Chapter 4Manufacturing Materials and Processes Test
INSTRUCTIONS
Answer the questions with short, complete statements or drawings as needed.
QUESTIONS
Part 1: Manufacturing Materials
1. Define ferrous metals.
2. Identify the two main types of ferrous metals.
3. Define nonferrous metals.
4. What is another name for plastics?
5. Define thermoplastic.
6. Define thermoset.
7. Define tensile strength.
8. Why are refractories used for such applications as furnace liners?
9. What are composites?
10. Describe the characteristics of gray cast iron.
11. Given the gray cast iron material specification 30A, what does the prefix 30 denote?
12. Define ductility.
13. What are the properties of white cast iron?
14. Which cast iron has the internal characteristics of gray cast iron and the exterior properties of white cast iron?
15. Define malleable.
16. Identify at least two uses for nodular cast iron.
17. How is it possible to alter the properties of steel?
18. Name a steel that is low in carbon and is commonly used for forged and machined parts.
19. Describe high carbon steel.
20. Describe the difference between hot- and cold-rolled steel.
21. Describe the properties of the following steel alloying elements: manganese, molybdenum, and tungsten.
22. Describe stainless steel.
23. Give the typical contents of stainless steel.
24. Identify the contents of the 200, 300, and 400 series stainless steels as identified by the American Iron and Steel Institute.
25. Identify at least four common uses for stainless steel.
26. Given the steel identification number SAE 1020, describe the components: SAE, 10, and 20.
27. Identify the steel recommended for the following general applications: agricultural steel, bolts and screws, car and truck gears, transmission shafts.
28. Define heat treating.
29. Define normalizing.
30. Define case hardening.
31. Define carburization.
32. Define tempering.
33. How is the Rockwell hardness test performed?
34. Describe the properties of aluminum.
35. Define extruded.
36. Identify the alloying elements in brass.
37. Identify the alloying elements in bronze.
38. What is the advantage of adding phosphorus to bronze?
39. Describe at least one industrial use for gold.
40. Identify the metal that has the weight advantage of aluminum and the strength of steel.
41. What are the elements of and process for making tungsten carbide?
In Questions 42 through 57, identify the type of metal or metals that are part of the given Unified Numbering System (UNS) series:
42. A00001 to A99999
43. C00001 to C99999
44. E00001 to E99999
45. L00001 to L99999
46. M00001 to M99999
47. P00001 to P99999
48. R00001 to R99999
49. Z00001 to Z99999
50. D00001 to D99999
51. F00001 to F99999
52. G00001 to G99999
53. H00001 to H99999
54. J00001 to J99999
55. K00001 to K99999
56. S00001 to S99999
57. T00001 to T99999
58. Give the general definition of plastic.
59. Name the process of joining two or more molecules to form a more complex molecule with physical properties that are different from the original molecules.
60. Identify the term that refers to polymer-based materials that have elastic qualities not found in thermoplastics and thermosets.
61. Give the name and basic characteristics of ABS.
62. Give the name and basic characteristics of ASA.
63. Give the name of the thermoplastic that has the versions nitrate, acetate, butyrate, propionate, and ethyl cellulose.
64. Name the type of thermoplastics that are very resistant to chemicals, friction, and moisture. These materials have excellent dimensional stability for use as wire coating and insulation, nonstick surfaces, chemical containers, O-rings, and tubing.
65. Identify the common name for the polyamide thermoplastic.
66. Name a thermoplastic that is rigid with very high impact and stress fracture resistance at temperatures between -40° and 210 °F (-40° to 99 °C), and is used when constant bending is required in the function of the material design.
67. Give the name of a plastic that is inexpensive to produce and that has many desirable properties, including heat, chemical, scratch, and moisture resistance. It is also resistant to continuous bending applications. Products include appliance parts, hinges, cabinets, and storage containers.
68. Name the plastic that is inexpensive and easy to manufacture, has excellent transparency, and is very rigid. However, it can be brittle and has poor impact, weather, and chemical resistance. Products include model kits, plastic glass, lenses, eating utensils, and containers.
69. Name the plastic that is commonly called PVC.
70. Identify at least two applications for PVC and its characteristics for these applications.
71. Briefly discuss the major differences between thermoplastics and thermosets.
72. Name the plastic material that dates back to the late 1800s. This plastic is hard and rigid, has good compression strength, is tough, and does not absorb moisture, but it is brittle. These plastics are commonly used for the manufacture of electrical switches and insulators, electronics circuit boards, distributor caps, and binding material and adhesive.
73. Name the material that is commonly used as a plastic for reinforced composites, also known as reinforced thermoset plastics (RTPs). Typical uses are for boat and recreational vehicle construction, automobiles, fishing rods, tanks, and other structural products.
74. Identify the type of plastics that are also referred to as synthetic rubber.
75. Give the term that refers to the heating of the material in a steel mold that forms the desired shape.
76. Name the material that has the trade name Neoprene and was the first commercial synthetic rubber. This material has better weather, sunlight, and petroleum resistance than natural rubber. It is also very flame resistant, but does not resist electricity. Common uses include automotive hoses and other products where heat is found, gaskets, seals, and conveyor belts.
77. Name the material that has a wide range of makeup from liquid to solid. Liquid and semiliquid forms are used for lubricants. Harder forms are used where nonstick surfaces are required.
Part 2: Manufacturing Processes
78. What is another name for casting?
79. Define casting.
80. Name the most commonly used method of making castings.
81. Discuss the function of cores in the casting process.
82. List at least two advantages of using cores.
83. Describe centrifugal casting.
84. List at least two advantages of the die casting process.
85. Describe the permanent casting process.
86. Name the casting technique that is referred to as “lost wax.”
87. Why is shrinkage allowance required in casting design?
88. What is the estimated shrinkage for most irons?
89. Define draft.
90. In casting design, is draft added to the minimum or maximum design sizes of the part?
91. Identify at least two reasons why fillets are used in casting design.
92. List at least three considerations that influence the amount of extra material that must be left on a casting for machining allowance.
93. What is the recommended standard finish allowance for iron or steel?
94. Describe hot spots in casting.
95. Define forging.
96. What is the grain structure advantage of using the forging process to manufacture a part rather than making a machined part?
97. Describe upset forging.
98. Describe swaging.
99. Describe bending.
100. Describe punching.
101. List at least two advantages of machine forging.
102. Briefly describe the stamping process.
103. Give the name of the machine that performs the stamping operation.
104. Name the process that takes metal-alloyed powders and feeds them into a die where they are compacted under pressure to form the desired shape. The compacted metal is then removed from the die and heated at temperatures below the melting point of the metal.
105. What is the process called that takes the compacted metal that has been removed from the die in the previous question and then heats it at temperatures below the melting point of the metal?
106. Briefly describe the metal injection molding (MIM) process.
107. Name the manufacturing process that is the most commonly used process for creating thermoplastic products. The process involves injecting molten plastic material into a mold that is in the form of the desired part or product. The mold is in two parts that are pressed together during the molding process. The mold is then allowed to cool so the plastic can solidify. When the plastic has cooled and solidified, the press is opened and the part is removed from the mold.
108. Name the manufacturing process that is used to make continuous shapes such as moldings, tubing, bars, angle, hose, weather stripping, films, and any product that has a constant shape. This process creates the desired continuous shape by forcing molten plastic through a metal die.
109. Name the manufacturing process that is commonly used to produce hollow products such as bottles, containers, receptacles, and boxes. This process works by blowing hot polymer against the internal surfaces of a hollow mold.
110. Give the name of the manufacturing process that is generally used to create products such as vinyl flooring, gaskets, and other sheet products. This process fabricates sheet or film thermoplastic or thermoset plastics by passing the material through a series of heated rollers.
111. Name the process that works by placing a specific amount of polymer pellets into a metal mold. The mold is then heated as it is rotated. This forces the molten material to form a thin coating against the sides of the mold. When the mold is cooled, the product is removed.
112. Give the name of the process that works by placing material into an initial hot die where it takes the preliminary shape. As the material cools, a die that matches to the shape of the desired product forms the final shape.
113. Name the process that works by taking a sheet of material and heating it until it softens and sinks down by its own weight into a mold that conforms to the desired final shape. Vacuum pressure is commonly used to suck the hot material down against the mold.
114. Give the name of the process that uses a computer model that is traced in thin cross sections to control a laser that deposits layers of liquid resin or molten particles of plastic material to form the desired shape.
115. Name the common fabrication process for thermosets that uses a specific amount of material that is heated and placed in a closed mold where additional heat and pressure are applied until the material takes the desired shape. The material is then cured and removed from the mold.
116. Give the name of the process that is similar to casting, but that uses a foam material that expands during the cure to fill the desired mold.
117. Give the name of the material that is also commonly referred to as reinforced plastic.
118. Briefly describe the layering process that is used for making reinforced plastic.
119. Give the name of a process where resin is used to make quality composite products with a smooth surface on both sides. This method places reinforcing material into a mold and then pumps resin into the mold.
120. Name the process that uses vacuum pressure to force a thin layer of sheet-reinforced polymer around a mold.
121. Give the name of the process that uses machines to wind resin-saturated reinforcement fibers around a shaft.
Part 3: Machine Processes
122. List at least two reasons why the mechanical drafter should be familiar with machining processes.
123. List four types of machining operations that can be performed on a drilling machine.
124. Identify one of the primary functions of the grinding machine.
125. Describe the main function of a lathe.
126. Describe a feature of milling machines that influences the ability of operations and shapes that can be performed.
127. Identify two types of saw tools that can be used for cutoff and machining operations.
128. Describe chemical machining.
129. Describe electrochemical machining (ECM).
130. Describe electrodischarge machining (EDM).
131. Describe electron beam (EB) machining.
132. What is another name for ultrasonic machining?
133. Describe the basic function of a laser device.
134. Laser machining may be used on what materials?
135. What does the abbreviation CNC mean?
136. Briefly explain the CNC process. Describe computer-integrated manufacturing.
137. What is the purpose of boring?
138. Identify at least one function of a counterbore.
139. Describe drill depth.
140. Describe and give one application of a knurl.
141. Describe the primary function of a key.
142. Define keyseat.
143. What is the function of a reamer?
144. What action will the machinist take when no spotface depth is given?
145. Define surface texture.
146. In what units is surface roughness height measured?
147. Discuss the results of designing a part with specifications that require overmachining.
148. Describe the difference between jigs and fixtures.
149. Normally a jig or fixture is drawn as an assembly of the unit ready for use, and the workpiece or part to be held is drawn in position. How is the workpiece drawn in relationship to the jig or fixture?
150. Name the quality control/detection system that uses statistical techniques and problem solving to monitor, evaluate, and provide guidance for adjusting the process to improve quality.
Chapter 4Manufacturing Materials and Processes Problems
INSTRUCTIONS
This chapter is intended as a reference for manufacturing materials and processes. The concepts discussed serve as abasis for further study in following chapters. A thoroughunderstanding of dimensioning practices is necessary beforecomplete manufactured products can be drawn. Problem assignments ranging from basic to complexmanufacturing drawings are assigned in the following chapters.
Part 1: Problems 4.1 Through 4.14
Provide a brief but complete definition for each of the following terms. Use your own words to describe the appearance of the actual feature and the related drawing used to represent the feature.
PROBLEM 4.1Counterbore
PROBLEM 4.2Chamfer
PROBLEM 4.3Countersink
PROBLEM 4.4Counterdrill
PROBLEM 4.5Drill (not through the material)
PROBLEM 4.6Fillet
PROBLEM 4.7Round
PROBLEM 4.8Spotface
PROBLEM 4.9Dovetail
PROBLEM 4.10Kerf
PROBLEM 4.11Keyseat
PROBLEM 4.12Keyway