Term
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Definition
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Term
| Concepts for manufacturing design |
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Definition
| Keep it simple; design it to work; least possible machining; design for maintenance |
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Term
| What is relevant about the Cluster Mill story? |
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Definition
| Dr. W's childhood Rugby story: Scrum is when players huddle after a foul. Small guy hanging in middle is the hooker. |
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Term
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Definition
| Temperature is under that when metal glows. Nice surface finish. Brittle. In class example: Cold Rolled Steel Bar; more $$ than hot rolled |
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Term
| Define Hot Rolled. What is unique about hot rolled steel? |
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Definition
| Metal is glowing hot. With steel, black oxide forms. In class example: Hot Rolled Steel Plate w/ Black oxide |
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Term
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Definition
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Term
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Definition
| Shapes are build into the rollers. These rollers compress the cross-section of metal bars into the shape of the rollers. |
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Term
| What are the two methods of creating threads? |
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Definition
| Thread cutting and thread rolling |
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Term
| What is the difference between cut threads and rolled threads? |
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Definition
Machine Threading - Neat, Accurate, Precise, weaker
Rolled Threading - Strong, tip of threads is at a larger diameter
Perfect Bolt - Roll First, then Cut |
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Term
| How can you tell the difference between a cut thread and rolled thread? |
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Definition
| Cut Threads are the same diameter as the shank while Rolled Threads are bigger at the ends. Possibly can see tool withdrawal on cut threads. |
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Term
| How does cold welding occur in rolling and what defect this can lead to? What standard does American Steel use to prevent such defects? |
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Definition
| End of roller will pinch material together not sealing the middle. Alligatoring can occur. Cut 3 feet off the end of rolled material. |
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Term
| What is the toothpaste tube process? |
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Definition
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Term
| What was the idea behind the story about the teacher who was a sailing enthusiast? What does tacking mean? What did he create? |
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Definition
| Tacking - sailing diagonally which allows a sail boat to sail into the wind. The professor used an in-class example, the turbine blade, to create a windmill sail boat design. Although it worked, it was top heavy and unsafe. |
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Term
| Define Hot Extrusion. What changes are made to the normal extruding equipment when using steel? |
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Definition
| Is when the material is glowing hot. Must increase the entrance angle into die. Also must use lubrication, such as molten glass because oil will ignite. |
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Term
| What is a spider mandrel? |
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Definition
| The center of the die has an obstruction connected by small fin-like shapes. The mandrel creates a hole in an extrusion's cross section. |
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Term
| Why are spider mandrels not used anymore? |
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Definition
| Can attach a mandrel to the front of the piston pushing through the die. |
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Term
| From the Ipad story, what animal uses tacking in Florida? |
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Definition
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Term
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Definition
| Strips the steel of black oxide by using an acid that eats away at it |
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Term
| What type of objects does Cold Extrusion create? |
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Definition
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Term
| What idea was behind the story of little kids jumping in puddles? |
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Definition
| Impact Extrusion; external constraints are removed |
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Term
| What was unique about old metal toothpaste containers? |
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Definition
| When they were rolled, they would stay rolled. |
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Term
| What is the difference between deep drawing and cold impact extrusion? |
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Definition
| There are constraints around the material in deep drawing which act to guide the metal; used often on aluminum |
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Term
| Explain the concepts of the Sled dog commercial. |
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Definition
| FWD vs. RWD. Tried to show that FWD was much more effective. The story was told as an example when explaining drawing wire from the front vs. extruding from the rear. |
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Term
| What is the difference between drawing and extrusion? |
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Definition
| Drawing pulls from the front after a small amount is pushed out while extrusion pushes from the back |
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Term
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Definition
| No, the piston is typically moving slightly. |
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Term
| What was relevant about the examples of the Camping Lantern and Windshield Wiper Blade? |
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Definition
| Constructed using sheet metal |
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Term
| What did the in-class example of a socket show? |
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Definition
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Term
| Outline the Rotary Swaging Process. |
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Definition
| Initially, an open die forge may create the doughnut shape. Next, a mandrel (made from heavy duty metal) presses in a doughnut shape against a mandrel to create hex and square shapes. Swaging is used for things that require symmetry all the way around; uses red hot metal; is an offshoot of forging. The workpiece and compressing mechanism do not rotate in swaging, just the cam system. |
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Term
| What is the missing link between Forging and Rolling? |
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Definition
| Roll-Forging. Don't eff this up. Roll-Forging. It makes a single discrete part. |
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Term
| What process allows you to create perfect metal spheres easily? |
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Definition
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Term
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Definition
| A ram impacts a blank and folds it up along the edges of the ram. |
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Term
| What is drawing mainly used to create? |
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Definition
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Term
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Definition
| the area where a blade penetrates metal; shiny |
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Term
| How to get a clean surface finish from a shearing process? |
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Definition
| Use a shaving blade on top of the shearing blade |
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Term
| Define perforating and explain how it is different from punching. |
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Definition
| Perforating is where the holes are aligned in a military fashion. Usually there are more than three. Punching is when a single hole is punched. |
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Term
| Explain the difference between blanking and punching. |
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Definition
| Blanking is when the piece being cut out is used (keeping the blank) while in punching, the metal separated by the punch is removed and later recycled |
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Term
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Definition
| cutting out a piece of sheet metal from the edge |
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Term
| Lancing, and a reason to use this process |
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Definition
| cutting on the outer edge of the sheet without removing a section; This could be used to create a tab. The slit intersects the edge of the metal. |
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Term
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Definition
| Cutting into a part of the sheet without cutting a section out. |
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Term
| How would a washer be made? |
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Definition
| Punching out small center hole, then blanking out larger hole |
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Term
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Definition
| A machine used to bend and shear metal |
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Term
| What post process will strengthen a piece of bent sheet metal |
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Definition
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Term
| Why do you have to over bend a piece of sheet metal to achieve the desired degree of bend? |
|
Definition
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Term
| What are the strengths and weaknesses of the 4 types of bends. |
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Definition
- Plain (no bend) - Not safe, not stiff
- Flange - Not safe, stiff
- Hem - Safe, Not stiff
- Bead - Safe, Stiff
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Term
| What principle was behind the seamless gutter story? |
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Definition
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Term
| How do you stop a sheet metal tube from collapsing while bending? |
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Definition
| One way is to insert a tightly wound spring e.g. plumber's spring. For DIY projects, use sand. In instrument making, pour bismuth into pipe and let the molten bismuth solidify, bend the tube, then reheat the bismuth and pour out. |
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Term
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Definition
| Increasing the internal diameter of the tube at a local spot |
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Term
| How is a bellows formed and how does it work? |
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Definition
| Bellows (think of fire starter used fan a flame) formed with a 2 piece die. Insert a tube and add rubber and apply force. The rubber will expand the tube. Remove the rubber and tube, then apply force onto the bent tube to produce the creases. |
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Term
| What are the differences between embossing and coining? |
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Definition
| In embossing there a positive side and a negative side, with only one image on the product. In coining, there are two different images that are pushed out. |
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Term
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Definition
| a secondary process which squeezes the sides of a can, moving them up and creating a smooth surface; makes the wall thickness thinner and makes the can taller. |
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Term
| What is the object that holds the blank in forming a can? |
|
Definition
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Term
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Definition
- Create a blank out of sheet metal
- Deep drawing to make a cup
- Ironing & Doming - elongates the sides of the can and makes a dome-like bottom
- Pinch rollers, to remove the earing
- Add waves in the can with bulging
- Deep draw a flange on the top of the can (for the pop top)
- Blank and deep draw a lid
- Roll form the lid and can body together
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Term
| What is an earing in the can formation process and what does it signify? |
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Definition
| wavy pattern at the top of the can before ironing; shows that the previous processes were done correctly. |
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Term
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Definition
| used to make a disk into a circular shape; Imagine a basket being created from a disk. A heavy-duty wiper pushes the fast-spinning disk into the basket shape. The wall thickness does not change; creates horizontal scratches on metal |
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Term
| Define Stretch forming and what is the common use discussed in class? What is the major problem and how is it solved? |
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Definition
| when a piece of sheet metal is stretched over a frame; reduces wrinkles; creates residual tensile stresses; Use peen forming to change tensile stresses to condensed stresses. |
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Term
| Why are residual tensile stresses so severe? |
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Definition
| The material is already pulling itself apart and will therefore worsen even a minor crack. |
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Term
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Definition
| bombarding sheet metal with small metal balls to compress the sheet metal; creates residual compressive stresses. Think of a peen hammer. |
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Term
| Define Explosive Forming. What example was used in class? |
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Definition
| A bomb explodes near sheet metal placed beneath a cast. The explosion pushes the sheet metal into the cast; usually done under water; The top part of a tank is made with this method. |
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Term
| What is the advantage of powder metallurgy with respect to titanium? |
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Definition
| can form titanium without melting |
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Term
| Outline Powder Metallurgy. |
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Definition
- Place loose metal powder into a die
- Compress powder into a green state object
- Take green state object and place into a sintering oven to bake
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Term
| What are the three factors occurring in the Sintering process? |
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Definition
| Temperature, Time, and Atmosphere - usually use a temperature that is half of the MP |
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Term
| What are the advantages and disadvantages of Powder Metallurgy? |
|
Definition
Advantages
1. Little Waste
2. Forged-Like Strength
3. Good for Refractory Metals
4. Good for refractory metals - no melting
5. Allows mixing and distributing of powders
6. Impregnation for oiled bearings
7. Porosity Control for filters and varying density
Disadvantages
1. Expensive Dies
2. Expensive Powders |
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Term
| Describe the Impregnation Process |
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Definition
| Create a strong, porous component then use a vacuum to remove air from pores. Use a syringe to insert oil. Well suited for creating bronze bearings. |
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Term
| Explain the story about the Artisan. What processes were used to create the plate mural? |
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Definition
| Look at the notes. (90) [Explosive forming] |
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Term
| Graphite is a form of ________. What are the properties of Graphite? |
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Definition
Carbon
Strong in one direction, weak in the other. (Atomically, graphite is like a pile of sheets, which allow slip and shear along the plane.)
Conducts Electricity.
Will ignite under high temperatures
Easy to Machine
Low Friction Lubricant |
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Term
| What are some uses of graphite? What is the primary application of graphite and how do its properties play a crucial role? |
|
Definition
Boats use carbon fiber because it grounds electrical components.
Tennis rackets and golf clubs integrate graphite in their construction.
The primary application: Electric motor brushes. These need to have low friction, without liquid lubricants, while still conducting electricity. |
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Term
| What are the material properties of ceramics? |
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Definition
| typically porous; electrically insulating; refractory material; poor machinability; prone to thermal shock |
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Term
| Why aren't jet engines made from ceramics? |
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Definition
| Although they can withstand high temperatures, they have a poor thermal shock property which causes cracks and shattering from the many temperature changes. A much better use is in power turbines which run for months at a time. |
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Term
| What is the process to make a ceramic? |
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Definition
- Mix clay with water to create slip.
- Form the desired shape.
- Put in a kiln to fire it and harden it.
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Term
| Property of deflocculants. |
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Definition
| Allow particles to evenly distribute; used to make turbine blades out of ceramics |
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Term
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Definition
| Glaze is painted on clay before firing. After firing, a glass-like exterior is produced on the ceramic. |
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Term
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Definition
| Crushing solids, taking big grains and making them smaller. |
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Term
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Definition
| Put slip into a die and spin so that slip will stick to walls. Dry and fire the part. |
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Term
| What are the properties of Glass? |
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Definition
1. Electrical Insulator - Air improves this property.
2. Elevated Temperatures - Higher than graphite, less than ceramics
3. Poor Machinability
4. Optical Properties
5. Poor Thermal Shock |
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Term
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Definition
| See through, Shatterproof, and Scratchproof. Sodium ions are removed from normal glass and are replaced with potassium ions. |
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Term
| What is an interesting property of molten glass? |
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Definition
| Can be pulled into the air from a pool due to viscosity |
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Term
| How do you form a high quality piece of glass? |
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Definition
| use the Float Glass process; usually use molten tin; Pour molten glass on top of tin and it will evenly distribute over the tin and float. The other material must have a higher density, lower melting point, and be chemically inert: non-wetting and non-reactive |
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Term
| A difference between nonwetting and wetting surfaces? |
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Definition
| Nonwetting has a high surface tension. Wetting has a low surface tension. |
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Term
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Definition
| Old-style insulation was made from newspaper, which was flammable, soaked up water, animals nest in it, loses fluffiness. Nowadays, glass fiber is used, which is made by a cotton candy process, or blowing steam over molten glass. |
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Term
| What is a possible solution to plastic bottles and the plastic island in the Pacific? |
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Definition
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Term
|
Definition
| Caused by spinning; creates a pure parabolic shape |
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Term
| What does Manu Factus mean? What does the definition mean today? |
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Definition
| Made by Hand; Fabrication |
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|
Term
| Name the most recent three ages. |
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Definition
| Computer, Information, Mobile/Wireless |
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Term
| What were the first computers made for? |
|
Definition
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|
Term
| What are the effects of war on technology? |
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Definition
| Better machines determine who wins a war. Armed conflicts push manufacturing technology further. |
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Term
| What happens to the time lengths of the ages as time goes on? |
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Definition
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Term
| What story showed design for maintainability. Which car had the better system, which has the worst system, and why? |
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Definition
| Oil Change story; The BMW had the best system where the oil was pumped up into the upside down filter. The MR2 needed a special tool to get to the filter. |
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Term
| Two important factors in design |
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Definition
| Design it to work and so it is easy to make. |
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Term
| Universities teach in ___________. |
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Definition
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|
Term
| What has one of the highest thermal expansion coefficients? |
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Definition
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Term
|
Definition
| Students wanted beautiful linkages with rounded edges. The rounded edges served no functional purpose and added unnecessary labor to their projects. Square linkages could be made quickly and with little effort, thus are preferred. |
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Term
| What are some important concepts in manufacturing? |
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Definition
| Material Selection & Design |
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Term
| Define Ferrous, Non-Ferrous, Thermoplastics, Thermosets, and Elastomers. |
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Definition
Ferrous: Contain much iron
Non-Ferrous: No iron content
Thermoplastics: Melt down; reusable
Thermosets: Can't reuse; common in electrical components
Elastomers: Can experience large amount of stress before fracturing |
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Term
Explain the differences in car production materials from the past and today:
drop in cast iron - rise in Aluminum - drop in copper |
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Definition
| engine block was changed from cast iron to aluminum; radiators aren't made from copper anymore |
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Term
| If a material conducts thermally what will it do 99% of the time. What is an exception? |
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Definition
| Conduct Electrically. Diamond will not conduct electrically but is good at conducting thermally. |
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Term
| What are the properties of titanium? |
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Definition
| elastic, bio-inert (ideal for hip replacements), good corrosion resistance, best strength-to-weight ratio, expensive, highly reactive when molten, not good for casting; welding & casting requires vacuum |
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Term
| Explain Open Die Forging. What is its main use? |
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Definition
keep hitting a heated ingot to form a stock material; turns a cast structure into a wrought structure; used to make long beams for building material.
"Mechanized Blacksmith"
Metal must be kept red hot. |
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Term
| Explain Closed Die Forging. What kind of parts does it make? |
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Definition
| makes discrete components; cannot be used for passageways; parts are pressed, not hammered; uses hot, wrought metal; The die and press are one machine. |
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Term
|
Definition
This takes the place of closed die forging yet acts as open die forging; has removable/replaceable dies; does not produce internal passageways; can punch a hole in the same direction as press moves
[See video] |
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Term
| Difference between piercing and punching? |
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Definition
| Piercing cuts through a surface but not all the way through. Punching cuts completely through. |
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Term
| What is the best and strongest grain structure that can be achieved in a component? |
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Definition
| Grains small and aligned in one direction, parallel to the material boundaries |
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Term
| Ingots are cast structures with which grain structure? |
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Definition
| Large and random; relatively weaker material |
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Term
| When molten, metal becomes _______. |
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Definition
|
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Term
|
Definition
| Used in impression die forging, these allow extra metal to flow in in order to create an accurately dimensioned component. |
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Term
| Why is a crankshaft forged? |
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Definition
| must be strong or the rod will snap and destroy the engine |
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Term
| What are the three defects of forging? |
|
Definition
- Not enough metal
- Not hot enough (cracks develop)
- Moving too much metal too fast
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Term
|
Definition
Ag (Argentum)
In a way, an opposite of titanium: Not good for organisms (biocide) - the myth of silver bullets killing werewolves; used for older plateware; most electrically and thermally conductive metal; mixed with epoxy to make conductive adhesives; good for plumbing |
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Term
|
Definition
Cu (Cuprum)
Like silver, not good with organisms (biocide); used on boat bottoms to prevent barnacle growth;
excellent electrical/thermal conductivity |
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Term
|
Definition
Pb (Plumbum)
platinum and gold are heavier, but lead heavier than titanium
slightly higher MP than tin
corrosion resistant, low strength, high density fishing weights, TOXIC
mixed w/antimony so bullets dont stick to barrel |
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Term
|
Definition
1. Expedition from England to US along the Northwest Passage - Sailors stored all their food in lead cans, got stuck in icy waters for 3 winters, ate all the food, then had to abandon ship. People started migrating south and all died. At first, they were thought killed from cold but really from lead poisoning. Everyone went crazy, got lost, couldn’t get back home.
2. Hunters shoot birds w/lead bullets. When they miss, birds would eat fallen bullets/shot to help grind up their food. They eventually die from lead poisoning. |
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Term
| Lead bullet alternative (shot) |
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Definition
| Iron was attempted but it messed up barrel; tried tungsten w/ other metals called “Hevi shot” made from tungsten, copper, tin. Bismuth is also an alternative but very expensive. As an aside, bismuth is an ingredient of Pepto Bismol. |
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Term
|
Definition
| Service Merchandise tested diamonds with a probe for authenticity. Thermally conductive? Yes. Electrically conductive? No. |
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Term
| What is the best way to create a bolt? How do the grain structures look using this process? |
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Definition
| Orbital Forging. Looks like a winding circle from the top of the head of the bolt. |
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Term
|
Definition
| used in orbital forging, it is like kneading dough; push down while rotating; presses on an edge and wobbles on a point and the face orientation never changes. The spiraling grain structure is one feature of a grade 8 bolt. |
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Term
|
Definition
| raw material (ore) -> refinery -> shaping into pipes, beams wire mesh -> stock material |
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|
Term
| metal processes overview (8) |
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Definition
| casting, forging, rolling, extrusion, PM, machining, fabricating, RP |
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Term
| Metal Casting Process pro/con |
|
Definition
good for organic shapes, internal passages, non-symmetric, curved surfaces
bad material properties: air bubble, very large grainsweak structure, slow operation, wasteful in material, defects |
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Term
|
Definition
1. Melt metal in furnace
2. pour into mold cavity
3. cool and solidify
4. Finishing |
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Term
|
Definition
| Power line man tool used to help change out the transformer failed due to manufacture. Had to slightly change design so that it could hook all the way over the line |
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Term
| Non-ferrous Casting Metals |
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Definition
| tin, lead, zinc, magnesium, aluminum, copper, nickel+cobalt, titanium |
|
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Term
|
Definition
low melting pt, corrosion resistant for food cans, non-toxic, low strength
used with other metals alloyed with Sb&Cu for pewter (plate were cast) |
|
|
Term
|
Definition
|
|
Term
|
Definition
moderate MP, corrosive, flows well when molten, nontoxic, more bluish color tin
used for cheap casting
#1 galvinized steel-chain link fence-zinc will corrode 1st sacrificial anode
#2 casting bc good surface tension |
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Term
|
Definition
Rod used when working on battery
Pulley wheel not very strong |
|
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Term
|
Definition
| Got a tree trimmer for Christmas made from pvc pipe and cast zinc. before he cut one tree the little cast trigger part broke. |
|
|
Term
| How did he describe the Rough Surface of the Craftsman Wrench? |
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Definition
| Cornflakes in Putty. Metal is the putty, Black oxide is the cornflakes. |
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Term
|
Definition
Mg
good strength:weight ratio like titanium, corrosive-don’t use in water, burns easily, expensive, high melting point |
|
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Term
|
Definition
| a firestarter with Mg shaving on one end and steel strike on the other side for a spark and Ford Focus mag wheels |
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Term
|
Definition
Al
higher MP, descent products that last, good conductivity, lightweight, moderate strength, and good substitutes for magnesium
not good for military; Bradely infantry fighting vehicle would burn very easily if shot or attacked. |
|
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Term
|
Definition
peice of stock aluminum
cast fan blade |
|
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Term
|
Definition
Cu
high melting pt, corrosion resistant, TOXIC to marine & microbes
Bronze (copper&sn) alloys:for bearings
Brass (copper& zinc) alloys easily machined, malleable |
|
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Term
|
Definition
bus bar for electrical systems. pure copper used for electrical/thermal conductivity
Goldish color copper alloy-cast valve for gas/water
Bronze alloy: slightly pinker than copper, wheel |
|
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Term
|
Definition
Ni & Co
MAGNETIC PROPERTIES, high temperature
used for gas turbine blades, military application |
|
|
Term
|
Definition
| MAGNETIC PROPERTIES: used to protect electronics from EM waves. Used wire mesh to reduce EMW aka Swedish soft iron cage. Highest magnetic permebility |
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Term
|
Definition
Very hard to cast because of high melting point and rapid oxidization when melted.
- Molybdenum (Mo)
- Niobium (Nb)
- Tungsten (W)
- Tantalum (Ta)
- Rhenium (Re)
Common in rocket engine parts; a mnemonic for remembering these five elements: The chemical symbol letters rearrange to spell "brown meat". |
|
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Term
|
Definition
| Cadmium, Berillium, Antimony, Lead |
|
|
Term
|
Definition
| Rarely used in natural form, this is mostly mixed with steel. Dr. Crane acquired some during his research with NASA. |
|
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Term
|
Definition
| Cupola, crucible, coverter |
|
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Term
|
Definition
| spinning adds heat while scrap metal falls to the bottom. Uses melted metal, heated through induction |
|
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Term
|
Definition
| contains a tuyere: a tube that carries oxygen/air into furnace |
|
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Term
|
Definition
| Castle in England (warwirk) was like a museum full of armor suits. But they were all tiny suits, which designers (blacksmiths) used to show customers (kings queens) different styles. All suits had little labels next to each piece. |
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Term
|
Definition
Red Anvil- no sharp edges rough walls, granular finish
3 legged black base, inexpensive & heavy
blue pillar block (steel) holds bearing, finished to sit flat |
|
|
Term
| Why use sand in Sand Casting? Pro/Con |
|
Definition
| Advantages: cheap & available, high resistance to temp, reuseable, supports heavy loads, easily conforms to complex shapes, collapses to allow for shrinkage, permeable to steam and gases formed when metal cools. Sand absorps gases when hot, and allows escape when cooling Disadvantages: heavy molds, lots of sand, time consuming and not permanent |
|
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Term
|
Definition
| Fine sand leads to high strength, good finish; Course sand results in better permeability & collapsibility |
|
|
Term
|
Definition
- silica (SiO2) like Clearwater beach - retains heat
- Manmade sand: zircon (good thermal cond), chromite, olivine
- Bank Sand 20% clay-naturally bonded, good to hold sand together (like river bank)
- Synthetic/Sharp Sand- washed bank sand allows clay to be added precisely
Mulling Machines: used to mix sand, clay binder, and cereal for diffusing moisture |
|
|
Term
|
Definition
Green (moist not color reference) Sand Molds
Skin Dried molds
Dry sand molds
Cold Cure molds |
|
|
Term
|
Definition
• most common, cheap, reusable, good collapsability
• mix of sand, clay, water |
|
|
Term
|
Definition
• skin/surface dried 0.5” by torch or air
• greater strength for larger castings
• slower operation due to dring times |
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• oven dried/baked
• stronger, better dim accuracy
• poor collapsibility (hot tearing)
• slow and expensive |
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• Sand grains chemically bonded by using additives: linseed oil
• Greater strength/ very accurate
• Expensive + not reusable |
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| (Molding box) consist of Cope(top), Drag (bottom), turnover board |
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| can be made from any material. used to be wood, now plastic RP. Usually bigger than needed since metal will shrink unevenly when cooling. Thermo software used to predict shrinkage |
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Sprue - Vertical passage to pour metal
Riser- vertical passage to see when full
o made with sticks placed in sand
o STORY: Pieces of metal from leftover riser look like Russian troller-fishing vessel |
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| Horizontal passage from pattern to sprue |
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Definition
| allow metal to run thru different routes so it cools evenly |
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-(like blind hole, riser that doesn’t go all the way thru)
o used to trap slag (black oxide)-product of high temp reaction in ceramics. can cause cracks, very light so will float into blind riser |
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Definition
good for hollow pipe w/flanges
very slow process, esp for engines, req mult assem lines |
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Definition
split patterns
used to position each half of the pattern to line up
has latches on each end |
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Definition
| used to fill space when casting, ie the hollow part of the pipe, made of clay & meant to be discarded |
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| added to pattern to hold core in place |
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holds up an unsupported core
usually made out of same material as the molded part |
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1. Mechanical drawing of part
2. make cope+drag pattern plate w/core prints
3. make core box to mold core
4. paste core halves together
5. put flask on top cope pattern then ram w/sand (same for drag
6. place core in drag then cope on top |
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Term
| 3 Casting Defect Properties |
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Definition
o dangerous-when someone dies
o annoying-when superficial
o costly-when have to be recast |
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Term
| Blow, scar, blister, scab |
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Definition
Casting Defects
cavities on the surface due to lack of breathability
temp change causes gases/bubles/steam
can use wire in problem area s to create an escape channel in sand
not good looking |
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Casting Defect
extra piece of metal due to sand erosion- very expensive
Cure: make sure there are no areas where metal runs fast |
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Definition
Casting Defect
not enough gates, metal cools b4 filling entire mold.
Cure: having extra runners to help cover more area more quickly |
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Definition
| Casting Defect interface where 2 metals oxidize and do not blend. find w/NDT (dye penetrant) Can Kill! |
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| casted pump from nasa w/ internal scab that could not escape. Had to use xray to detect |
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: Shrinkage defect (hot tear) things tend to shrink towards thicker parts of mold. Old steam engines in England had curvy spokes on the wheels. Fix w/ artificial cooling using a chill
expensive lathe for VA hospital full of putty holes to repair defective casting. “annoying” bc kept drilling for a place to mount new digital readout |
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| Casting Defect Example of a wash? |
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Definition
| HUGE Valve: Brass(copper alloy) corrosion resistant and biocideresists microbes, has granular finish and a cope/drag seam |
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Term
| In order to be able to cast, what is required to be designed first? |
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Definition
| o Requires overhead conveyors, chains, pulleys |
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Definition
| -high thermal conductivity metal used to assist in cooling |
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Definition
solve weight problems with sand casting
• Advantages:
o Shells cool rapidly + allow gases to escape
o Only 5% sand used
o High quality surface finish
o Easily automated , light weight mold
• Disadvantages
o Resin binding expensive, limited size shell
o High cost pattern
o No complex cores
o Not good for passage ways |
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Definition
o Uses a split pattern, material choice is important
1. Zircon sand bc high thermal conductivity mixed w/resin(thermosetting plastic
2. Metal pattern from steel or aluminum
3. Pattern clamped to a box
4. Sand/resin mix blown over pattern in even coat
5. Pattern is heated to cure resin in a shell
6. Cools down then removed from box
7. 2 shells are clamped together then surrounded by shot for support
8. Molten metal poured into shells
9. After cool shell is broken away to reveal casting |
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Term
| Investment Casting literal meaning |
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Definition
| to go in, to dip into something “lost wax process” |
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Term
| 2 investment casting stories |
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Definition
Hawaii trip to jewelry manufacturer & saw gold jewelry being made
power station built in 1920 from brick. Newspaper report incident where turbine shed a blade that went thru 3ft thick walls & landed 2miles away. |
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| 4 investment casting examples |
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Definition
Turbine Blade- tiny holes on edge are aerodynamic and re-energize the boundary layer
Previous nasa pump not made thru sand casting, but actually investment casting w/ smooth brown wax mold
pink wax mold very brittle. Hot tear thin flat plate w. thick nob has a chill wire in it
green wax w/ ceramic core to make passages thru turbine blade |
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| Investment casting Pro/con |
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Definition
o Good for dovetail shapes bc mold is flexible, making tubine blades,jewelry bc good detail + surface finish, small parts, high meting pt metals, higher production rates using tree
o Bad: expensive, time consuming, not for intricate internal passagways, refractory sludge not reusable |
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Definition
| o Used for making turbine blades, v-8 engine blocks, 4 cyc engine Saturn cars(w/foam in process) |
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Definition
like sand casting but no packing, slurry poured over pattern
2 types: Plaster and Ceramic |
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| Plaster mold casting Pro/con |
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Definition
uses plaster of paris
Good: surface details, slow cooling allows thin walls
Bad: mold is destroyed @1200C not for steel/iron/ferrous material, refractory sludge not reusable, wood pattern would cause swelling from moistur, less than 10kg components |
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| Ceramic Mold Casting pro/con |
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Definition
uses refractory slurry of zircon/alumina/fused silica
Good: stainless steels, up to 700 kg
Bad: lack of breathability |
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Definition
concept not process
o Split mold made from steel or graphite can last longer
o Can use sand cores
o Mold cannot collapse so pressurizing (requires pneumatic hydraulic cylinder) the molten metal prevents shrinkage/hot tears also continue to add metal as it shrinks
o Internal surface coated w/refractory slurry
o Mechanical ejector pins (leave evidence small round impressions
o Good: large production runs
o Bad: high cost molds, intricate shapes not posibble bc split mold, no breathability |
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Term
| Die Casting-Metal Injection Molding [MIM] |
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Definition
o More sophisticated method than simple sand casting
o Cold Chamber-molten metal poured by hand w/ ladel (not submerged)then pushed w/ injection plunger
Higher pressure than hot chamber
o Hot Chamber-molten metal is submerged then injection plunger uses tunnels to fill die
o Came from permanent mold casting but w. extreme pressures
o Uses complex multi part molds:draft angles, retracting cores, extractor pins
o Alloys mold in place pins, screws, threaded inserts (like stick in popsicle)
o Holes smaller than 1/8” should not be tapped but rather used threaded inserts |
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Definition
die cast 35-mm camera now made from carbon fiber
lawn mower housing (very big for die casting) now made from pressed sheet metal |
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Definition
| UF professor Dr. Duffy had a fly mower (no wheels) going up a hill created a hinge and cut off knee caps |
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| Forensics in Mechanical Engineering |
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Definition
o Ex: pulley wheel: nice surface finishinvestment casting???
Lil circular indentations DEFINITELY from die cast injector pins
o EX: Test Tube holder: injector pins die cast
Not ideal for die cast, but $$$ markup off sets production cost
o Ex: Pump head from pressure washer:very big for die casting
Injector pin marks found by motor mounts |
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Definition
not used much bc we use pvc now
o Spin molten metal to make hollow pipes-spinning helps cool
o Tekcast-looking to mold water pump propellers
Good :could make up tp 4k b4 needing new mold
o Boeing replaced forging w/titanium casting |
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Definition
| molten metal poured on steel cast then excess is poured at at 5s, then 1, 2, 6 min |
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Definition
brass ornamental/decorative bedside lamp
Lightweight organic shape, not concerned w/inside (hollow) |
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Definition
| -“the missing link btw casting/forging |
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Definition
| Melt metal, then pour into die, close die w/pressure, eject squeeze casting leaving a "shell" |
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| Why is sand in metal bad? |
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Definition
1. Dulls tools
2. Weakens metal |
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Definition
| Easily turned into powder (crumble) |
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When a thinner area cools quicker than a thicker area and the thin spot tears.
Ex. Water spicket nob |
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| Investment Casting Process |
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Definition
1. Make pattern
2. Place patterns into silicone rubber mold then add more silicone on top then let it solidify
3. Pull apart both halves and remove pattern
4. Pour melted wax into silicone mold box
5. Remove wax pattern from silicone mold and continue to reuse the mold
6. Place multiple wax patter on wax tree
7. Dip wax tree into liquid stucco numerous times
8. Place stuccoed wax tree into oven to heat up and melt wax inside, wax can be reused
9. Turn stucco mold upside down with opening on top and pour molten metal into mold
10. After metal dries, brak stucco and remove final product |
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Term
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Definition
1. Piston for pressure to insert metal
2. A gas release
3. Valve to maintain pressure for gas release
4. Cooling coils to speed up cooling process
5. Ejector pins to get product out (you get marks on the final product bc the pins push on the warm soft metal)
6. Removable cores - core slides (hydraulic)
7. Big ole piston press to keep the mold from coming apart because of the pressure |
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| Raw material processed into usable products (bars, rails, pipes) |
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Substitute for calcium when ingested.
Ex. Old ppl were eating the fish in the sea and were ingesting cadmium and their bones were becoming brittle.
Ex. In old batteries |
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| a pipe that pushes air into a furnace |
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Definition
1. Gas combustion - requires oxygen
2. Electric - purer metal bc of even distributing, expensive |
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Definition
| long production line of rollers to make hot rolled steel. Uses red hot wroght. Metal has ugly blackoxide. Good grain structure. Cheap. |
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Term
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Definition
1. metal cools too quickly
2. deforming too much too quickly |
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Term
| examples of Rotary Swaging |
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Definition
ratchet socket for removing bolts
philip head screw driver |
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Definition
| solid representation of whats inside (used for hollow part) used for making sockets for wrenches |
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Definition
| putting a head on bolts and nails. Head is formed in dye then punched. Grain structure goes from center out = bad (1 or 2 grade bolt) |
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Definition
| used to fund cold shuts. Spray the metal, let dry, hit with UV light and look for spray that has built up exposing cracks |
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Term
| Examples of shape rolling |
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Definition
| rectangular bar, channel, angle, I-section |
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Term
| defects in rolled plates and sheet |
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Definition
| alligatoring (can kill you). metal is cleaved into 2 pieces, cant see it, dramatically changes the strength of the material. hid by black oxide |
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Definition
| makes discrete components of manageable size |
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Term
| Examples of impression dye forging |
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Definition
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Definition
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Term
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Definition
| an casted ingot that has been beat with a hammer to produce a smaller grain structures and stronger metal |
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Term
| What is a lead in extruding? |
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Definition
| The angle the red hot metal presses against to guide it into the hole |
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Definition
| used to produce wires and keeps tension on the metal as it comes out |
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Term
| why use sheet metal forming |
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Definition
| strong, cheap, lightweight, good grain structure |
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Term
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Definition
1. deformation
2. penetration
3. bending (fracturing)
*never cut metal with scissors bc it produces major deformation |
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Definition
| where the pressure of the blade bends the metal verses cutting it |
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Definition
| the metal will always spring back some because of the stress strain diagram and the metal must bend past the elastic deformation |
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Definition
| Rollers that have their dies on them that create a discrete components |
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Term
| what are the steps of bulging? |
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Definition
1. create a two half die
2. put the tube inside the die
3. insert a piece of rubber side the tube
4. apply pressure onto the rubber and as it expands it reshapes the tube into the shape of the die
5. release pressure on rubber and remove from tube
6. undo the die halves and remove product |
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Term
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Definition
| bend the sheet metal in a single plane (1-D) by press break |
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Term
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Definition
| bend the sheet metal into 2 planes (2-D) |
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Term
| whats an example of bulging? |
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Definition
| electric tube protector - had hex head, little screw, threads on top |
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Term
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Definition
| taking a blank and using a press and blank holders to form a cup like product |
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Definition
| the wavy edge made on a can after deep drawing |
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Term
| Story about PM processing. |
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Definition
| During the British war, the army would transport ammo in crates surrounded by hay pulled by a mule. The mule would fart and the gas would get caught in the hay then ruin the brass casings. |
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Term
| Exotic properties of PM materials |
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Definition
1. Power placement
2. The metal can be impregnated with oil
3. Controlled porosity |
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Term
| What is the impacting the power in PM from all sides called? |
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