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Killicks common > Processes > Flashcards

Processes Flashcards

1
Q

What is the definition of ductility?

A

A materials ability to be drawn out (under tension) without rupture, and retain its new shape

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2
Q

What is the definition of malleability?

A

A materials ability to be pressed, rolled or beaten out (under compression) without rupture, and retain its new shape

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3
Q

What is the definition of toughness?

A

A materials ability to withstand impact and shock loads

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4
Q

What is the definition of strength?

A

A materials ability to withstand tensile, compressive or shear (offset) forces, resisting without rupture

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5
Q

What is the definition of brittleness?

A

A materials ability to fracture without deformation

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6
Q

What is the definition of hardness?

A

A materials ability to withstand wear and abrasion, and the ability to cut other softer materials

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7
Q

What is the definition of elasticity?

A

A materials ability to deform under load and return to its normal size and shape after the load is removed

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8
Q

What is the definition of corrosion resistance?

A

A materials ability to resist chemical and electrochemical attack

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9
Q

What is the definition of electrical conductivity?

A

A materials ability and rate at which a material will conduct electrical current

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10
Q

What is the definition of thermal conductivity?

A

A materials ability and rate at which a material will conduct heat

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11
Q

What are the advantages of plastics?

A

Ease of moulding
Low densities
Good electrical insulation
Low co-efficient of friction
Resistant to corrosion and chemical attack
Damps out vibration

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12
Q

What are the limitations of plastics?

A

Lower strength, rigidity and shock resistance
Low service temperature
Soft and scratch easily
Generally expensive except for large batches
Tendency to change shape due to shrinking, warping, creep and cold flow
Deterioration due to strong sunlight and air exposure

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13
Q

What are the main reasons for testing materials?

A

Research, design and development
Quality control
Investigation of failures

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14
Q

Define stress?

A

Stress = applied force (N)/cross sectional area (mm2)

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15
Q

Define strain?

A

Strain = change in length/original length

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16
Q

What are the three types of stress?

A

Tensile stress
Compressive stress
Shear stress

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17
Q

Define Hooke’s law?

A

Within the elastic range, the strain is directly proportional to the stress. Stress/strain = constant

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18
Q

What is creep?

A

The progressive deformation of a material under constant load over an extended time period

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19
Q

What is fatigue?

A

Caused by cyclical stress. When a material is repeatedly bent or twisted back and forth or repeatedly stretched then squashed

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20
Q

What are the four ways to reduce fatigue?

A

Good design
Improved surface finish
Avoid corrosion
Surface harden

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21
Q

What are the four methods of corrosion protection?

A

Design
Environment
Coating
Galvanic protection

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22
Q

What four ways could you protect a ships hull and components from corrosion?

A

Paint hull
Use sacrificial anodes
Good design (stainless steel and phosphor bronze)
Control moisture levels

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23
Q

What are the four heat treatment processes?

A

Annealing
Normalising
Hardening
Tempering

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24
Q

Describe annealing?

A

Heat to a specific temperature below lower critical temperature and then allow to cool in a controlled manor

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25
Q

Describe normalising?

A

Heat to just above upper critical temperature and allow to cool in air

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26
Q

Describe hardening?

A

Heat to above upper critical temperature and then quench it

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27
Q

Describe tempering?

A

Heat to a specific temperature below lower critical and then quench it

28
Q

What two properties will sand casting metals have?

A

A relatively low melting point
Good fluidity, with the ability to flow into intricate shapes without chilling

29
Q

What is the main difference between sand casting and die casting?

A

Sand casting uses a one off mould
Die casting uses a reusable metal die

30
Q

What are the three types of casting?

A

Sand
Die
Investment

31
Q

Explain the process for sand casting?

A

Place the bottom half of the moulding box (drag) over the half pattern and pack down with sand
Turn over and place the top half of the moulding block (cope) onto the bottom half
Position the other half of the pattern and pack down with sand
Cut holes for the runner and riser
Open the mould and remove both halves of the pattern
Repair any defects and then coat with plumbago
Position core if required
Reassemble the drag and cope and pour the molten metal
Allow to cool, when cold break open the mould and remove the casting
Fettle as required

32
Q

What are the uses for sand casting?

A

Gear blanks
Valve chests
Machine tool beds
Surface plates
Angle plates
Manhole covers

33
Q

What properties will die casting materials have?

A

Low melting point

34
Q

Explain the pressure die casting process?

A

Force the molten metal at a suitable pressure and temperature into the closed die so that it is completely filled
Open the die and eject the casting. The die is sprayed with graphite spray for longevity and ease of casting ejection
Close the die in preparation for the first stage again

35
Q

What are the uses for pressure die casting?

A

Engine pistons
Fuel pump bodies

36
Q

Describe the process for investment casting?

A

Build a ceramic mould around a wax pattern
Mould is then heated to harden it and melt out the wax pattern
Molten metal is then poured into the mould
After cooling, the mould is broken to release the casting

37
Q

What are the uses for investment casting?

A

Gas and jet engine blades
Cams
Nozzles
Valves

38
Q

What are the advantages for investment casting?

A

Dimensional accuracy
Good surface finish
Minimal machining
Can cast many materials including super alloys

39
Q

Explain hand forging?

A

The material is hammered into shape after it has been heated to its plastic state. This forging breaks up and refines the grain structure. The finer the grain structure becomes the stronger and tougher the metal becomes. The grain flow is also changed to follow the contour of the components

40
Q

What are the advantages for hand forging?

A

Uses less raw material than a component machined from solid stock
A forged component is stronger than one machined from solid stock or casting

41
Q

What are the disadvantages for hand forging?

A

Slow and labour intensive
High degree of skill needed
Expensive
Not suitable for mass production

42
Q

What are the uses for drop forging?

A

Connecting rods
Crankshafts
Spanners

43
Q

What are the two processes for joining materials?

A

Permanent
Temporary

44
Q

Give examples of permanent joining processes?

A

Riveting
Welding
Soldering
Brazing

45
Q

Give examples of temporary joining processes?

A

Nuts
Bolts
Screws
Studs

46
Q

Give three examples of types of rivets?

A

Round
Flat
Countersunk 90 degrees

47
Q

Explain the process of soldering?

A

Mechanically clean components
Chemically clean by applying a flux to remove oxide film when heated
Heat joint to above freezing range of solder
Apply filler metal to alloy with parent metal
Filler metal will fill clearance between components via capillary action

48
Q

What are the three types of adhesives?

A

Epoxies
Cyanoacrylates
Anaerobics

49
Q

Give applications for left hand threads and reasons for choice?

A

Hose connection heads of an oxyacetylene welding torch- safety, hoses cannot be connected to the wrong position on the torch or cylinders
Left hand spindle andnutona grinding machine- operation of the grinder will cause each grinding wheel and nut to self tighten

50
Q

How is quality defined?

A

A component has quality when it meets requirements

51
Q

What is the main goal of quality assurance?

A

Ensure that the product fulfils or exceeds the expectations of the customer

52
Q

What will the customer expect from a product?

A

That it will give a predictable, effective and reliable operating life
Spare parts will be readily available
Spare parts will be interchangeable with the existing equipment

53
Q

What is the international quality standard?

A

ISO 9000

54
Q

What is the purpose of inspection?

A

To identify products which do not match their specifications (non-conforming products)

55
Q

What must be done with a non-conforming product?

A

Make sure that it is clearly identified as non-conforming
Quarantine it
Decide what to do with it

56
Q

What can be done with non-conforming products?

A

Scrapping
Adjusting
Reworking
Obtain authority to pass the defective product on to the customer but clearly identify it as below standard

56
Q

Give three examples of assemblies which can be interchanged?

A

An exhaust valve running in a valve guide
A cylinder liner fitted in an engine crankcase
A shaft running in a bearing

56
Q

What is interchangeability?

A

The ability to select components for an assembly at random and fit them together within specified tolerances

57
Q

What forms can work instructions come in?

A

Detailed step by step instructions
Sketches of a finished product
Very simple statements

58
Q

What are the benefits of using written instructions?

A

The supervisor who gives the instruction can be sure the correct information has been received
The written instruction can be given clearly, even if the noise in the workplace makes it difficult to give verbal instruction
The people who do the work are able to check the written instruction if they forget anything
The supervisor and the person doing the work can refer to the instruction if any queries arise

59
Q

What information should be included on a drawing?

A

Sufficient dimensions to manufacture the component
Title block including revision number, scale, originator, angle, surface roughness/finish required
The material to be used
The tolerances and nominal sizes

60
Q

What sources of technical information are there?

A

Book references
Joint service publications
Illustrated parts catalogues
Parts identification lists
HASAW act and codes of practice
British standards
International standards
Technical publications and manuals

61
Q

What is the purpose of a work plan?

A

To prevent errors and save time

62
Q

What will a ideal work plan set out?

A

Activities as a logical sequence of events
Key values and times clearly indicated

63
Q

What is the purpose of electrode coating?

A

Creates slag layer to prevent weld metal cooling too quickly
Provides shielding gas to prevent oxidisation

Killicks common (4 decks)

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