Manufacturing Processes: Shot Peening and Casting
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Questions and Answers

Which of the following features does Magics offer?

  • Workflow Animation
  • Analyze builds (correct)
  • Image processing
  • File formats

    • Materialise Mimics software can create 3D anatomy models by using data from medical images.

    True (A)

    Name one function of the Solid Viewer software.

    Markup

    Velocity 2.0 helps teams keep current sprints on _____ track.

    <p>track</p> Signup and view all the answers

    Match the following software with their key feature:

    <p>Magics = Apply textures Mimics = AI-enabled segmentation Solid Viewer = Collaboration Velocity 2.0 = Bottleneck prevention</p> Signup and view all the answers

    Which feature of Mimics enhances the visualization of foreign objects?

    <p>Image processing (C)</p> Signup and view all the answers

    Solid Viewer software allows users to customize reports and algorithms.

    <p>False (B)</p> Signup and view all the answers

    What does Velocity 2.0 help teams understand regarding productivity?

    <p>Productivity drivers</p> Signup and view all the answers

    What is the primary purpose of shot peening?

    <p>To induce compressive residual stresses (A)</p> Signup and view all the answers

    Shot peening and sand blasting use the same type of particles for surface treatment.

    <p>False (B)</p> Signup and view all the answers

    What process creates an induced compressive stress layer to increase resistance to fatigue?

    <p>Shot peening</p> Signup and view all the answers

    Micro casting is also known as ______.

    <p>lost-wax casting</p> Signup and view all the answers

    Which of the following is NOT an application of microcasting?

    <p>Clothing fabric (A)</p> Signup and view all the answers

    An STL file can contain information about the texture of the 3D model.

    <p>False (B)</p> Signup and view all the answers

    Which material is typically used for sacrificial patterns in microcasting?

    <p>Wax (B)</p> Signup and view all the answers

    Match the following surface treatment processes with their characteristic features:

    <p>Shot peening = Induces compressive residual stresses Sand blasting = Improves roughness and cleanliness Microcasting = Lost-wax casting method Firing = Solidifies the refractory material</p> Signup and view all the answers

    What is a degenerate facet in the context of STL files?

    <p>A facet where all edges are collinear.</p> Signup and view all the answers

    The sacrificial models used in microcasting leave ash after burning.

    <p>False (B)</p> Signup and view all the answers

    A valid tessellated model must have no _____ or overlapping facets.

    <p>missing facets</p> Signup and view all the answers

    Match the following microcasting applications with their respective functions:

    <p>Distributors = Aerodynamic applications Cork supports = Containers for storage Pump body = Construction of pumps Inverter boxes = Electromechanics</p> Signup and view all the answers

    In shot peening, what happens when shots impact the surface?

    <p>They generate indentations and create a compressive stressed layer.</p> Signup and view all the answers

    Which type of error is caused by large curvature during tessellation?

    <p>Missing facets (B)</p> Signup and view all the answers

    Valid tessellated models can have multiple adjacent facets sharing the same edge.

    <p>False (B)</p> Signup and view all the answers

    What is one problem commonly associated with tessellation in CAD systems?

    <p>Gaps or holes in the model.</p> Signup and view all the answers

    What happens when a valid tessellated model is used as input?

    <p>It is sliced into layers. (D)</p> Signup and view all the answers

    Invalid tessellation leads to a definitive stopping boundary during the slicing process.

    <p>False (B)</p> Signup and view all the answers

    What is additive manufacturing (AM) software used for?

    <p>To create, adapt, and manufacture 3D printed parts by providing instructions for each layer.</p> Signup and view all the answers

    The software that ensures the AM process happens without errors is called ___ software.

    <p>Process monitoring</p> Signup and view all the answers

    Match the following AM software with their primary functionalities:

    <p>CAM software = Provides instructions for producing parts layer by layer PLM software = Digitizes and controls the entire product lifecycle Slicing tool path generation = Generates G-code for printing 3D and CAT scanning software = Analyzes parts non-disruptively</p> Signup and view all the answers

    Which feature is NOT associated with Materialize Magics Software?

    <p>Generating G-code for printing (B)</p> Signup and view all the answers

    AM software is only useful for large-scale manufacturing.

    <p>False (B)</p> Signup and view all the answers

    Name one feature of CAM software.

    <p>Provides instructions for producing parts layer by layer.</p> Signup and view all the answers

    Study Notes

    Assignment 03

    • Shot peening: A cold work process used to impart compressive residual stresses on a component's surface, modifying its mechanical properties and reducing stress profiles.

    • How shot peening works: Impacted by shot (metal, glass, or ceramic particles), the surface experiences plastic deformation, generating multiple indentations leading to a compressive stressed layer on the metal surface.

    Shot Peening vs. Sand Blasting

    • Shot peening: Imparts compressive stresses, leading to increased strength and resistance to fatigue, stress corrosion, and cavitation erosion.
    • Sand blasting: Improves surface roughness and cleanliness.

    Microcasting (Lost-Wax Casting)

    • Definition: A casting process using sacrificial patterns identical to the part's geometry, made of materials that liquefy and burn away, leaving no ash.

    • Application: Used to create complex shapes, especially for small parts and intricate geometries.

    • Process: Creating patterns and embedding them in an inert material (e.g., plaster, liquid ceramic), allowing for the molten metal to occupy the cast spaces to create the finished component.

    Selective Laser Sintering (SLS)

    • Working Principle: A powder bed is selectively melted using a focused laser beam, building layers one on top of the other to create the final solid part.

    • Advantages: No part supports required which saves time, and little post-processing needed, good part stability.

    Laser Engineered Net Shaping (LENS)

    • Working principle: Similar to SLS, but the powder is injected by a nozzle, creating the final component.

    • Advantages: Wide range of processing materials, little post-processing required, no part supports required.

    • Disadvantages: Large physical size of the unit, high power consumption, high cost.

    Electron Beam Based Powder Bed

    • Working Principle: A focused beam of electrons is used to melt or sinter metal powder (similar to Laser Sintering).

    • Advantages: High precision, superior material properties, high energy efficiency, fast build rates.

    • Disadvantages: Complex setups, high power consumption.

    STL File Format

    • Definition: A file format used widely in 3D printing and CAD, consisting of an unordered list of triangular facets representing the outside surface of an object, without color, texture or other attributes.

    • Problems: Missing facets/gaps, overlapping facets and/or non-manifold topology conditions leading to faulty geometries causing problematic prints. Often results in an approximate rather than precise model.

    • Valid STL Model: No missing facets, overlapping facets or degeneracies.

    • Invalid STL Model: Presence of missing facets, overlapping facets or any other abnormalities such as geometrical degeneracies that will cause mistakes on construction.

    AM Software

    • Importance: Essential for managing the entire additive manufacturing process, ensuring the process happens without errors and coordinating the entire product's lifecycle.

    • CAM software: Provides instructions for building parts, layer by layer.

    • Process monitoring software: Ensures the AM process runs accurately without errors.

    • MES software: Controls and coordinates the product lifecycle from quotation to final use

    • PLM software: Digitizes and controls the entire product lifecycle.

    • 3D and CAT scanning software: Analyses parts non-destructively.

    • Part finishing software: Software that uses appropriate methods for accurate 3D product design.

    • Slicing tool path generation software: Generates g-code to control the 3D printer.

    • Printer interface software: Provides essential information about material levels, print status, error notifications, and more.

    • Feature examples: MAGICS (file editor and preparation), MIMICS (medical image processing), and SOLID VIEWER (viewing, sharing and collaboration software), and Velocity 2.0 (managing project sprints for consistent productivity).

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    Assignment 03 PDF

    Description

    This quiz explores key manufacturing processes such as shot peening and microcasting. Understand how shot peening imparts compressive stress to enhance mechanical properties and contrast it with sand blasting. Additionally, dive into the intricacies of lost-wax casting for creating complex shapes.

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