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Questions and Answers
What type of production typically involves small lot sizes of less than 100 parts?
What type of production typically involves small lot sizes of less than 100 parts?
Which manufacturing process method involves creating parts using molds?
Which manufacturing process method involves creating parts using molds?
Which of the following is NOT a type of machining process?
Which of the following is NOT a type of machining process?
In which type of production are quantities typically between 100 and 5000 parts generally produced?
In which type of production are quantities typically between 100 and 5000 parts generally produced?
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What is a key factor in selecting a manufacturing process for a product?
What is a key factor in selecting a manufacturing process for a product?
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What dimensions are typically associated with microfabrication technologies?
What dimensions are typically associated with microfabrication technologies?
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Which of the following is NOT a common process involved in microfabrication?
Which of the following is NOT a common process involved in microfabrication?
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When selecting materials for manufacturing, which property is least relevant?
When selecting materials for manufacturing, which property is least relevant?
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The type of materials used in manufacturing does NOT include which of the following?
The type of materials used in manufacturing does NOT include which of the following?
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Which of the following mechanical properties indicates a material's resistance to permanent deformation?
Which of the following mechanical properties indicates a material's resistance to permanent deformation?
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In the context of material properties, what does creep resistance refer to?
In the context of material properties, what does creep resistance refer to?
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What is the primary role of material engineers in the manufacturing process?
What is the primary role of material engineers in the manufacturing process?
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Which of the following best describes a characteristic considered in the appearance of a material?
Which of the following best describes a characteristic considered in the appearance of a material?
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In manufacturing processes, which property typically indicates how a material can be shaped or joined?
In manufacturing processes, which property typically indicates how a material can be shaped or joined?
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What type of steel is specifically mentioned as a category of ferrous metals?
What type of steel is specifically mentioned as a category of ferrous metals?
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Job shops typically utilize dedicated machines for production.
Job shops typically utilize dedicated machines for production.
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Batch production consists of lot sizes that typically range from 100 to 5000 parts.
Batch production consists of lot sizes that typically range from 100 to 5000 parts.
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Casting processes only involve the use of permanent molds.
Casting processes only involve the use of permanent molds.
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Forming and shaping processes include techniques like rolling and powder metallurgy.
Forming and shaping processes include techniques like rolling and powder metallurgy.
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Finishing processes involve initial shaping and forming of materials.
Finishing processes involve initial shaping and forming of materials.
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Microfabrication can produce components at dimensions of one-billionth of a meter.
Microfabrication can produce components at dimensions of one-billionth of a meter.
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The primary consideration when selecting materials for manufacturing includes only the economic cost.
The primary consideration when selecting materials for manufacturing includes only the economic cost.
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LIGA is a process associated with the production of microelectromechanical systems (MEMS).
LIGA is a process associated with the production of microelectromechanical systems (MEMS).
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Ferrous metals do not include stainless steel.
Ferrous metals do not include stainless steel.
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Density and melting point are considered mechanical properties of materials.
Density and melting point are considered mechanical properties of materials.
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Study Notes
Types of Production
- Production quantity and rate are crucial economic factors in process selection
- Production types, from least to most produced:
- Job shops: Small lots (under 100) using general-purpose machines
- Small-batch: 10 to 100, similar machines to job shops
- Batch: 100 to 5000, using more advanced machinery
- Mass Production: Over 100,000, utilizing dedicated machinery and automation
Selection of Manufacturing Processes
- Choosing the correct manufacturing process is vital for efficiency, quality, and cost
- Process selection depends on part geometry, tolerances, surface requirements, and workpiece material properties
- Continuous demand for new approaches to manufacturing challenges and cost reduction exists
Types of Manufacturing Processes
- Multiple methods may be used to manufacture parts from various materials
- Broad categories include:
- Casting (expendable and permanent molds)
- Forming and Shaping (rolling, forging, extrusion, drawing, and molding)
- Machining (turning, drilling, milling, and more specialized techniques)
- Joining (welding, brazing, soldering, and more)
- Finishing (honing, lapping, polishing, and plating)
- Microfabrication/Nanofabrication (processes for very small parts)
Types of Manufacturing Processes - Specific Examples
- Casting: Investment casting, sand casting, permanent mold casting, lost foam casting, shell mold casting, die casting, single crystal casting, ceramic mold casting, centrifugal casting, and squeeze casting
- Forming and Shaping: Rolling (flat, shape, ring), forging (open-die, closed-die, roll), extrusion (direct, cold), drawing (direct, tube), and piercing
- Shearing: Blanking, slitting, punching, and piercing
- Bending and Drawing: Bending, hemming, roll forming, deep drawing, hydroforming, and stretch forming
- Forming: Spinning, magnetic-pulse forming
- Polymer Processing: Extrusion, injection molding, compression molding, pultrusion, blow molding, vacuum bag forming, transfer molding, thermoforming
- Rapid Prototyping: Stereolithography, fused-deposition modeling, three-dimensional printing, and laminated-object manufacturing
- Joining Processes: Fusion welding (shielded metal-arc, gas-metal arc, flux-cored arc, gas-tungsten arc), Other welding (friction-stir, resistance, explosion, cold), Fastening and bonding (adhesive bonding, bolted connections, rolled connections, wave soldering, brazing)
- Machining and Finishing: Turning, drilling, milling, broaching, Wire EDM, chemical machining, laser machining, water jet machining, surface grinding, centerless grinding, lapping, and electrochemical polishing
Selection of Materials
- Wide variety of materials are now available, each with unique properties, advantages, limitations, and costs
- Material selection often involves consultation with material engineers
- Trends in materials substitution are driven by technological and economic factors
Properties of Materials
- Mechanical properties (strength, ductility, hardness, toughness, elasticity, fatigue, creep)
- Physical properties (density, specific heat, thermal expansion, conductivity, melting point, electrical and magnetic)
- Chemical properties (oxidation, corrosion, degradation, toxicity, flammability)
- Manufacturing properties (castability, formability, machinability, jointability, and heat treatment)
Types of Materials
- Ferrous metals (carbon, alloy, stainless, tool steel)
- Nonferrous metals (aluminum, magnesium, copper, nickel, titanium, superalloys, precious metals)
- Plastics (polymers)
- Ceramics, glasses, and graphite
- Composites (reinforced plastics, metal-matrix, ceramic-matrix)
- Nanomaterials (carbon nanotubes, fullerenes, nanoparticles, nanowires, quantum dots, shape memory alloys, amorphous alloys, semiconductors, superconductors)
Process Selection Calculations
- Example calculations demonstrated for various processes
- Cost analysis to determine the crossover point (minimum batch size for injection molding to become more cost-effective than machining)
- Example calculation (specific strength determination for drone material selection), showing how to calculate specific strength
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Description
Explore the various types of production and manufacturing processes in this quiz. From job shops to mass production, understand the differences and factors influencing process selection. Test your knowledge on manufacturing challenges and methods used in industry.
