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Questions and Answers
Which of the following processes involves the shaping of a workpart by applying forces that exceed the yield strength of the material?
Which of the following processes involves the shaping of a workpart by applying forces that exceed the yield strength of the material?
Material removal processes are typically efficient in terms of material usage.
Material removal processes are typically efficient in terms of material usage.
False
Name one example of a property-enhancing process.
Name one example of a property-enhancing process.
Heat treatment or Sintering
______ processes, such as casting and molding, waste little material.
______ processes, such as casting and molding, waste little material.
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Which material removal process involves the rotational cutting of a workpiece?
Which material removal process involves the rotational cutting of a workpiece?
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What is the difference between net shape and near net shape processes?
What is the difference between net shape and near net shape processes?
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Match the following processes with their descriptions:
Match the following processes with their descriptions:
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What is the primary goal of processing operations in manufacturing?
What is the primary goal of processing operations in manufacturing?
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Surface processing operations include cleaning, surface treatments, and ______.
Surface processing operations include cleaning, surface treatments, and ______.
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Surface processing operations are designed to change the shape of the starting material.
Surface processing operations are designed to change the shape of the starting material.
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Name one type of operation included in property-enhancing operations.
Name one type of operation included in property-enhancing operations.
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The starting material in solidification processes is typically in a ______ or highly plastic state.
The starting material in solidification processes is typically in a ______ or highly plastic state.
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Match the following shaping processes with their definitions:
Match the following shaping processes with their definitions:
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Which of the following is not a category of shaping processes?
Which of the following is not a category of shaping processes?
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Deformation processes can involve both ductile and brittle solids.
Deformation processes can involve both ductile and brittle solids.
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What two processes typically occur in particulate processing?
What two processes typically occur in particulate processing?
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What type of production facility is used for low production quantities?
What type of production facility is used for low production quantities?
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High production is typically suited for customized products.
High production is typically suited for customized products.
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Name the two categories of mass production.
Name the two categories of mass production.
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The labor force in a job shop is highly __________.
The labor force in a job shop is highly __________.
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Match the following production types with their characteristics:
Match the following production types with their characteristics:
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Which production type is suited to hard product variety?
Which production type is suited to hard product variety?
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Cellular manufacturing eliminates the need for setups between different part styles.
Cellular manufacturing eliminates the need for setups between different part styles.
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What is the typical layout used in quantity production?
What is the typical layout used in quantity production?
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What does unilateral tolerance allow?
What does unilateral tolerance allow?
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Limit dimensions specify the maximum and minimum dimensions allowed for a part feature size.
Limit dimensions specify the maximum and minimum dimensions allowed for a part feature size.
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What is the maximum tolerance that most machining processes can achieve?
What is the maximum tolerance that most machining processes can achieve?
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Sand castings are generally inaccurate, and tolerances of _____ to _____ times those used for machined parts must be specified.
Sand castings are generally inaccurate, and tolerances of _____ to _____ times those used for machined parts must be specified.
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Which process is characterized as more accurate?
Which process is characterized as more accurate?
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Unilateral tolerance can apply both maximum and minimum dimensions.
Unilateral tolerance can apply both maximum and minimum dimensions.
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Who is sometimes referred to as the Father of Refrigerated Freight?
Who is sometimes referred to as the Father of Refrigerated Freight?
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Match the following manufacturing processes with their accuracy:
Match the following manufacturing processes with their accuracy:
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Which of the following is NOT a type of product?
Which of the following is NOT a type of product?
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All products can be easily understood before purchase.
All products can be easily understood before purchase.
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What is the first stage of the Stage-Gate Product Development Process?
What is the first stage of the Stage-Gate Product Development Process?
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The primary purpose of actions offered by companies is for _______.
The primary purpose of actions offered by companies is for _______.
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Match the following characteristics of successful product development with their descriptions:
Match the following characteristics of successful product development with their descriptions:
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Which phase comes directly after Idea Screening in the Stage-Gate Product Development Process?
Which phase comes directly after Idea Screening in the Stage-Gate Product Development Process?
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Product cost refers to how much a customer pays for the product.
Product cost refers to how much a customer pays for the product.
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Who is primarily responsible for designing and developing products?
Who is primarily responsible for designing and developing products?
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Which stage of the design process is most critical in determining the cost associated with delivering a product?
Which stage of the design process is most critical in determining the cost associated with delivering a product?
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The detailed design phase has the least impact on the overall cost of a product.
The detailed design phase has the least impact on the overall cost of a product.
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What percentage of the total cost of a product is typically fixed during the design stage?
What percentage of the total cost of a product is typically fixed during the design stage?
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The four phases of design are conceptual design, detailed design, ____________, and distribution, servicing, disposal.
The four phases of design are conceptual design, detailed design, ____________, and distribution, servicing, disposal.
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Which design phase is primarily concerned with how the product will be made?
Which design phase is primarily concerned with how the product will be made?
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Match the design phases with their focus:
Match the design phases with their focus:
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Distribution, servicing, and disposal are considered the final phases of design and do not affect product costs.
Distribution, servicing, and disposal are considered the final phases of design and do not affect product costs.
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List one role involved in the manufacturing process.
List one role involved in the manufacturing process.
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Study Notes
Course Information
- Course title: DAM 11002: Manufacturing Process
- Week: 1
- Textbook author: MP Groover
- Textbook title: Fundamentals of Modern Manufacturing 3/e
What is Manufacturing?
- Manufacturing involves changing the shape, properties, or appearance of starting materials.
- Many objects are made from multiple parts and materials.
- Manufacturing methods have developed from hand-made to automated.
- Historically, manufacturing initially meant "made by hand."
- Modern manufacturing heavily depends on mechanized equipment and human supervision.
Manufacturing - Technologically
- Application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to create parts or products.
- Manufacturing always involves, at least, a sequence of operations.
- The process adds value to the material by changing its shape or properties.
Manufacturing - Economically Important
- Manufacturing is a crucial aspect of a nation's economy.
- The manufacturing sector contributes significantly to a nation's Gross National Product (GNP).
- Manufacturing activities encompass agriculture, minerals, construction, and various services.
Manufacturing Industries
- Industries are categorized into:
- Primary industries (farming, mining): These cultivate and exploit natural resources.
- Secondary industries (manufacturing): These convert primary outputs into consumer or capital goods.
- Tertiary industries (services): These are the service sector.
Materials in Manufacturing
- Engineering materials are broadly classified into three categories:
- Metals
- Ceramics
- Polymers
- Their different chemistries lead to varying mechanical and physical properties, influencing manufacturing methods.
- Composites (nonhomogeneous combinations of these three) also play a role.
Manufacturing Processes
- Two basic process types:
- Processing operations: these operations transform a work material from one state of completion to another, altering the geometry, properties, or appearance of the starting material.
- Assembly operations: these operations join two or more components to create a new combined entity.
Processing Operations Classification
- Solidification Processes: starting material is a heated liquid or a semifluid
- Particulate Processes: starting material is in powder form
- Deformation Processes: starting material is a ductile solid
- Material Removal Processes: starting material is a ductile or brittle solid
Solidification Processes
- Starting materials are heated to liquid or semi-liquid states.
- Examples: metal casting, plastic molding
Particulate Processing
- Involves pressing and sintering powders of metals or ceramics.
- Heat bonds the individual particles together to form solid objects.
Deformation Processes
- Shaping materials by applying forces exceeding their yield strength.
- Examples: forging, extrusion
Material Removal Processes
- Removing excess material to achieve the desired shape.
- Examples: turning, drilling, milling, grinding, nontraditional processes.
Waste in Shaping Processes
- Material removal processes typically result in waste.
- Net-shape processes minimize waste by shaping materials to the final form with minimal machining.
- Near-net-shape approaches also minimize waste by reducing the necessary machining.
Property-Enhancing Processes
- These processes modify material properties without materially altering the shape.
- Examples: heat treatment of metals and glasses; sintering of powdered metals and ceramics.
Surface Processing Operations
- Surface treatments involve processes like cleaning, mechanical working (e.g., sandblasting), and chemical or thermal treatments.
- Coating and deposition improve surface properties.
Assembly Operations
- Joining two or more parts to form a new entity.
- Joining processes: welding, brazing, soldering, adhesive bonding
- Mechanical assembly: fastening by mechanical methods (screws, bolts, nuts), press fitting, expansion fits.
Production Systems
- People, equipment, and procedures used for material combinations.
- Essential for efficient manufacturing operations.
- Includes:
- Production facilities (factory, equipment, material handling)
- Manufacturing support systems (departments like manufacturing engineering, production planning & control, quality control)
Production Facilities
- The factory, its equipment, and material handling systems.
- Plant layout—how equipment is arranged in the factory.
- Manufacturing systems: logical groupings of equipment.
- Examples: automated production lines, machine cells (robotic arm with other machines).
Facilities versus Product Quantities
- Company designs manufacturing systems based on product quantities.
- Examples: low production (job shops), medium production (batch or cellular manufacturing), high production (quantity, flow line)
Low Production
- Job shops are used, making customized, specialized products in relatively small quantities.
- General-purpose equipment and highly skilled labor.
Medium Production
- Batch or cellular manufacturing is used, with setups needed between batches.
- Hard or mixed product variety.
- Equipment may be general or specialized, and workers may be skilled or semi-skilled.
High Production
- Often called mass production, designed for high-volume production of a specific product.
- Two categories: quantity or flow line production.
Quantity Production
- Mass production of single parts with single machines or groups of machines.
- Standardized machines with specialized tooling.
- Equipment dedicated to a single product type.
- Process layout or cellular layout.
Flow Line Production
- Multiple machines are arranged in a sequence, typically in production lines.
- Complex products need multiple processes.
- Units are moved through the sequence for completion.
- Workstations are often designed specifically for the product to maximize efficiency.
Manufacturing Support Systems
- Departments manage production operations, from design to quality control.
- Key departments include:
- Manufacturing Engineering
- Production Planning & Control
- Quality Control
Overview of Major Topics
- A diagram illustrating the systems and their interrelation
Dimensions and Tolerances
- Factors impacting product performance.
- Dimensions: measured sizes (linear or angular) of components on drawings.
- Tolerances: acceptable variations from specified part dimensions.
- Important in manufacturing to ensure product function and quality.
Dimensions
- Numerical value of a part feature in appropriate units indicated on the drawing.
- Represents the nominal or basic sizes of the part and its features.
Tolerances
- Total amount a specific dimension is allowed to vary between maximum and minimum limits.
- Reflect variations in manufacturing processes.
- Define the limits of acceptable variation in the product.
Bilateral Tolerances
- Variations are allowed in both positive and negative directions from the nominal dimension.
Unilateral Tolerances
- Variation is allowed in only one direction (positive or negative), not both.
Limit Dimensions
- Maximum and minimum dimensions permissible for a part feature.
Tolerances and Manufacturing Processes
- Some processes are inherently more accurate than others.
- Example differences in accuracy between machining processes and casting processes.
- Tolerance requirements depend on the manufacturing process.
Design & Manufacturing a Product
- Two general product types:
- Physical Goods: tangible goods that can be seen and experienced before purchase.
- Services: actions offered for customer transactions.
Stage-Gate Product Development Process
- Steps in developing new products, with management reviews at each stage.
Characteristics of Successful Product Development
- Factors to consider when evaluating the success of a product development effort
- Product quality
- Product cost
- Development time
- Development cost
- Development capability
Who Design & Develop Products?
- Team leadership plays important role in project success.
- Various professionals work in parallel to create a successful and efficient product.
Design
- Design analysis is broken into four phases: conceptual, detailed, manufacturing, distribution and disposal.
- The design phase is very important in the product lifecycle and largely affects the product's total cost.
Products in Various Stages of Life Cycle
- Product sales, stages, and profitability typically are related.
Production Systems Diagram
- Overall structure of factory operations, showing interrelation between facilities and associated support systems.
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Description
Explore the fundamental concepts of manufacturing in this quiz, featuring content from MP Groover's 'Fundamentals of Modern Manufacturing.' Understand the evolution from manual to automated processes and the economic significance of manufacturing. Test your knowledge on the definitions and methodologies that shape the manufacturing industry today.
