Term
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Definition
a. Subjecting raw materials to a sequence of operations to create value.
b. Application of physical and chemical processes to alter the geometry, properties, and appearance of starting material to make parts or product. |
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Term
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Definition
| individual products, iPhones, tires, bricks. |
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Term
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Definition
| spool of copper wire, plastic tubing |
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Term
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Definition
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Term
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Definition
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Term
| 6. Construction and public utilities |
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Definition
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Term
| 7. Service (retail, transp., banking, comm., education, government) |
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Definition
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Term
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Definition
| cultivate and exploit natural resources |
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Term
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Definition
| take output of primary industries and convert it into consumer and capital |
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Term
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Definition
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Term
| 11. Manufactured products |
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Definition
a. Consumer goods: cars, TV’s, tennis racquets.
b. Capital goods: aircraft, machine tools, bulldozers. |
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Term
| 12. Low Production: 1-100 per year |
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Definition
i. Low production quantity means high product variety is possible.
b. Fixed position layout: ships, locomotives.
c. Process layout
i. Lathes in one department, milling machines in another department.
ii. Flexible but may not be designed for high efficiency. |
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Term
| 13. Medium Production: 100-10,000 per year |
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Definition
a. Batch Production
i. Hard product variety
ii. Process layout
iii. Used for make-to-stock
iv. Set up times are long (disadvantage)
b. Cellular Manufacturing
i. Soft product variety
ii. Each cell can produce a variety of part configurations
iii. Group technology
iv. Cellular layout |
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Term
| 14. High Production: 10,000-millions per year |
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Definition
a. Flow line production
i. Single-model production line
ii. Mixed-model production line |
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Term
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Definition
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Term
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Definition
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Term
| 17. Strain Hardening Exponent |
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Definition
| where K is the strength coefficient and n is the strain-hardening coefficient. |
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Term
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Definition
| where Yf is the stress required to keep the metal flowing |
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Term
| 19. Strain Rate Sensitivity Exponent |
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Definition
where m is the strain rate sensitivity and C is the strength coefficient.
a. For any given temperature, flow stress increases as strain rate increases.
b. Flow stress decreases as temperature increases.
c. m increases as temperature increases.
d. C increases as strain increases. |
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Term
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Definition
| a combination of two or more chemically distinct and insoluble phases with a recognizable interface, in such a manner that its properties and structural performance are superior to those of the constituents acting independently. |
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Term
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Definition
| the discontinuous or dispersed phase |
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Term
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Definition
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Term
| 23. Polymer-matrix composites (PMC): |
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Definition
| consist of strong/stiff fibers in a polymer matrix. |
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Term
| 24. Fiber reinforced composite (FRC) |
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Definition
a. Support the fibers and transfer stress to fibers
b. Protect fibers against physical damage and environmental attack
c. Reduce crack propagation since matrix materials are tough and ductile |
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Term
| 25. Glass-fiber reinforced plastic (GFRP) |
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Definition
a. Easily drawn from molten state
b. Readily available
c. High strength
d. Low stiffness
e. High Density
f. Lowest cost
g. Chemically inert – good for corrosive environment
h. Use fiberglass with diameter of 3 to 20 micron |
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Term
| 26. Carbon-fiber reinforced plastic (CFRP) |
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Definition
a. Highest specific modulus
b. Highest specific strength
c. High tensile modulus and strength at elev. T
d. Oxid’n problem
e. Not affected by moisture and chemicals at room temperature
f. Cost effective |
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Term
| 27. Kevlar fiber (Aramid) |
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Definition
a. Outstanding strength to weight ratio
b. Tough
c. Resistant to creep and fatigue
d. Resistant to combustion and high temperatures
e. High strength in tension
f. Weak strength in compression |
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Term
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Definition
a. Aerospace applications
b. Good mechanical properties
c. Resistant to moisture
d. Better high temperature properties then polyester |
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Term
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Definition
a. Diverse application
b. Good room temperature properties
c. Ease of fabrication
d. Cost effective |
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Term
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Definition
fiber roving’s, resin impregnation tank, performing die, curing die, and pullers.
a. Used to manufacture components having length and cross-section.
b. Easily automated.
c. Production rates are high.
d. Cost effective.
e. Wide variety of shapes possible.
f. No practical limit to length of stock. |
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Term
| 31. Short (discontinuous) fibers |
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Definition
a. Mechanical properties improve as a result of increasing average fiber length.
b. Typical aspect ratio 20-60.
c. May have better isotropic properties. |
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Term
| 32. Long (continuous) fibers |
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Definition
a. Typical aspect ratio 200-500.
b. Better under temperature and time at load, and critical applications.
c. Function of the matrix. |
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Term
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Definition
a. Continuous fiber reinforcement preimpregnated with a polymer resin that is only partially cured.
b. Material is delivered in tape form to a manufacturer who refrigerates it until just before use. |
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Term
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Definition
| a process in which the resin and fibers are combined at the time of curing in order to develop a composite structure. |
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Term
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Definition
a. High stiffness and strength.
b. Two outer sheets separated by a lightweight core.
c. Outer sheets are made of a stiff material (aluminum, reinforced plastic, wood, steel).
d. Core materials are either rigid polymeric foams, wood, or honeycombs.
e. Function of the core: separate the stiff outer sheets.
f. Used for roofs, floors, walls of buildings, aerospace, aircraft wings and fuselage. |
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Term
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Definition
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Term
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Definition
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Term
|
Definition
a. Calcium aluminoborosilicate
b. Most commonly used |
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Term
|
Definition
a. Magnesia aluminosilicate
b. High strength
c. High stiffness
d. Higher cost |
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Term
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Definition
a. High-performance
b. Elevation temperature resistance
c. Acid corrosion resistance |
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Term
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Definition
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Term
|
Definition
a. 99% or higher carbon
b. Higher stiffness
c. Conductive |
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Term
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Definition
a. High strength
b. High stiffness
c. Low specific strength
d. Low stiffness |
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Term
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Definition
i. Material placed between two molds.
ii. Shape of a log.
iii. Fiber lengths of 3 to 50 mm.
iv. Sheet-molding compounds may also be used. |
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Term
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Definition
i. Prepregs laid into a mold.
ii. Layup is covered with a plastic bag, which is then vacuumed.
iii. Curing takes place at room temperature of elevated temperature. |
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Term
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Definition
| i. 200-400 kPa pressure applied instead of a vacuum. |
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Term
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Definition
i. Hand layup or spray layup
ii. Slow
iii. High labor costs |
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Term
| e. Resin-transfer molding |
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Definition
| i. Resin is mixed with a catalyst and pumped into a cavity filled with fiber reinforcement. |
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Term
| f. Transfer/Injection molding |
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Definition
i. Automated process
ii. Good surface finish
iii. Dimensional stability
iv. Mechanical properties |
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Term
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Definition
grant of a property right to an inventor, issued by the United States Patent and Trademark Office (USPTO).
a. Right to exclude others from making, using, offering for sale or selling the invention.
b. Patentee must enforce the patent.
c. Invention must be novel, non-obvious and useful.
d. Utility Patents: new and useful process, machine, article of manufacture, composition, or improvement thereof; 20 years.
e. Design patents: new and original ornamental design; 14 years.
f. Plant patents: invents, discovers, or asexually reproduces any distinct and new variety of plant; 20 years. |
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Term
|
Definition
protection to authors of original works, literary, dramatic, musical and artistic works.
a. Extends to written, pictorial, audio, and theatrical works.
b. Does not extend to ideas, processes, and principles.
c. Owner of copyright has exclusive rights to reproduce and prepare derivative works, or authorize others to do so, for sale, lease, rental, and transfer of ownership. |
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Term
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Definition
distinctive mark used to distinguish a product, includes any word, name, symbol or device adopted by a manufacturer or merchant.
a. Provides owner with exclusive right to use the mark.
b. ™ can claim the right regardless of if there is an application with USPTO.
c. ® may be used only after USPTO registers the mark. |
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Term
|
Definition
means of restricting information on formulas, designs, systems or compiled information.
a. Organizations would rather avoid time, expense, and risk involved with patent procedures and safeguard it as trade secret. |
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Term
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Definition
assurance or guarantee that a product will provide a specified level of quality
a. Express warranty: statement regarding satisfactory performance after purchase.
b. Implied warranty (2 types)
i. Warranty of merchantability: an assurance by the seller that goods are fit for their ordinary or intended purpose.
ii. Warranty of fitness: applies when a buyer describes their intended use for a product and then relies on the judgment of the seller to select the appropriate product. |
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Term
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Definition
a. Negligence: the producer has not demonstrated careful design and causes injury.
b. Breach of warranty: similar to breach of contract but includes the manufacturer (breach of express of implied warranty).
c. Strict liability: product is defective and causes harm.
d. Product Defects
i. Design defects
ii. Manufacturing defects
iii. Marketing defects |
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Term
| 51. Rapid prototyping (RP): |
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Definition
a technology that speeds up the iterative product-development process considerably.
a. Why is there a need for RP? Tooling costs are high. |
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Term
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Definition
material removal from a workpiece that is larger than the final part.
i. This process is sped up by:
1. Computer-based drafting
2. Interpretation software
3. Manufacturing software
4. CNC machinery |
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Term
| i. Fused deposition modeling (FDM) |
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Definition
1. Thermoplastic filament is extruded onto an x-y plane.
2. The plane moves down one layer at a time in the z-direction.
3. Extrusion die diameter is 0.05 to 0.12 mm.
4. Weaker support materials may be extruded. |
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Term
| ii. Stereolithography (STL) |
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Definition
1. Curing a liquid photopolymer.
2. Cost of liquid polymer about $300 per gallon.
3. Max part sizes 0.5m x 0.5m x 0.6m. |
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Term
| iii. Multijet/polyjet modeling (MJM) |
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Definition
1. Printheads deposit a photopolymer on a build tray.
2. UV bulbs nearby immediately cure the layers.
3. Layers as thin as 16 micrometers can be created.
4. Max part sizes 0.5m x 0.4m x 0.2m
5. Advantage: thin part layers. |
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Term
| iv. Selective laser sintering (SLS) |
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Definition
1. Sintering metallic powders with a laser.
2. Materials include ABS, PVC, nylon, polyester, polystyrene, epoxy, wax, metal, and ceramic. |
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Term
| v. Electron beam melting (EBM) |
|
Definition
1. Electron beam source is able to melt titanium and cobalt-chrome powder.
2. Must be produced in a vacuum.
3. Limitation: small parts (0.2m x 0.2m x 0.18m)
4. Individual layer thicknesses of 0.05 mm to 0.20 mm.
5. May be developed for stainless steel, aluminum, copper alloys. |
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Term
| vi. Three-dimensional printing (3DP) |
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Definition
1. Printhead deposits inorganic binder onto a layer of polymer, ceramic or metallic powder.
2. Similar to MJM, except 3DP prints a binder onto a powder.
3. Can be done in color.
4. Common metals that are 3DPd are stainless steel, aluminum, titanium.
5. Infiltrating metals include copper and bronze for heat transfer and wear resistance. |
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Term
| vii. Laminated object manufacturing (LOM) |
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Definition
1. Control software is used to cut paper and vinyl sheets.
2. Each sheet has registration holes, and sheets are placed into a build fixture.
3. Economical and popular in schools. |
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Term
|
Definition
i. Purely software form of prototyping.
ii. Advanced graphics and virtual-reality environments. |
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Term
| e. Direct Manufacturing and Rapid Tooling |
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Definition
i. Limitations include:
1. Raw material costs are high, and production speed is relatively slow.
2. Properties of parts are not as consistent as that of traditionally-manufactured parts, especially fatigue, wear, and life cycle. |
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Term
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Definition
| direct production of metal, ceramic, and polymer components by rapid prototyping. |
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Term
|
Definition
production of tooling and patterns by rapid prototyping for use in manufacturing.
i. Investment casting patterns
ii. Room-temperature vulcanizing
iii. Acetal clear epoxy solid (ACES) injection molding
iv. Sprayed-metal tooling
v. Keltool process
1. Tool envelope size 150 mm x 150 mm x 150 mm.
2. Mold life can range from 100,000 to 10 million parts. |
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Term
| 52. Material Removal Process |
|
Definition
a. Machining: material removal by a sharp cutting tool (turning, milling, or drilling).
i. Advantages of Machining
1. Variety of work materials can be machined.
2. Variety of part shapes and special geometric features possible, such as:
a. Screw threads
b. Accurate round holes
c. Very straight edges and surfaces
3. Good dimensional accuracy and surface finish.
ii. Disadvantages of Machining
1. Waste material
2. Time consuming |
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Term
|
Definition
| material removal by hard, abrasive particles (grinding). |
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Term
| c. Nontraditional processes: |
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Definition
| various energy forms other than sharp cutting tool to remove material. |
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Term
|
Definition
single point cutting tool removes material from a rotating workpiece to form a cylindrical shape.
i. Performed on a machine tool called a lathe.
ii. Performed on the outside diameter of an existing cylinder.
iii. Variations of turning performed on a lathe:
1. Facing
2. Contour turning
3. Chamfering
4. Cutoff
5. Threading |
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Term
|
Definition
used to create a round role, usually by means of a rotating tool with two cutting edges.
i. Compare to boring which can only enlarge an existing hole.
ii. Cutting tool is called a drill or drill bit.
iii. Machine tool: drill press. |
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Term
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Definition
machining operation in which work is fed past a rotating tool with multiple cutting edges.
i. Axis of tool rotation is perpendicular to feed.
ii. Creates a planar surface.
iii. Peripheral milling
1. Cutter axis parallel to surface being machined.
2. Cutting edges on outside periphery of cutter. |
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Term
|
Definition
1. Cutter axis perpendicular to surface being milled.
2. Cutting edges on both the end and outside periphery of the cutter. |
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Term
|
Definition
1. Maximum chip thickness at end of cut.
2. Leaves a smooth surface.
3. Tendency for tool to chatter.
4. Proper holding of workpiece is important. |
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Term
|
Definition
1. Cutting starts at thickest location on chip.
2. Downward component of cutting force holds workpiece in place.
3. Rigid clamping is necessary.
4. Not suitable for parts with surface scale.
5. May cause excessive wear on cutter teeth.
6. Good for finishing cuts on aluminum pieces. |
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Term
| 53. The Merchant Equation: |
|
Definition
of all the possible angles at which shear can occur, the material selects a shear plane angle, , that minimizes energy.
a. To increase shear plane angle:
i. Increase the rake angle.
ii. Reduce the friction angle. |
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Term
|
Definition
|
|
Term
|
Definition
a. Approximately 98% of the energy in machining is converted into heat.
b. This can cause temperatures to be very high at the tool-chip.
c. The remaining energy is retained as elastic energy in the chip. |
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Term
| 56. High Cutting Temperatures |
|
Definition
a. Reduce tool life.
b. Produce hot chips that pose safety hazards to the machine operator.
c. Can cause inaccuracies in part dimensions due to thermal expansion of work material. |
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Term
| 57. Determining Cutting Temperature |
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Definition
| where T is the measured tool-chip interface temperature and v is the cutting speed. |
|
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Term
|
Definition
| a. Performed on the inside diameter of an existing hole. |
|
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Term
| 59. Material removal rate (MRR) |
|
Definition
a. Units: m3*min-1
MRR=V*f*d where v is the cutting speed, f is the feed, and d is the depth of the cut. |
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Term
|
Definition
removes large amounts of material
a. Leaves material for finish cutting.
b. High feeds and depths, low speeds. |
|
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Term
|
Definition
completes part geometry.
a. Final dimensions, tolerances, and finish.
b. Low feeds and depths, high cutting speeds. |
|
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Term
|
Definition
| used to slightly enlarge a hole, provide better tolerance on diameter, and improve surface finish. |
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Term
| 63. High Speed Machining (HSM) |
|
Definition
a. Cutting at speeds higher than those used in conventional machining operations.
b. Interest in HSM due to potential for faster production rates, shorter lead times, and reduced costs. |
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Term
|
Definition
a. Ratio of horsepower to maximum spindle speed.
b. Conventional machine tools have a higher hp/rpm ratio than HSM.
c. Dividing line is around 0.005 hp/rpm.
d. HSM includes 15 hp spindles that can rotate at 30,000 rpm (0.0005 hp/rpm). |
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Term
|
Definition
a. Special bearing designed for high rpm.
b. High feed rate capability.
c. CNC motion controls with “look-ahead” features to avoid “undershooting” or “overshooting” tool path.
d. Balanced cutting tools, tool-holders, and spindles to minimize vibration.
e. Coolant delivery systems that provide higher pressures than conventional machining.
f. Chip control and removal systems to cope with much larger metal removal rates. |
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Term
|
Definition
a. Aircraft industry, machining of large airframe components from large aluminum blocks.
b. Multiple machining operations on aluminum to produce automotive, computer, and medical components.
c. Die and mold industry. |
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Term
|
Definition
a. Material removal by action of hard, abrasive particles in a bonded wheel.
b. Finishing operations after part geometry has been established.
c. Grinding, honing lapping, super-finishing, polishing, and buffing.
d. Used on all types of materials.
e. Extremely fine surface finishes, up to 0.025 micrometers.
f. Dimensions held to extremely close tolerances. |
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