Week 10: Mass Production 1 (30 Flashcards)

What factors determine the scale of production?

Market demand, production costs, and available resources.

Why is prototyping crucial in product development?

To test design, functionality, and market acceptance; reduces risk.

Differentiate between 'looks-like' and 'works-like' prototypes.

'Looks-like' validates design aesthetics, while 'works-like' tests functionality.

What is the purpose of a pilot run?

To test production processes and consumer acceptance before mass production.

What is meant by 'designing for manufacturing'?

Ensuring products are optimized for efficient, cost-effective, and quality production.

What are the benefits of mass production?

Reduced cost per part, consistency, and scalability.

Explain the concept of 'amortization' in production.

Spreading the cost of machinery over the production of multiple parts.

Why are interchangeable parts important in mass production?

They enable easy assembly and repair without custom fitting.

What are the three types of tolerances?

Bilateral, unilateral, and direct tolerances.

Define bilateral tolerance.

Variation is allowed in both directions (e.g., ±0.02).

Define unilateral tolerance.

Variation is allowed in only one direction (e.g., +0.02/-0.00).

What is direct tolerance?

Maximum and minimum dimensions are specified directly.

Why are tolerances important in manufacturing?

They ensure part compatibility and functionality in assemblies.

What is ISO 2768-1?

A standard defining tolerances for linear and angular dimensions.

What tools are used for part inspection?

Vernier calipers, coordinate measuring machines (CMMs).

What is metrology?

The science of measurement used in quality assurance.

How do jigs differ from fixtures?

Jigs guide tools during operations; fixtures secure workpieces in place.

What is the role of molds in manufacturing?

To provide a hollow form that shapes materials into specific designs.

What is a draft angle in mold design?

A taper that allows parts to release from molds easily.

What are undercuts, and how are they managed?

Areas preventing part ejection; managed using removable cores or inserts.

What is sand casting?

A process using expendable sand molds to shape metal parts.

What materials are commonly used in sand casting?

Cast iron, aluminum, bronze.

Why is shrinkage important in mold design?

Molds are made oversized to compensate for material shrinkage during cooling.

What is investment casting also known as?

Lost-wax casting.

What are the advantages of investment casting?

High precision and ability to produce intricate shapes.

Name two examples of products made using investment casting.

Turbine blades, jewelry.

What is a 'match plate' in sand casting?

A dividing plate that controls the parting line in sand molds.

What is the primary advantage of permanent molds?

Reusability for producing thousands of identical parts.

What role do vents play in mold design?

They allow air to escape as molten material fills the mold.

What is the difference between expendable and permanent molds?

Expendable molds are single-use; permanent molds are reusable.