3508ENG: Materials & Manufacturing - Practical Exam Review

Flashcards covering metrology, manufacturing systems (Job Shop, Flow Shop, Lean), additive manufacturing, and non-destructive testing based on lecture exam questions.

Gage Precision Requirement

The precision of a gage for inspection must be at least 10 times higher than the tolerance band of the parts being inspected.

Stereolithography (SLA)

An additive manufacturing process where liquid resin is transformed to solid locally by photopolymerization using a scanning laser beam.

Standardization

A fundamental requirement for the manufacturing of interchangeable parts, which is essential to mass production.

Lean Engineer

A role responsible for tasks such as designing manufacturing cells, quick-change workholders, and integrating in-line inspection devices, but not typically developing a process plan.

Micrometre and Vernier Calliper

Measuring tools capable of measuring a part length to a precision of $12.62\,mm$.

Job

In a manufacturing environment, a collection of operations done on machines designed to accomplish a specific process.

Kanban

An inventory-control system used to control supply chain operations and a key attribute of a lean-type manufacturing system layout.

Job Shop-type Layout

A manufacturing system layout associated with the highest flexibility, processing the largest variety of components and low production volumes.

Allowance

Specifies the conditions of tightest fit between two mating parts and conditions for clearance or interference fit.

Ultrasonic Inspection Methods

Includes pulse-echo (using a single transducer unit), through-transmission (using sender and transducer units), and resonance methods.

Plug Gage

An attribute gage used for checking the internal dimensions of a part.

Snap Gage

An attribute gage used for checking the external dimensions of a part.

Supports (Additive Manufacturing)

Structures used to separate parts from the platform after fabrication, support features to prevent distortion, and keep part features in place during fabrication.

Fabrication Time

The stage in additive manufacturing that usually takes the greatest amount of time compared to preprocessing or post-processing.

3D Printing

A process that prints parts by using droplets to bind solid particles, also known as selective inkjet binding.

Fused Deposition Modelling (FDM)

A rapid prototyping process that uses thermoplastics as its feedstock.

Waste of Overproduction

A type of lean manufacturing waste identified by the presence of excess inventory.

The Seven Wastes

A lean manufacturing concept identifying inefficiencies: Overproduction, Transporting, Waiting, Excess inventory, Defects, Motion, and Overprocessing (Note: Excess machine capacity is NOT one of these).

Route Sheet

A production control element used in process planning to define the path of material through the manufacturing system.

Continuous Process

A type of process layout most likely used by facilities such as a paper mill.

Magnetic Particle Inspection

A non-destructive testing method that can be used on materials such as Nickel.

Radiographic Inspection Limitations

A method where flaws and defects are most difficult to inspect in parts made of lead alloys.

Coordinate Measuring Machine (CMM)

A specific example of a contact inspection method.

Acoustic Emission Monitoring

A non-destructive inspection technique that is best suited for incorporation into sheet metalworking machinery.

Critical Flaws

Specific types of flaws or defects that cause a part to be rejected.

Eddy-current

Electrical currents generated on the surface of conductive materials, such as aluminum, copper, magnesium, or iron, when brought near an alternating magnetic field.

MO-CO-MOO

Basis for operations in lean manufacturing meaning "make one–check one–move one."

Visual Inspection (VI)

An easy and inexpensive non-destructive testing method suitable for field work, limited to detecting surface flaws and dependent on operator skill.

Liquid/Dye Penetration (L/DP)

A method using a wetting liquid and developer to study surface flaws; it cannot be used on porous materials or hot inspection samples.

Accuracy

The degree to which a measured value agrees with the true value of the quantity of interest.

Precision

The degree of repeatability or reproducibility in the measurement process.

Rule of 10 (Gage Tolerance)

A design standard where the gage tolerance is set to $10\%$ of the product tolerance.

Wear Allowance

A design consideration in gages that must be applied to the GO member only.

Tessellation

The process of dividing a 3D surface into smaller, discrete geometric elements (usually triangles) to form a mesh for additive manufacturing software.