ME 280 ME Design Pg 1 of 5 T2 S08 Name______

Matching: When selecting appropriate combinations of materials and manufacturing processes, we do a materials first screening followed by a manufacturing processes screening, or a manufacturing processes first screening followed by a materials screening. Classify each of the five phrases at the left as either: (Write A or B in the space provided: A.) materials screen, or B.) manufacturing processes screen)

1.  / ______/ Physical part size
2.  / ______/ Shape generation capability
3.  / ______/ Applied loads (forces and torques/moments)
4.  / ______/ Ambient conditions
5.  / ______/ Production run quantity

Select the word or phrase from the list below that best matches the following phrases.

6.  / ______/ Material and labor costs to make part patterns, jigs, fixtures, molds, and sheet metal punches
7.  / ______/ A geometric feature that prevents removal of a part from the cavity or core half of a mold
8.  / ______/ Moving part of an injection mold (forms the internal shape of the molded part)
9.  / ______/ Lost wax process
10.  / ______/ Forming of blooms, billets and slabs
11.  / ______/ Process for making sheet metal cooking pots
12.  / ______/ Combination of punch and die
13.  / ______/ Subtractive process that produces manufactured waste
14.  / ______/ Raw materials that are scrapped during part fabrication
15.  / ______/ The amount time required by a manufacturing process to produce one part

assembly

cavity

core

cycle

die set

drawing

investment casting

machining

manufactured waste

masking

material cost

processing cost

process plant

rolling

subassembly

tooling

tooling cost

total manufacturing cost

undercut

utility

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

List five team rules presented in the text for being an effective team member

16. 
17. 
18. 
19. 
20. 

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

Matching: Select the letter of the manufacturing process at the right for the sub-process described at the left.

21.  / _____ / Lost wax process / A. / Deformation
22.  / _____ / Brazing / B. / Sheet Metal
23.  / _____ / Vacuum molding (thermoforming) / C. / Finishing
24.  / _____ / Drawing / D. / Machining
25.  / _____ / Rolling / E. / Assembly
26.  / _____ / Bending / F. / Polymer Process
27.  / _____ / Turning / G. / Casting
28.  / _____ / Honing
29.  / _____ / Drilling
30.  / _____ / Blow molding

Matching: Write the letter of the phrase, that best matches each question, in the blank provided.

31.  / ______/ Fastening process joining two or more metal parts by controlled fusion
32.  / ______/ Bulk deformation process used to form sheets, bars, rods and structural shapes
33.  / ______/ A process that removes material from a work piece by a sharp cutting tool
34.  / ______/ Produces slots, notches, extruded holes and holes in sheet metal
35.  / ______/ Shearing smaller shaped pieces of sheet metal
36.  / ______/ Process using a molten parison injected with air which expands to fill the mold
37.  / ______/ Solidification of molten metal after it is injected into a die set under high pressure
38.  / ______/ Handling, inserting and fastening of parts of a product
39.  / ______/ Casting process that uses wax patterns dipped in a ceramic slurry to create a mold
40.  / ______/ Secondary machining process used to reduce surface roughness

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

A. / Adhesive Bonding
B. / Assembly
C. / Bending
D. / Blow Molding
E. / Blanking
F. / Compression Molding
G. / Die casting
H. / Drawing
I. / Drilling
J. / Forging
K. / Grinding
L. / Injection Molding
M / Investment casting
N. / Machining
O. / Punching
P. / Rolling
Q. / Sand casting
R. / Sheet metalworking
S. / Thermoforming
T. / Welding

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

Multiple choice. Write the letter of the choice that best answers the question.

41.  / _____ / The amount of matter per-unit volume is called:
a) connectivity b) melting point c) conductivity d) density
42.  / _____ / Physical properties include all of the following except:
a) heat capacity b) friction coefficient c) elastic modulus d) electrical conductivity
43.  / _____ / Which of the following methods is used to produce products such as pots and pans, soda cans, and cartridge casings: a) blanking b) embossing c) drawing d) punching
44.  / _____ / The quantity that characterizes the behavior of a material in response to an external, or applied force is called:
a) strength b) material property c) mechanical property d) physical property
45.  / _____ / Product function is interdependent on:
a) material properties b) product geometry c) manufacturing processes d) all of these
46.  / _____ / A measure of the amount of force per-unit area that a material can withstand before it fails is called: a) strength b) weight c) intensity d) hardness
47.  / _____ / All the following are ceramics except:
a) zirconia b) magnesia c) silicon nitride d) carbon fiber
48.  / _____ / The resistance to stretching, bending or twisting loads is called:
a) ductility b) impact strength c) compressive strength d) stiffness
49.  / _____ / The ability of a material to plastically deform is called:
a) stiffness b) hardness c) ductility d) impact
50.  / _____ / The ability of a material to undergo a number of cyclical loads without fracturing is called: a) impact strength b) compressive strength c) fatigue strength d) yield strength
51.  / _____ / The ability of a material to resist stretching under loads over long time periods at elevated temperatures is called:
a) impact strength b) creep resistance c) comprehensive strength d) ductility
52.  / _____ / The ability of a material to resist localized surface indentation or deformation is called:
a) ductility b) stiffness c) yield d) hardness
53.  / _____ / Polymeric materials that can be repeatedly softened by heating and hardened by cooling are called: a) thermoplastic b) acrylic c) thermoset d) polystyrene
54.  / _____ / The measure of the rate of heat flow between two surfaces, per unit area per unit time, per unit of thickness, per degree of temperature difference is called: a) corrosion resistance
b) specific heat c) coefficient of thermal expansion d) thermal conductivity
55.  / _____ / All of the following are classes of ferrous metals except:
a.) cast-iron b) alloy steel c)bronze d) stainless steel
56.  / _____ / The temperature at which is solid changes to a liquid is called:
a) thermal conductivity b) specific heat c) thermal expansion d) melting point
57.  / _____ / Materials that are heterogeneous mixtures of polyester or epoxy resins and fibers made from materials: including glass carbon and Kevlar are called:
a) ceramics b) thermoplastics c) polymers d) composites
58.  / _____ / Which other following methods is used to size sheets for subsequent operations
a) drawing b) shearing c) bending d) punching
59.  / _____ / The ability of a process to form geometric shapes is called: a) material compatibility b) interdependency c) process capability d) process first selection
60.  / _____ / Which process produces the smoothest surface:
a) sand casting b) boring c) grinding d) milling
61.  / _____ / Forming plastic indentations to form ribs, beads or lettering on surface of metal is called:
a) punching b) blanking c) shearing d) embossing
62.  / _____ / Cutting or separating sheet metal along a straight line is called:
a) blanking b) drawing c) shearing d) bending
63.  / _____ / Which all the following molding methods (of polymer processing) is used to produce hollow parts with thin walls: a) blow b) injection c) compression d) transfer
64.  / _____ / Manufacturing processes that are used to add to or remove geometric features from the basic forms are called: a) primary b) secondary c) tertiary d) initial
65.  / _____ / Increasing the diameter of an existing hole by rotating the work piece is called:
a) drilling b) boring c) edging d) facing
66.  / _____ / Removal of material from a flat surface by using a rotating cutter tool is called:
a) EDM b) sawing c) milling d) grinding
67.  / _____ / Which the following is often used as a secondary process to true up critical dimensions, surfaces, or to smooth the surface finish:
a) deformation b) casting c) polymer processes d) machining
68.  / _____ / The process of plastically compressing material between two halves of die set by hydraulic pressure or the stroke of a hammer is called : a) casting b) rolling c) deforming d) forging
69.  / _____ / Handling actions, during assembly, include the following except:
a) moving b) shipping c) placing d) orienting
70.  / _____ / The process in which molten metal is poured into a mold to solidify is called:
a) polymer processing b) casting c) machining d) finishing
71.  / _____ / Touching a hot stove and jerking away is an example of: a)choice reaction time
b) simple reaction time c)relevance reaction time d) stimulus reaction time
72.  / _____ / All of the following parts are an example of an human-machine interface except:
a)car steering wheel b)motorcycle handlebar c)TV remote d)forest
73.  / _____ / Display and warning signals can be enhanced by
a) legibility b) visibility c)conspicuity d)intelligibility e) all of these
74.  / _____ / We sense joint and muscle movement by our:
a) tactile sense b)sense of touch c)kinesthetic sensed)biorhythms
75.  / _____ / A term used to describe the abilities, limitations and other physiological or behavioral characteristics of humans which affect design and operation of tools, machines, systems, tasks, jobs, and environments is:
a)ergonomics b)human factors c)bio-feedback d)both a and b
76.  / _____ / Examples of design for adjustability include all of the following except:
a)microphone stands b)driver car seats c)stereo head phones d)computer printers
77.  / _____ / A sub field of human factors that deals with the measurement of the human form such as height and reach is called:
a) biometrics b)anthropometrics c) biomechanics d)animatronics
78.  / _____ / All of the following are examples of a close fit strategy except:
a)shoes b)gloves c) roller skates e)wallet
79.  / _____ / At this stage of team development team members recognize differences in individual abilities, personalities and work styles leading to possible disagreement and conflict.
a) performing b) norming c) storming d) forming
80.  / _____ / We can practice effective listening by doing the following except:
a) showing respect b) asking questions c) stop-talking d) daydreaming
81.  / _____ / An effective meeting agenda will include: a) estimated time for each topic b) person assigned to facilitate the topic discussion c) topics to be discussed d) all of these
82.  / _____ / A project schedule illustrates:
a) estimated beginning time of tasks b)ending time c) milestones d) all of these
83.  / _____ / The four elements of teamwork include the following except:
a) collaboration b) empathy c) communication d) decision making
84.  / _____ / To illustrate the name and function of each project team member we use a: a) task schedule b) responsibilities table c) project notebook d)organizational chart
85.  / _____ / In which team decision making method does a single “no” vote kill a proposal:
a) majority vote b) consensus c) unanimous vote d) paper, rock, scissors method

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

86-100. Marketing, Sales and manufacturing have agreed to make 5,000 new parts that go into a given product line. The following information has been gathered to analyze the costs of the proposed part.

total cost, C = M + T + P

cost per part, c = cM + cT + cP = cw wp (1+ a) + T/q + ct t

Mfg. Process / Milling / Material cost ($/lb) / 8
Material / Aluminum alloy / Tooling cost ($) / 50,000
Part weight (lb) / 5 / Cycle time (minutes/part) / 30
Fraction of material wasted / 0.20 / Machine rate ($/hr) / 85

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

Calculate the material cost per part, (show your work) (3 pts)

Calculate the tooling cost per part, (show your work) (3 pts)

ME 280 ME Design Pg 4 of 5 T2 S08 Name______

Calculate the processing cost per part, (show your work) (3 pts)

Calculate the total cost per part, (show your work) (2 pt)

Calculate the total cost (for the 5,000 piece production run) (1 pt)

Calculate the total cost for a 1,000 piece run. (3 pts)