Karteikarten
Manufacturing Final 2
Karten in diesem Stapel (200)
- 1What do amorphous plastics look like? What are the related to?Spagehtti and Crystallinity
- 2What types of plastics can be completely transparent?amorphous plastics
- 3Are all polymers miscible?No some can not mix
- 4What is the definition of Poly BlendsGains properties of different types of polymers
- 5What are some examples of poly blends? What do the seprate into?PET and PVA
Sheet-like Layers called lamellae - 6What is lamellaesheet like layers
- 7what arrangement do poly blends create?lamellar morphology
- 8What makes plastic bottles for carb beveragespoly blends (PET) and (PVA)
- 9What plastic makes a bottle strong?PET
- 10What does a PVA do for a plastic bottle for carbonated beverage?stay fizzy
- 11What plastic can carbon dioxide not pass through?PVA
- 12Can carbon dioxide pass through PETYes very much so
- 13What are the 3 defects that occur within polymers?Creep
Stress Whitening
Crazing - 14What is creep and when do you see this type of defect?In polymers, when exposed to static pressures the polymer shifts, smashes, or stretches
- 15What is stress whitening and when do you see this type of defect?Caused by folding or bending of polymers. material becomes less translucent
- 16What is crazing and when do you see this type of defect?development of localized wedge shaped regions of highly deformed material
- 17what amount of plastic production is in disposable products?1/3
- 18What does biodegradeable mean?designed to degrade completely when exposed to microorganisms in soil or water with no toxic by products
- 19What type of bioplastics are used to create biodegradable plasticsStarch Based
Lactic Based
fermented sugar bioplastics - 20what type of bioplastic is extracted from potatoes wheat and ricestarch based bioplastic
- 21what type of bioplastic comes from polymerized lactic acid?Lactic Based
- 22What are the major difference between the mechanical properties of plastics and metals? 5 things-Plastics are formed, machined, cast, and joined into various shapes.
- Plastics have easier into complex shapes.
- polymers are generally a higher strength-to weight ratio
- Plastics have high corrosion resistance
- Plastics have higher thermal expansion - 23What are the major difference between the physical properties of plastics and metals? 5 things• Plastics have a lower density, elastic modulus, thermal conductivity, electrical conductivity
• Plastics have a high Noise reduction
• Plastics are electrical/ thermal insulator
• Plastics are weaker than metals.
• Plastics come in a wide choice of colors - 24Linear Polymers infoLinear polymers have a chainlike, sequential structure and will soften repeatedly when
heated. - 25Branched polymersBranched polymers have side-branch chains that are attached to the main chain will also
soften repeatedly when heated, though not as easily as linear polymers - 26The resistance to deformation and stress cracking is increased in what polymer?Branched
- 27the density of branched polymers is __________ than linear polymersLower
- 28This polymer has adjacent chains linked by covalent bondsCross-linked polymers
- 29Which of the 3 thermoset polymers cannot melt again after hardeningCross-linked polymers
- 30Whta does cross-linked structure increasehardness
strength
stiffness
brittleness
dimensional stability - 31What is the glass-transition temperature?The temperature at which an amorphous polymer transitions from being hard, rigid,
brittle, and glassy to being rubbery and leathery. - 32What is PMMAPolymethylmethacrylate is an acrylic glassy synthetic resin obtainedpolymerizing methyl methacrylate polymer used in dental and medical applications as an adhesive and is often referred to as bone cement, used perspex, plexiglas, and lucite.
- 33What is ABSAcrylonitrile-butadiene-styrene is rigid, dimensionally stable, has good impact
resistance, good abrasion resistance, good chemical resistance, good strength, good toughness,
good low-temperature properties, and has high electrical resistance - 34What i the definition of a composite material?Structures made of distinct materials, the identities of which are maintained even after the component is completely formed.
- 35How many materials are in a composite?2 or more
- 36What benefits do composites bring? 5 thingsimproved strength
stiffness
corrosion resistance
electrical properties
appearance - 37What is matrix materialthat surrounds other components of the system
- 38What 3 types of matrix are there and there applicationsmetal matrix-brake rotors
ceramic matrix-concrete
polymer matrix-fiber reinforced plastics - 39What is Embedded componentthat which is contained in the matrix
- 40What 5 types of Embedded component are thereMay be: Metal
Ceramic
Polymer
Combination
Carbon - 41Aspect Ratio (AR)Ratio of fibers length to its diameter.
- 42Is this one short or long fiber AR 20-60if mechanical properties improve as a result of increasing the average fiber length (short fiber)
- 43Is this one short or long fiber AR 200-500if no such improvements occur (long fiber)
- 44what is the rule of mixtureseach component contributes to the properties of the composite in proportion to its volume fraction.
- 45Give an example of a composite materialDuraplate
- 46what is resiliencyability to spring back/ elasticity
- 47What is the definition for critical length in compositeslong enough for stress to be transferred from the matrix to the fiber.
- 48when reinforcing fibers what should occur with the fiberit should take more force to pull out the fiber then to break it
- 49What are some characteristics of unidirectional compositesFibers in the load are alingned parallel or perpenduclar to the fibers.
Force and Fibers run same direction - 50When is the highest strength and stiffness obtained in a unidirectional composite?when fibers are aligned in the direction of tension force.
- 51What process allows reinforcing fibers in two dimesional shapes?pultrusion
- 52What is this picture a process of?Pultrusion
- 53Explain Biaxial compositesRandom (cross ply) orientation gives useful strength
- 54Give an example of Biaxial compositesoriented strand board
pressure vessel - 55Define LaminateJoin unidirectional composites into layers of two or more
- 56How many sheets in a laminateodd # sheets
- 57Describe Repairing compositesfracture of one fiber does not impair the total structure
failure is often gradual and repairs may be possible - 58What is the matrix?the “glue” that holds other components together
- 59Describe the properties of a good reinforcing fiber for composites. 4 thingsa high elastic module
high strength
low density
is wetted by the matrix - 60What type of polymer are most matrix for composites?thermoset matrix
- 61Describe an Open-mold processonly one mold (male or female) is needed
- 62What 3 materials are used in an Open-mold processwood
reinforced plastic
sheet metal - 63Describe a Plaster/ destroyable moldCan be broken up after setting so intricate duct work can be made
- 64What must a Plaster/ destroyable mold have when dealing with composites?must use a mold release agent
- 65In a Plaster/ destroyable mold what happens to the surfaceSurface of finished part conforms to and reproduces the mold surface
- 66When shaping composites what is a hand lay up?pieces placed by hand and resin placed on them
- 67When shaping composites what is a Spray-upresin supplied by spray gun & reinforcing (roving) is applied at same time
- 68What is roving? What type of material is this process used for?resin supplied by spray gun & reinforcing
Composites - 69When shaping composites what is tape laying machinescut and lay prepregnated sheets under computer control
- 70How is Sheet Molding made?made with continuous sheets of compound or resin and a reinforcing agent
- 71When can you use roving? 2 thingsSheet Molding Composites
Shaping Composites - 72What is this process?Sheet Molding Composites
- 73Sheet Molding reinforcement may be done in what 2 ways?continuous or in the form of roving
- 74In filament winding what direction is it oriented>in the direction of the stress
- 75What ways are filament windings woundHelical
Polar
Hoop Windings - 76When is matched die molding best good? 3 thingsFor higher production rate
close tolerances
best surface finish - 77What is Dry MoldingThe matrix added after dye closed
- 78What is Wet moldingresin & reinforcement placed lower lower die & die is closed
- 79What does RIM stand for in composite processReaction injection molding (RIM)
- 80Explain Reaction injection molding (RIM)Matrix and reinforcement are mixed as it is injected into the mold
- 81When is RIM best used?Close tolerance
Good surface finish
Minimal processing after production - 82What is Metal Casting?Molten metal placed into approved mold cavities or dies
- 83What is the chill zoneArea near the mold where the metal that is being cast cools faster
- 84What does the chill zone do to the grainsmake them smaller
- 85what does the chill zone domake that are stronger
- 86What is this a picture of?Chill Zone
- 87What is this a picture of?Chill Zone
- 88What are the reasons to produce alloys?Strength
Wear resistance
Corrosion resistance
Ductility
Lubricating properties
Electrical properties - 89What are cast steelsReadily welded to build up components of unusually large size and complexity
- 90What are the properties of white cast ironHard and brittle wear resistant parts
Virtually unmachinable except grinding - 91What are the properties of gray ironLow Cost
is preferred choice in all fields where ductility and high strength are needed - 92What alloy must be backed by a stronger material low adhesion to other metalsTin based alloys
- 93Which alloy has Toxic nature limits it to uses where human contact is possibleLead-based alloys
- 94What are the properties of magnesium alloysLow density and reasonable strength corrosion resistance
- 95What are the properties of Aluminum based alloysUsed when high strength-to-weight ratio needed
high corrosion resistance
Lighter than Steel - 96What are the properties of Copper based alloysAttractive color
Good corrosion resistance
High electrical conductivity. - 97What are some applications of aluminum bronzesMarine applications
worm gears
Valves
non-sparking tools - 98Chargethe mixture of alloying elements that will be at the specified composition upon melting
- 99Fluxesvarious (usually inorganic) compounds that can be mixed with the metal to react with the melt
- 100Meltthe molten metal alloy that will be used to produce the casting
- 101Tappingwhen melt reaches proper temperature, method used to extract the metal from furnace.
- 102Pouringtransferring the tapped material to the casting
this is when temperatures are adjusted to produce the desired results. - 103What is a expandable mold?is used only once and must be broken up to free the solidified casting (sand casting investment casting)
- 104What is a permanent mold?expected to last up to several hundred or thousands of casting and must be able to release the solid castings
- 105What is also known as the feeder head in sand casting?Riser
- 106Pouring Basin in sand castingreceptacle where the stream of metal is poured into the casting
- 107Spruein sand castingfluid transported down to the mold
- 108Runnersin sand castingprovide uniform flow rates to various parts of cavity
- 109Gates in sand castingallow the flow of material into the mold cavity provide for ease of separation
- 110Riser in sand castingprovide a reservoir of molten metal for when the casting cools and the metal shrinks
- 111Vents in sand castingallow place for built up gasses to escape, exhaust air from the mold cavity as the metal fills the opening
- 112—Know these things
- 113One of the newer casting processes, is used for high-volume production of small engineered parts weighing one half pound or lessNear Net Shape Casting
- 114Investment Casting-also known as lost wax processNear Net Shape Casting
- 115producing metallurgically sound close tolerance castingsNear Net Shape Casting
- 116—Near Net Shape Casting
- 117Die casting(permanent mold process) propertiesproduce accurately dimensioned
sharply defined
smooth or
textured metal parts - 118In Die casting clamping force required determined by:Surface area of the casting measured at the parting line of the die
pressure required to inject the molten metal into the die - 119Hot ChamberRequires less pressure
Lower Melting temperature metals (Pb, Sn)
Injection chamber immersed in molten metal bath - 120Cold ChamberRequires higher pressure
High melting point (Al, Cu)
Hydraulic plunger seals injection port - 121Metallic Foamslight weight,
impact energy absorbing
thermal management
like a sponge - 122mixing or injecting gas through molten alloysMethod of making metal foam
- 123adding a foaming agent through the molten alloysMethod of making metal foam
- 124pressure infiltrating the molten metal into a wax or polymer- foam precursorMethod of making metal foam
- 125Foam precursor produces whatproduce a range of porous material with varying densities and cell sizes
- 126Describe the difference between short and long freezing ranges.Short freezing range generally involves a temperature difference of less than 50 degree
Celsius and a long freezing range is greater than 110 degrees Celsius. - 127What is superheat? Is it important?the increment of temperature of an alloy above its melting point
improves its fluidity, allowing it more time to adequately flow
(delaying solidification) in a cast - 128used to specify the degree of superheat because it is more easily specifiedPouring temp
- 129What is the function of chillsincrease the rate of solidification in critical regions
- 130used during sand casting in order to prevent or reduce the occurrence of porosity causing shrinkageChills
- 131What are Chills made ofInternal chills: sae material
External Chill: the same material or iron, copper, or graphite. - 132casting cannot shrink freely during cooling, owing to constraints of various portions of the molds and coresTearing
- 133a brittle internal fracture, resulting from the presence of low melting point solute rich liquid present at the grain boundaries and driven by the buildup of stresses caused by the coherent metal grains.Tearing
- 134Green-Sand moldsand in the mold is moist
or damp
least expensive method
sand is recycled - 135high strength, these molds are generally used for large castingsGreen-Sand mold
- 136Cold-Box moldvarious organic and inorganic binders are
blended into the sand for strength
expensive - 137more dimensionally accurate than green-sand moldsCold-Box mold
- 138No-Bake moldsynthetic liquid resin is mixed with the sand
cold-setting process - 139What is the function of a coreThe core allows for the
formation of an interior (Hollow) surface to a casting - 140What is the purpose of a riserserve as reservoirs to supply the molten metal necessary to prevent shrinkage
during solidification - 141ventVents allow place for carry off gasses produced when the molten metal comes into
contact with the mold and, exhaust air from the mold cavity as the metal fills the
opening - 142The formal name is Evaporative-patternlost-foam
- 143no parting lines, cores, or riser systemlost-foam
- 144The casting requires minimal finishing and cleaning operationslost-foam
- 145The process can be automated and is economical for long production runs; however, the cost to produce the die and the need for two sets of tooling are significant factors.lost-foam
- 146forming and shaping of metallic materialsForging
- 147using localized compressive forcesForging
- 148blows are delivered with a hammer or dieForging
- 149allows free deformation of at least some work piece surfaces.Open die forging
- 1504 types of open die forgingNotching
Step forging
Progressive forging
Hammer forging - 151gradual reduction in the height of the entire length of a work pieceCogging
- 152Used when forged part has thick and thin section to it and it is necessary to redistribute the materialFullering and edging
- 153Impressions or holes are made in the work during forgingPiercing
- 154Cools faster than the body of the component during forging Restrict metal flow at the line where dies meet Helps to ensuring complete filling of the impressionFlash
- 155Ability to produce more complex shapes than open die forgingImpression die forging
- 156must have dies with negative shape contourImpression die forging
- 157material escapes into gutter area (flash)Impression die forging
- 158Work piece is completely trapped in the die usually no flash createdClosed die forging
- 159Forging operation usually performed at the end of a round rod or wire in order to produce a larger cross-sectionHeading
- 160Internal diameter and/or the thickness of the tube is reduced with or without the use of internal mandrelsTube swaging
- 161Insufficient material to fill the die these waves may form in the webDefects in forging (Laps)
- 162Too much material is used (die cavities filled prematureDefects in forging Cracks
- 163Special application of closed die forging no lubricant is used highly intricate parts can be produced with a great degree of precision size of the blank is critical (amount of material)Coining
- 1643 Types of die lubricants used for hot forgingwater-based graphites
oil-based graphite
water-based synthetics or non-graphite - 165percentage of water based graphites used60%
- 166percentage of oil-based graphite25%
- 167percentage of water-based synthetics or non-graphite15%
- 168Typically spray-applied to deposit a solid lubricating film of graphiteWater and Graphite lubricants:
- 169Allowing for smooth release metal movement Forming at high temperatures and pressuresWater and Graphite lubricants:
- 170Lubrication of warm and hot forging and extrusionWater and Graphite lubricants:
- 171Produce very little smoke,fumes, or flames LubricantWater and Graphite lubricants:
- 172Graphite remains after water vaporizes providing solid lubricationWater and Graphite lubricants:
- 173Vaporize quickly under forging temperatures and loadsGraphite-Free Lubricant
- 174More easily maintained in their ready-for-use state no agitation after mixing LubricantGraphite-Free Lubricant
- 175Easier to use with application equipment LubricantGraphite-Free Lubricant
- 176The Cylindrical Billet (work piece) is pushed against the deforming die or die against the work pieceExtrusion Process
- 177What 2 tupes of Extrusion ProcessDirect
Indirect - 178The product moves and the punch (die) is stationaryDirect or Forward extrusion
- 179The product is stationary and punch (die) movesIndirect (reverse or back) extrusion
- 180Antoher word for Square diesShear Die
- 181Die used for nonferrous materialSquare Die
- 182Dies for ferrous metals haveDie Angle
- 183Dies used with food products are made of what?stainless steel, Teflon or brass
- 184Special dies called, Porthole and Spider and BridgeHollow metal cross section
- 185Lubrication has what 4 effects?Material FLow during extrusion
surface finish and integrity
product quality
extrusion force - 186Has a Combination of direct and indirect extrusion as well as forgingCold Extrusion Metal
- 187What metal process is the Slug cut and placed in dieCold Extrusion Metal
- 188Cold extrusion metal provide what 3 things?Better mechanical properties
Dimensional tolerances
Improved surface finish - 189Cold extrusion metal has how many products produced per hour?2000 per hour
- 190Material is pulled through a stationary die of gradually decreasing cross section instead of being pushedDrawing
- 191What determines the final size in drawing?Land
- 192Examples of drawn partswire
Seamless tubing - 193Dies for Food extrusion have smooth what?Smoother the die plate the better the product
- 194Stainless steel and teflon are preferred over Bronze in what extrusion type?Dies for Food extrusion
- 195What is RTE?Ready-to-eat
- 196One-step process since the 1960s. Twin-screw extruders are in common use in food production since the 1980sRTE
- 197support a mandrel that material flows aroundSpider die
- 198Uses: High pressure capable (seamless) pipe.Spider Die
- 199where the metal going through a square die on the outer edges is essentially stationary, somewhat of a buildup on the die.Dead Metal ZOne
- 200High heat levels from friction create defect toward center of billet in funnel shapePipe Defect
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