1. Name three methods of powder production.
Chemical, electrolytic and mechanical disintegration processes.
2. In cold compacting: (powder blending)
- The powder mixture is subjected to a high compressive pressure (between 150 and
1000 MN/m²).
- A maximum length/width die ratio of 3:1 should not be exceeded if significant density
variations are to be avoided.
3. Define sintering – Give time to the material to join together by producing a spark.
Also, heating process that permanently fuses together the powder mixture into a
component of sufficient strength to carry out the job for which it was designated. The
preform is subjected to an elevated temperature for up to 2 hours usually in either a
vacuum or controlled atmosphere. Too high a sintering temperature will result in
component distortion.
4. All plastics are produced by powder metallurgy.
5. Name 5 groups of machines
- Lathe group.
- Shaping machines.
- Milling machines.
- Drilling/boring group.
- Abrasive machining group (grinding and lapping machines).
6. Shear strength is half of yield strength.
7. In cutting cast iron: Blade is strong like diamond high pressure carbonate material
8. Several questions in final exam involve the key word BROACHES.
Broaches are a complex type of form tool that are frequently used to transform circular
holes into more complicated shapes.
- Spline and round broaches.
- Square and keyway broaches.
- Gears are produced by broaches.
9. How are gears produced?
- By metallurgy (cavities might occur).
- Using broaches, lathe machine (better and more uniform).
10. Define cutting - It is the shearing of material.
11. Power of cutting.
Power of cut = (Force of cut) * (Velocity of cut)
P_c = F_c * V_c
Add picture!
Temperature is highest in the middle of the chip.
12. Define knurling.
Manufacturing process using the lathe machine that produces a visually-attractive
diamond-shaped (criss-cross) pattern is cut or rolled into metal.
13. Define hardness and toughness.
- Hardness, amount of force required to break a material.
- Toughness, tension force required to increase the length of a material.
14. Define water-jet cutting.
A pump pressurizes water to approximately 30 to 60,000 psi. Water passes through a
nozzle (70-500 µm) and velocities of up to 800 m/s (Mach 2 to 3) are reached, enough to
cut the material.
15. Electro-discharge machining-spark erosion (EDM).
Material travels from piece to electrode.
16. How do we cut curves?
Using EDM (Electro Discharge Machine) by wire.
17. What is the difference between thermoplastics and thermosettings?
- Thermoplastics, they can be re-melted.
- Thermosettings, they just burn (undergo an irreversible chemical process when
heated).
18. What is the minimum wall thickness of plastics in design considerations?
1.5 to 2 mm.
19. Rapid prototypes.
- CAD.
- STL, stereolithography is an additive manufacturing technology for producing models,
prototypes, patterns, and in some cases, production parts (standard technique used in
industry).
20. Fused deposition modeling.
It basically prints the designed shape with hot plastic while moving horizontally.
Materials used: ABS, elastomers.
21. LOM (Laminated Object Manufacturing).
Rapid prototyping system developed by Helisys Inc. Layers of adhesive-coated paper,
plastic, or metal laminates are successively glued together and cut to shape with a knife or
laser cutter. (Each slice of model is cut using lager. Then bonded together, then hot rolled
press.
22. SLS (Selective Laser Sintering).
Additive manufacturing technique that uses a high power laser to fuse small particles of
plastic, metal, ceramic, or glass powders into a mass that has a desired 3-dimensional
shape.
23. 3D Ink Jet Printing.
It glues the powder over and over. The resolution of each layer is 0.1 mm.
24. Rapid tooling.
Process which employs rapid prototyping models directly or indirectly to create a mold
quickly.
25. Rapid manufacturing.
Using rapid prototyping techniques to make parts. Parts can be tailored to user’s exact
specifications. Disadvantage: no mass production.
26. Reverse engineering process transformation.
Using a reverse engineering software geomagi the coordinates are transferred to a
polygontriangular which is a surface geometry. This is similar to an STL file and can be
converted to an IGES or STEP file.
27. ISO 9000:
Guidelines establish efficiency quality in assurance system
28. Six sigma
To achieve 6 sigma level of quality it is 3.4 errors per million opportunities.
3 sigma
Statistical termal that indicates the point where the process needs to be corrected.
Other questions from class:
-Degree of polimerization: is the ratio of the molecular weight of the polymer to the molecular
weight of the mer
- Plastic Forming:Compression molding (thermosets only): heating and compression mold
Injection Molding (mostly Thermoplastics): gravity feeding raw material & compressing by motor
Compression mold
- Mechatronics: multidisciplinary field that is the synergistic combination of mechanical systems,
electronics, sensor, actuators, and software
- STL: stereolithography, which was the first Rapid Prototype technology, has been adopted as the
standard of the rapid prototyping industry.
-SLA: Stereolithographic apparatus
-FDM: Fused Deposition Modeling
-LOM: Laminated Object Manufacturing
-SLS: Selective Laser Sintering
-RT: Rapid Tooling: is a process that employs rapid prototyping models, directly and indirectly.
-RM: Rapid Manufacturing: is much cheaper than RT since it does not required tooling.
-MEM: Micro-Electro-Mechanical System
-Applications of MEM: 1-Medical devices (biotechnology, communications, consumer products.
2- industrial and aerospace devices. 3-Automotive (crash sensor, airbags). 4-testing devices
-CMM: Coordinate Measurement Machines accuracy of 0.000020”=0.00049 mm
-ISO: Organization for Standarization
*Ceramics
High strength, high temperature resistance, electric insulators.
Low fracture toughness
Ceramic composites to compensate for toughness (brittleness)
Types: -traditional, - Industrial
Materials: raw material is CLAY, glass, oxide ceramics, zirconia, carbides, silica, diamond graphite
Ceramics as cutting & abrasive materials: Cubic Boron Nitrite or Diamond is hardest material
available
Clay structure: Silicon ions, O ions, Al ions, OH ions
Forming and Shaping ceramics: soft, wet clay forming, pressing mod, baking in oven to rigidify
Forming glass: molten glass formed through continuous process or molds.
Glass Manufacturing: Blowing, centrifugal casting, and sagging, drawing, heat treatment.
*Computer Numerical Control (CNC)
Mechatronics: multidisciplinary field that is the synergistic combination of mechanical systems,
electronics, sensor, actuators, and software
Types: Long reach manipulator arm, mobile robot w arm deployed, Modular & reconfigurable robot
(MRR), Mobile robot w arm stowed,
Pick n place Robotic arm: used for spot welding, assembly, painting, testing.
*Plastics
Difference between Thermoplastics & Thermosets: Thermoplastics can be remelted any number of
times without risk of degeneration. Thermosets undergo irreversible chemical change when heated.
Composition: polymer long chain molecules & viscous additives
mers: units repeated in a chainlike structure.
Mono-mers: Organic materials where C atoms have covalent bonds w/ H, O,N,Fl,Ch,S.
Molecular Weight: Sum of mers in polymer chain
Polymerization: chemical change. Molecules linking in repeated units.
Degree of Polymerization (ratio): mol weight of polymer/mol weight of mer
Plastic Forming:
Compression molding (thermosets only): heating and compression mold
Injection Molding (mostly Thermoplastics): gravity feeding raw material & compressing by motor
Compression mold
Injection molding
Injection Molding Injection Pressure: Usually 15000psi
Clamp Force: 50 tons (injection Pressurexprojected area of part)
Ejection force: Ejection pins force part out of mold.
Adv: Short Cycle time, high volume production, high quality surface
Disadv: High capital investment, labor intensive, secondary operations might be required
Types of forming:
Compression molding, injection, extrusion, calendaring, blow molding, vacuum mold
Flash: caused by over-filling mold. Flash around edges of part
Elastomers: deform elastically & almost recover to original form when unloaded.
Composite materials: plastics reinforced with fibers to account for weakness in mechanical
weakness.
Vacuum Bagging/Autoclave: stack plies, add dry material to absorb excess resin & remove
volatiles, apply vacuum bag, trim, inspect, assemble.
Honeycomb Structures: aluminum, paper, composite etc, covered with top n bottom skin.
*Quality Assurance (Engineering Metrology)
Manual Measurement accuracy: 0.001in
Coordinate Measurement Machine (CMM) accuracy: 0.00002 in= 0.00049 mm
Laser Scanning Machine: +/- 0.00025 in
Go/ no Go: tool used to check a piece against its allowed tolerance.
Measuring Roundness: can be done using V-shape &dial indicator, and a probe & rotating table
Reverse Engineering: Recreating 3D solid model by CMM or laser scanning machines.
Reverse Engineering Software: Geomagic, Polyworks
Reverse Engineering Process (9):
Data Points: creating data points CMM or Laser.
Transformation: data points transferred to polygon mesh, which is a surface
geometry using Geomagic.
Creating ProE file: using previous information, a solid model is obtained.
Spline: in transferring data to solid models the operator might need to develop curves independently
to obtain desired shape using spline.
Error Minimization: use reverse engineering software to determine deviation from actual points.
This software also minimizes error and deviations.
Tolerancing: Repeating the steps 1-4 for several parts being copied. From a range of dimensions
one may estimate and may predict the tolerances.
Prototyping: creating small number of prototype parts, which is used for visualization and initial
laboratory testing.
Design for Manufacturing: anticipating the impact that manufacturing steps
would have on the final design.
Drawing (Blue Print): producing drawings that will be used by the manufacturer. These
drawingsinclude product dimensions and tolerances and usually include materials, manufacturing
process & finishing steps.
Sampling/validation of the manufactured product: a limited number of sample parts are initially
produced. This allows the developer to validate output against specifications.
Quality: defined as the ability of a product or service to satisfy a stated or implied need such as
standard of industry or voluntary standards of the company. Not the same as reliability
International Organization for Standardization ISO: In 1987 ISO issued specifications for quality
management and quality system elements
ISO 9000: Series of guidelines issued in 1944 of how to establish and operate an efficient quality
assurance system, covering most aspects of a business and its procedures, and specifies that such
procedures must be documented in a quality assurance manual.
Three Sigma: Old statistical term referring to the point where a process needs correction.
Six Sigma: Efficiency standard stating that 3.4 errors per million opportunities in quality, or
customer satisfaction
six sigma vs. three sigma: 3 sigma applied only to manufacturing processes, while 6 sigma applies
to all important business processes. Total allowance spread: 3 sigma (1/16) 6 sigma (1/12)
*Rapid Prototyping
Rapid Prototyping: AKA “three dimensional printing”
In Rapid Prototype. How many types we have: 4: SLA, Fused Deposition Modeling, Laminated
Object Manufacturing, Selective Laser Sintering, 3D Ink-jet printing.
Alpha prototype: replica of the part to be manufactured, showing principal geometric features such
as all geometric features, slots, cavities and surface texture.
Beta prototype: limited full-scale parts are made and tested in actual operation.
Layer Manufacturing: Software slices CAD model into thin layers (0.1mm thick)
STL format: Stereolithography first RP technology. It represented 3-D surface as assembly of
planar triangles.
Construction of object: After STL model is sliced, each slide is made at a time from different
materials, and then, they are glued together.
Cleaning: when the object is done, it is removed by detaching any support for the object.
