  • Not environmentally friendly
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19
Q

what is WATER JET CUTTING (WJC) and what are its advantages & disadvantages?

A

-Water is ejected from a nozzle orifice at high pressure
(up to 400 MPa)
-This produces a jet velocity greater than the speed of
sound
-Small nozzle opening produces a
very narrow width of cut

advantages)
-The ability to cut materials without burning or
crushing
- Inexpensive

Disadvantages)
-Loud process
-Not suitable for brittle materials
-It is not a powerful process therefore limited to
cutting thin sheets
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20
Q

what is ABRASIVE WATER JET CUTTING (AWC), where is it used? what are its advantages & disadvantages?

A
  • Just like water jet cutting only an abrasive is added, this allows for a stronger cutting method
  • Used in aeronautical industry for cutting composite materials as they do not de-laminate

advantages)
-Can cut thicker stronger materials

Disadvantages)
-Costly & the abrasive can damage the tool

21
Q

what is ABRASIVE FLOW MACHINING, where is it used?

A

-The workpiece is mounted in the machine and pistons
drive the abrasive fluid back and forth through it.

-used in the finishing of internal geometries of parts with complicated shapes

22
Q

What are the 4 types of thermal machining?

A

Electrical Discharge Machining (EDM)

Particle Beam Machining (PBM)

Laser Beam Machining (LBM)

Plasma Arc Cutting (PAC)

23
Q

What is Electrical Discharge Machining (EDM)? wwhat are the two types of EDM & how do they work? what are the applications?

A
  • The electrode & work-piece are suspended in a dielectric fluid.
  • The dielectric fluid allows for a spark to cross between the electrode and the workpiece
  • Spark erosion

1) Ram EDM
- The electrode is a die in the shape of the negative of the cavity made from graphite, copper, copper-tungsten alloy
- By feeding the die into the workpiece, the shape of the die is machined into the workpiece

2) Wire EDM
- wire works similar to a band saw, only the cutting is caused by the spark erosion

Applications)

  • Dies & punches (hardened materials)
  • High precision parts
24
Q

What is Particle Beam Machining (PBM)? what are its advantages & disadvantages?

A
  • Uses a beam of high-energy electrons focused on a workpiece to melt and vaporise it
  • thew electrons are produced by heating a tungsten filament
  • Similar to EDM only there is no solution between the tool and workpiece

advantages)
-minimal thermal damage

Disadvantages)
Harmful X-rays produced

25
Q

What is Laser Beam Machining (LBM)? how is it different from Particle Beam Machining? where is it used?

A
  • similar to PBM, only light is used rather than electrons
  • No heat damage as the light vaporises the atoms & a process known as Chemical ablation occurs ( atoms given excess energy & so bonds break)
  • Used in turbine engines to drill microholes
26
Q

What is PLASMA ARC CUTTING (PAC)? how is it different from Particle Beam Machining? what is plasma? where is it used?

A
  • Uses a superheated stream of electrically ionised gas to melt and remove materials
  • Gas is 10000-25000 degrees, hence the nozzle needs to be water cooled
  • Plasma is a mixture of electrons and ions

-Used for the cutting of structural materials

27
Q

What are the 4 types of joining?

A
  • Welding (Fusion and Solid State)
  • Brazing & Soldering
  • Mechanical Fastening
  • Adhesives
28
Q

what is the Heat Affected Zone (HAZ)? what effects may be present in the HAZ ? what effects the size of the HAZ?

A
  • A region close to the weld site that is subjected also to the effects of elevating the temperature
  • Re-crystallisation
  • Embrittlement
  • Cracking
  • The rate at which heat is applied:
  • Welding processes with a low rate of heat input
    (i. e. slow heating) will produce:
  • Large HAZ
  • High ductility
29
Q

What is Thermally-induced Residual Stress?

A
  • Thermally-induced Residual Stress results from parts not being able to expand or contract freely due to the weld
  • At the weld site there is a resting compression & the metal is in tension either side
30
Q

What is fusion welding? what are the 4 types?

A

-when a pool of molten metal is created from either melting of the initial materials or by addition of a filler material

1 ) Electron-Beam Welding (EBW)

2) Laser-Beam Welding (LBW)
3) Oxyfuel Gas welding
4) Arc welding process

31
Q

What is electron beam welding (EBW)? where is it used? disadvantages?

A
  • The heat source is a high velocity narrow beam ofelectrons
  • The kinetic energy of the electrons is converted into heat as electrons strike the work piece
  • the process does not require a filler material, flux or shield gas
  • High precision welding, there is minimal distortion & shrinkage e.g. aircraft & missiles
  • Costly & x-rays are produced
32
Q

What is Laser beam welding (LBW)? where is it used?

A
  • High powered laser is used to weld deep & narrow joints
  • requires a shielding gas to protect the weld site

-used in the automotive industry for transmission components

33
Q

What is Oxyfuel Gas welding? where is it used (what type of material)

A
  • A flame is produced by a burner
  • Filler material is added to provide the molten pool
  • used for the joining of poor conductors, e.g Iron & steel
  • Welding thin materials
34
Q

What two branches of Arc welding are there? and what categories within them?

A

1) Consumable Electrode welding - electrode provides filler

  • Shielded metal arc welding - simple electrode is coated with material to provide the shielding
  • Flux cored arc welding - the protective flux is contained within a continuous tubular electrode
  • Gas metal arc welding - The same continuous electrode exists but the protective surroundings are provided by the inert gas
  • Submerged arc welding (SAW) - Basically Shielded metal arc welding but the electrode is submerged in a deposit of flux

2) Non- Consumable Electrode welding - electrode provides heat
- Gas Tungsten Arc Welding - The tungsten electrode provides the heat for fusion, not the filler material

35
Q

What is Shielded Metal Arc Welding (SMAW)?

A

A type of consumable electrode arc welding

  • An electrode is made of the weld material.
  • The electrode is connected to a circuit.
  • An electric arc will pass from the electrode to the material, the arc will melt the electrode
  • The electrode also has a bonded coating that when melted will provide a protective slag coating and gas to protect the weld (the slag must be removed)
36
Q

What is Flux-Cored Arc Welding (FCAW)?

A

A type of consumable electrode arc welding

-Similar to Shielded metal arc welding only the electrode is a continuous tube containing the weld material & material that when melted will perform the protective roles

37
Q

What is Gas Metal Arc Welding (GMAW)?

A

A type of consumable electrode arc welding, also the most common type

  • A continuous supply of weld material is present within the continuous electrode.
  • Rather than FCAW the flux is provided by the inert gas which is dispensed along with the filler material, hence providing the protective layer.
38
Q

What is Submerged Arc Welding (SAW)?

A

A type of consumable electrode arc welding

-No shielding gas is used Instead a thick layer of granular flux is deposited ahead of a solid bare-wire electrode

39
Q

what is Gas Tungsten Arc Welding (GTAW)?

A

A type of non-consumable electrode arc welding

  • The tungsten electrode provides the heat for fusion, not the filler material
  • Inert gases must be used o protect the weld steel e.g. Helium
40
Q

what is Plasma Arc Welding (PAW)? what are the two types?

A

A type of non-consumable electrode arc welding

  • A concentrated plasma arc is produced and aimed at the weld area
  • The heat source is the plasma arc

There are two types;

1) Transferred plasma arc - where the arc is between the work-piece and the tool
2) Non -Transferred plasma arc - where the arc is within the tool nozzle, the heat is transferred by the plasma´

41
Q

What is Brazing? what is braze welding? how is it different to weldin

A
  • A joining process in which filler metal is placed at or between surfaces to be joined
  • The filler metal is deposited at the joint with a technique similar to oxyfuel gas welding
  • The material used is not the same as the parent material
42
Q

What are 4 common methods of mechanical fastening?

A
  1. Metal stitching or stapling
  2. Seaming (folding)
  3. Crimping
  4. Snap-in fasteners
43
Q

What is additive manufacture? what are the benefits and where is it used? what are the drawbacks?

A

-The opposite of subtractive manufacture, parts made from small building blocks

  • Less waste
  • allows for personalised products to be created. such as hearing aids & other medical components
  • very slow production
  • Expensive
44
Q

What are the three types of printing? how does inkjet printing work?

A

1) Stamping
2) Masking & Stencilling
3) Direct writing

  • droplets of ink are dropped onto the workpiece to create a line
45
Q

What are the three types of adhesives used in industry?

A

1) Cyanoacrylates
2) Anaerobics
3) Acrylic

46
Q

What are anaerobics? how do they cure? how long do they take to cure? where are they used?

A

Anaerobic’s are initially suspended in a bottle, the air prevents the adhesive from curing,

Curing occurs with the absence of air, e.g threadlocking

Anaerobic’s can take up to 24 hours to fully cure but are handle-able within a day

used when glueing metal on metal

47
Q

What are Cyanoacrylates? how do they cure? how long do they take to cure? where are they used? what does the addition of rubber particles do?

A

These are instant adhesives, such as super glue

Cure with the presence of moisture

Still take 24 hours to fully cure

Used for glueing plastic or rubber

Can help to prevent crack propogation

48
Q

What are epoxies? what are they used to glue?

A
  • Consist of a resin & a hardener that when mixed lead to curing
  • low tech materials such as wood & carbon fibre

Manufacturing Technology (2 decks)

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