Material Removal Processes Quiz in Manufacturing

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Questions and Answers

What is the origin of the word 'manufacturing'?

From the German word 'herstellen' meaning to produce

From the Latin word 'manufactus' meaning made by hand (correct)

From the French word 'manufacture' meaning large-scale production

From the Greek word 'manu' meaning production

What is the primary purpose of manufacturing?

To create new materials

To transform materials into items of greater value (correct)

To design new products

To assemble raw materials

What category of processing operation improves physical properties of the material without changing its shape?

Property-enhancing operations (correct)

Surface processing operations

Material Removal Processes

Shaping operations

What is the process of converting raw materials into usable products?

Manufacturing Signup and view all the answers

Which of the following is a shaping operation?

Solidification Processes Signup and view all the answers

What is the category of processing operation that involves cleaning, treating, coating, or depositing material onto the exterior surface of the work?

Surface processing operations Signup and view all the answers

What is the primary purpose of assembly processes?

To join two or more separate parts to form a new entity Signup and view all the answers

What type of mold is destroyed after a single use in casting processes?

Expendable mold Signup and view all the answers

Which of the following is an example of a material removal process?

Milling Signup and view all the answers

What is the primary purpose of deformation processes?

To shape a workpiece by applying forces that exceed the yield strength of the material Signup and view all the answers

Which of the following is an example of a joining process?

Welding Signup and view all the answers

What is the primary purpose of solidification processes?

To transform a material into a liquid or highly plastic state Signup and view all the answers

What is the primary focus of property-enhancing processes?

Improving mechanical or physical properties of the work material Signup and view all the answers

What is an example of surface processing?

Sand blasting Signup and view all the answers

What is a key consideration when selecting a manufacturing process?

All of the above Signup and view all the answers

How are most engineering materials typically categorized?

Into four basic categories Signup and view all the answers

What is the goal of understanding function/geometry and properties in manufacturing?

To identify candidate materials for a specific application Signup and view all the answers

What are the three main aspects of characterizing a manufacturing process?

Quality, economics, and flexibility Signup and view all the answers

Study Notes

Manufacturing Processes

Two or more separate parts are joined to form a new entity through assembly processes.

Solidification Processes

Starting material is heated sufficiently to transform it into a liquid or highly plastic state.
Examples: casting for metals, molding for plastics.
Casting process:
- Mold: contains a cavity that determines the shape of the component.
- Mold materials: sand, plaster, ceramic, and metals.
- Types of molds: open mold, closed mold, expendable mold (destroyed after single use), and permanent mold (can be used multiple times).

Deformation Processes

Starting work-part is shaped by application of forces that exceed the yield strength of the material.
Examples: forging, extrusion, and rolling.

Material Removal Processes

Excess material is removed from the starting workpiece to achieve the desired geometry.
Examples: machining (turning, drilling, and milling), grinding, and non-traditional processes.

Assembly Operations

Two or more separate parts are joined to form a new entity.
Types of assembly operations:
- Joining processes: create a permanent joint (e.g., welding, brazing, soldering, and adhesive bonding).
- Mechanical assembly: fastening by mechanical methods (e.g., use of screws, bolts, nuts, and other threaded fasteners; press fitting, expansion fits).

Property-Enhancing Processes

Performed to improve mechanical or physical properties of the work material.
Part shape is not altered, except unintentionally.
Examples: heat treatment of metals and glasses, sintering of powdered metals and ceramics.

Surface Processing

Cleaning: chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface.
Surface treatments: mechanical working (e.g., sand blasting) and physical processes (e.g., diffusion).
Coating and thin film deposition: coating exterior surface of the workpart.

Developing a Manufacturing Process

Understand function/geometry properties: mechanical, electrical, thermal, magnetic, optical, and deteriorative.
Identify candidate material(s) considering structure, composition, and required processing.
Material and geometry compatibility are crucial considerations.

Characterizing Processes

Quality: dimensional (bulk and surface) and properties (bulk and surface).
Economics: cycle time, materials utilization, and cost.
Flexibility: tooling development, setup time, and cycle time.

Materials in Manufacturing

Most engineering materials can be classified into one of four basic categories.

Manufacturing Technology

Definition: derived from the Latin word manufactus, meaning "hand-made".
Practical definition: process of converting or processing raw materials into usable products.
Purpose: transformation of materials into items of greater value by means of one or more processing and/or assembly operations.

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Description

Explore the world of manufacturing technology, from understanding the different products around us to the stages of product design development. Learn the definition of manufacturing and its application in various industries.