USF Manufacturing Processes Exam 1

Manufacturing is important for what three reasons?

- Technologically

- Economically

- Historically

What is technology?

The application of science to provide society and its members with those things that are needed and desired.

Why is manufacturing important technologically?

All technological products are manufactured.

Why is manufacturing important ecnomically?

Means by which a nation creates material wealth.

In the U.S. manufacturing constitutes approximately what percent of GDP?

12%

Why is manufacturing important historically?

- Human cultures that were better at making thing were more successful

- Making better tools meant better crafts & weapons, which allowed the people to live better and weapons allowed them to conquer other cultures in times of conflict.

What are the steps in the Development Process?

Market, Specification, Concept design, detail design, manufacture, sell

What is the definition of manufacturing?

the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products

This can include: Assembly of multiple parts ot make products

How is manufacturing carried out?

As a sequence of operations

What two Latin words is 'Manufacture' derived from?

- Manus (hand)

- Factus (make)

What does 'manus factus' mean?

Made by hand

Manufacturing is the _________ of __________ into items of __________ value by means of one or more processing and/or assembly operations.

transformation, materials, greater

Industries can be classified as....

- Primary

- Secondary

- Tertiary

What is a Primary Industry?

Those that cultivate and exploit natural resources

What is an example of a Primary Industry?

Agriculture, mining, forestry, fishing, mining, etc.

What is a Secondary Industry?

Taking the outputs of primary industries and converting them into consumer and capital goods

What is an example of a Secondary Industry?

Manufacturing, construction, food processing, textiles, etc.

What is a Tertiary Industry?

Service sector of the economy, comprises of businesses that provide services to other businesses and to individuals.

What is an example of a Tertiary Industry?

Healthcare, financial services, retail, education, etc.

What type of industry does manufacturing live in?

Secondary Industries

What are the three production quantity ranges?

- Low Production

- Mediam Production

- High Production

What is the annual quantity (Q) for a low production range?

1 to 100 units

What is the annual quantity (Q) for a median production range?

100 to 10,000 units

What is the annual quantity (Q) for a high production range?

10,000 to millions of units

What does product variety (V) refer to?

Different product types produced in the plant.

T/F: Production variety is the same as production quantity?

False

Explanation: Product variety is distinct from production quantity.

V: Different types of products a factory makes (e.g., different styles of chairs).

Q: The total number of items produced (e.g., 1,000 chairs made).

What is an inverse correlation?

An inverse correlation, also known as a negative correlation, is a relationship between two variables in which one variable increases as the other decreases, and vice versa.

An _______ ___________ exists between V and Q in factory operations.

inverse correlation

If a factory's V is high, then Q is likely to be ______.

low

If a factory's Q is high, then V is likely to be ______.

low

If a factory's V is low, then Q is likely to be ______.

high

If a factory's Q is low, then V is likely to be ______.

high

What is Soft Product Variety?

Small differences between products

Example: differences between car models made on the same production line.

What is Hard Product Variety?

Products differ substantially, and there are a few, if any, common parts.

Example: The difference between a small car and a large truck.

A manufacturing plant consists of a set of ________ and ________. Designed to transform a certain limited range of ______ into products of increased value.

processes, systems, materials

What are the three building blocks of manufacturing?

- Technological processing capability

- Physical product limitations

- Production capacity

Given a plant with a certain set of processes, there are _____ and _____ limitations on the parts or products that can be made in the plant.

size, weight

What is the plant capacity/production capacity?

Maximum rate of production that a plant can achieve under assumed operating conditions.

Most engineering materials can be classified into one of _____ basic categories?

3

What are the three basic categories materials can be classified into?

- Metals

- Ceramics

- Polymers

What are composites?

Non-homogenous mixtures of the three basic types (metals, ceramics, polymers) rather than a unique category.

What are the classifications under Metals?

- Ferrous metals

- Nonferrous metals

What are the classifications under Ceramics?

- Crystalline ceramics

- Glasses

What are the classifications under Polymers?

- Thermoplastics

- Thermosets

- Elastomers

What are the classifications under Composites?

- Metal matrix composites

- Ceramic matrix composites

- Polymer matrix composites

What are metals usually comprised of?

Alloys, which are composed of two or more elements, at least one of which is metallic

What are ceramics usually comprised of?

A compound containing metallic (or semi-metallic) and nonmetallic elements.

Nonmetallic: oxygen, nitrogen, and carbon

What are polymers usually comprised of?

Repeating structural units called 'mers,' whose atoms share electrons to form very large molecules.

What are composites usually comprised of?

A material consisting of two or more phases that are processed separately and then bonded together.

What is a phase?

A homogenous mass of material, such as grains of identical unit cell structure in solid metal.

What are the two basic types of manufacturing processes?

- Processing operations

- Assembly operations

What is processing operations?

The transformation of a work material from one state of completion to a more advanced state.

What is assembly operations?

The joining of two or more components in order to create a new entity.

How many categories of processing operations are there?

3

What are the categories of processing operations?

- Shaping operations

- Property-enhancing operations

- Surface processing operations

What is shaping operations?

Altering the geometry of the starting work material.

What is property-enhancing operations?

Improving physical properties of the material without changing its shape.

What is surface processing operations?

Performing to clean, treat, coat, or deposit material onto the exterior surface of the work.

How many categories are in the shaping process?

4

What are the four categories of the shaping process?

- Solidification

- Particulate processing

- Deformation processes

- Material removal processes

What is the solidification process?

Starting material heated to liquid or semifluid that solidifies to form part geometry.

What is particulate processing?

Starting material is a powder of metals or ceramics, and the powders are formed into desired geometry and then pressed/sintered to harden.

What is the deformation process?

Starting material is a ductile solid (commonly metal) that is deformed/shaped by application of forces that exceed the yield strength.

What is the material removal process?

Starting material is a solid (ductile or brittle), from which material is removed so resulting part has desired geometry.

What is net shape processes?

When most of the starting material is used and no subsequent machining is required to achieve final part geometry.

What is near net shape processes?

When minimum amount of machining is required.

What does the property-enhancing process do?

Improves mechanical or physical properties of the work material.

Example: heat treatment of metals and glasses, sintering of powdered metals and ceramics.

What are the surface processing operations?

Cleaning, Surface treatments, coating and thin film deposition

What is cleaning in the surface processing operation?

Chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface.

What is surface treatments in the surface processing operation?

Mechanical working such as sand blasting, and physical processes like diffusion.

What is coating and thin film deposition in the surface processing operation?

Coating exterior surface of the work part.

What are the types of assembly operations?

- Joining processes

- Mechanical assembly

What is assembly operations?

Two or more separate parts are joined to form a new entity.

What is joining processes?

Creating a permanent joint.

What are some examples of a joining process?

- Welding

- Brazing

- Soldering

- Adhesive bonding

What is a mechanical assembly?

Fastening by mechanical methods.

What are some examples of mechanical assembly?

- Screws

- Bolts

- Nuts

- Other threaded fasteners (press fitting, expansion fits, etc.)

What is computer integrated manufacturing?

Includes all of the engineering functions of CAD/CAM, firm's business functions that are related to manufacturing, CIM systems

Scope of CIM?

Encompasses CAD/CAM, design, business function, mfg. planning, mfg. control, and factory operations.

Scope of CAD/CAM?

Design, mfg. planning, mfg. control, and factory operations.

What does DFM stand for?

Design for Manufacturability

What is design for manufacturing (DFM)?

Assures that the design can be repeatedly manufactured while satisfying the requirements for quality, reliability, performance, availability, and price.

What does DFA stand for?

Design for Assembly

What is design for assembly (DFA)?

Methodology to analyze product concepts or existing products for simplification of the design and assembly process.

What does DFMA stand for?

Design for Manufacturing and Assembly

What is design for manufacturing and assembly?

- Designs should be simple to manufacture, assemble, and disassembly, service, and recycle. - Materials should be chosen for their characteristics and service life.

- Dimensional accuracy and surface finish should be broad as allowed.

- Secondary and finishing operations should be avoided/minimized.

What is the difference between DFM and DFA?

- Design for Manufacturability (DFM):

Focuses on designing products in a way that makes them easy to manufacture at the lowest cost while maintaining quality and functionality standards.

- Design for Assembly (DFA):

Concentrates on reducing the complexity of product assembly, such as minimizing the number of parts and simplifying assembly steps.

How does DFMA combine DFM and DFA?

DFMA combines these two approaches into a unified design methodology, which analyzes product designs to ensure they are both easy to manufacture and easy to assemble. This is achieved by:

- Reducing the total number of parts.

- Designing for ease of fabrication.

- Simplifying assembly operations.

- Optimizing material selection.

- Minimizing tooling and equipment requirements.

What are some of the design features affecting assembly?

- Snapfit

- Pressfit

- Integral rivet

- Separate rivet

- Screw

What is a snapfit?

Snapfits are designed to allow for components to be connected together by simply pressing them together. A tab on one part snaps into a notch of hole on the other part, holding them securely without the need for additional fasteners.

What are some examples of snapfits?

- Legos

- Battery compartment covers

- Snap-on phone cases

- Child-proof medicine bottle caps

- Croc Jibbetz

What is a pressfit?

Pressfit involves inserting one part into another where the inner part is slightly larger than the hole it's being inserted into. The interference between the parts creates a secure fit. Pressfit connections are often used for assembling bearings, gears, and other machine components.

What are some examples of pressfits?

- Pen caps

- Jar lids

- Bottle stoppers

What is a integral rivet?

Integral rivets are formed by deforming part of the material of one or both of the parts being joined, creating a permanent joint. They are part of the actual components being joined together.

What are some examples of integral rivets?

- The handles of knives where the material of the handle or blade is deformed to create the rivet

- Portions of metal in jewelry are deformed to create a rivet to hold different parts together.

What is a separate rivet?

Separate rivets are distinct pieces that are inserted through holes in the parts to be joined, and then deformed to hold the parts together. Unlike integral rivets, they are separate element added to the assembly.

What are some examples of separate rivets?

- Metal fencing (joining panels together)

- Leather goods (belts, handbags, etc).

What is a screw?

Screws are threaded fasteners used to hold parts together. They cab be inserted into pre-drilled or pre-tapped holes or can form their own threads as they are driven into the material. Screws can be removed and re-inserted, making them a versatile and reversible method of assembly.

What are some examples of screws?

- Electronics having screws to secure covers over battery units.

What is prototyping?

- Working model of the design