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final MFET #2
Terms in this set (60)
conversion of raw materials, through various processes, into finished goods/products needed for human needs.
a process which adds value to the good/product from the customer's perspective.
Factors in Manufacturing
Product design, Materials, Labor costs, Equipment, Manufacturing costs.
Strategies to reduce cost
Lean manufacturing, Systems approach
Collection of operations and processes to produce a desired product or component. Design or arrangement of the manufacturing
Converts unfinished materials to finished products
is the manufacture of a product from pieces such
as parts, components, or assemblies.
is the manufacture of a product by continuous operations.
Primary objective of manufacturing is to produce a component having a desired
Material, Geometry, Size, Finish
What the design is to accomplish. Apply assumptions and/or constraints. Form, Fit, Function, Performance & Life
Select and coordinate specific processes and
equipment. Supervise and manage their use. Need Knowledge of the Design Process.
Industrial (Manufacturing) engineer
Manufacturing systems layout
Specify ideal materials. Develop new and better materials.
Basic Manufacturing Processes
Casting, foundry, or molding process. Forming or metalworking processes. Machining processes. Joining and assembly. Surface treatments. Rapid prototyping. Heat treating.
Five manufacturing system designs
Job shop. Flow shop. Linked-cell shop. Project shop. Continuous process.
ability to hit what is aimed at.
repeatability of the process
The 6 Ms of Variation
Man. Machine. Measurement. Method, Mother Nature, Material.
intentional, desired difference between two mating parts.
undesirable but permissible deviation from a desired dimensions.
Dimensional Tolerance Bilateral
Plus or minus deviation from the nominal size
Dimensional Tolerance Unilateral
Deviation is in one direction from the nominal size
Dimensional Tolerance Limits
Maximum and minimum dimensions, no nominal given
Dimensional Tolerance geometric
Maximum allowable deviation of a form or position
from the perfect geometry
A property that dictates how a material responds
to applied loads and forces
the distortion or deformation of a material from a force or a load.
the force or the load being transmitted through the material's cross sectional area.
material will return to original shape when load
removed, linear portion of stress-strain curve, prior to elastic limit.
permanent change in shape when load removed, elastic limit exceeded.
is the resistance to permanent deformation in
the form of penetration or indentation
Brinell Hardness Test
Measures the indentation of a steel ball
Small steel ball or diamond tip cone
failure of a material due to long term exposure to elevated temperature.
temperature at which new crystal growth will
equilibrium phase diagram
diagram that shows the natural tendencies of a material or material system.
Mixture of two single phase solids from initial liquid phase. Liquid = solid1 + solid2
Mixture of two single phase solids from initial
solid phase. Solid1 = solid2 + solid3
controlled heating and/or cooling of materials for the purpose of altering their structures and/or properties.
subsequent heating to give the steel necessary ductility and fracture toughness.
Seven basic chip formation processes
Turning and Boring. Milling. Hole Making. Abrasive Machining. Sawing. Broaching. Shaping and Planing.
Coolant. Lubricant. Flush/Wash away chips
process of machining conical surfaces.
Machine minimum depth and diameter around hole to ensure full seating of a bolt head or washer.
remove small amounts of material to ensure exact hole size and improve hole surface finish.
3-2-1 Location Principle
used to ensure that every part placed in the device occupies. the same position with respect to the cutting tools.
Basics of the Casting Process
Mold cavity produced. Material is melted to the liquid phase. Heated to proper temperature. Treated - modify chemical makeup. Molten material poured into mold cavity. Solidification takes place. Part removed from mold cavity.
Finishing of workpiece/casting.
advantages to Cold Working
No heating required. Better surface finish. Superior dimensional control. Better reproducibility.
Disadvantages of Cold Working
Higher forces are required to initiate and complete
the deformation. Heavier and more powerful equipment and stronger tooling are required. Less ductility is available. Metal surfaces must be clean and scale-free.
Bulk Deformation Processes
Rolling, Forging, Extrusion. Wire, rod, and tube drawing. Cold forming, cold forging, and impact
Basic Rolling Process
Metal is passed between two rolls that rotate in opposite directions. Friction acts to propel
the material forward.
Processes that induce plastic deformation
through localized compressive forces applied
Metal is compressed and forced to flow through a
shaped die to form a product with a constant cross section. May be performed hot or cold. A ram advances from one end of the die and causes the metal to flow plastically through the die.
Wire, Rod, and Tube Drawing
Reduce the cross section of a material by
pulling it through a die.Similar to extrusion, but the force is tensile.
Sheet metal processes involve plane stress loadings and lower forces than bulk forming. Almost all sheet metal forming is considered
to be secondary processing.
mechanical cutting of material without the formation of chips or the use of burning or melting.
multiple bends are made with a single die.
the "unbending" that occurs after a metal has been deformed.
refers to the family of operations where plastic flow occurs over a curved axis and the flat sheet is formed into a threedimensional part.
Sheet metal is rotated and shaped over a male
form, or mandrel. Produces rotationally symmetrical shapes.
typically used to form solid-bottom cylindrical or rectangular containers from sheet metal.
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