Week 10: Mass Production 1 (30 Flashcards)

1. Q: What factors determine the scale of production?

A: Market demand, production costs, and available resources.

2. Q: Why is prototyping crucial in product development?

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

3. Q: Differentiate between “looks-like” and “works-like” prototypes.

A: “Looks-like” validates design aesthetics, while “works-like” tests functionality.

4. Q: What is the purpose of a pilot run?

A: To test production processes and consumer acceptance before mass production.

5. Q: What is meant by “designing for manufacturing”?

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

6. Q: What are the benefits of mass production?

A: Reduced cost per part, consistency, and scalability.

7. Q: Explain the concept of “amortization” in production.

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

8. Q: Why are interchangeable parts important in mass production?

A: They enable easy assembly and repair without custom fitting.

9. Q: What are the three types of tolerances?

A: Bilateral, unilateral, and direct tolerances.

10. Q: Define bilateral tolerance.

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

11. Q: Define unilateral tolerance.

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

12. Q: What is direct tolerance?

A: Maximum and minimum dimensions are specified directly.

13. Q: Why are tolerances important in manufacturing?

A: They ensure part compatibility and functionality in assemblies.

14. Q: What is ISO 2768-1?

A: A standard defining tolerances for linear and angular dimensions.

15. Q: What tools are used for part inspection?

A: Vernier calipers, coordinate measuring machines (CMMs).

16. Q: What is metrology?

A: The science of measurement used in quality assurance.

17. Q: How do jigs differ from fixtures?

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

18. Q: What is the role of molds in manufacturing?

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

19. Q: What is a draft angle in mold design?

A: A taper that allows parts to release from molds easily.

20. Q: What are undercuts, and how are they managed?

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

21. Q: What is sand casting?

A: A process using expendable sand molds to shape metal parts.

22. Q: What materials are commonly used in sand casting?

A: Cast iron, aluminum, bronze.

23. Q: Why is shrinkage important in mold design?

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

24. Q: What is investment casting also known as?

A: Lost-wax casting.

25. Q: What are the advantages of investment casting?

A: High precision and ability to produce intricate shapes.

26. Q: Name two examples of products made using investment casting.

A: Turbine blades, jewelry.

27. Q: What is a “match plate” in sand casting?

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

28. Q: What is the primary advantage of permanent molds?

A: Reusability for producing thousands of identical parts.

29. Q: What role do vents play in mold design?

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

30. Q: What is the difference between expendable and permanent molds?

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