Manufacturing Processes- Machine Operator
Final Exam Review (Accurate Solutions)
-Interfacial bond has sufficient strength for structural and non-structural applications
(sealing, insulation)
-Distributes load at interface → eliminates localized stresses resulting from joining with
mechanical fasteners (rivets, bolts) - ANSWER-Major Advantages of Adhesive Bonding
-Joint clearance (increase yields in tensile strength up and shear strength down)
-Joint area (larger joint area = larger joint strength)
-Nature of the bond at the interfaces between the filler metal and base metal -
ANSWER-Brazed joint strength depends on...
-Mechanical interlocking improves joint strength immensely
-Large contact surfaces (low strength of solders)
-Rarely used to make butt joints due to small faying surfaces required - ANSWER-Best
Practices for Effective Soldering
-Surface preparation is very important (clear of dirt, dust, oil, etc.) as they affect not only
the bond strength but also the wetting ability
-Joints only subjected to shear stresses; peeling should be avoided - ANSWER-Best
Practices for Effective Adhesion
-Torch Brazing (manual)
-Furnace Brazing (preassembled)
-Induction (coil) Brazing (for line brazing)
-Resistance Brazing (for spot brazing)
-Dip Brazing (molten bath of filler or salt which melts the filler material) - ANSWER-
Brazing Methods
a metal removal process in which a tool with multiple teeth moves linearly past a
stationary workpart. - ANSWER-Briefly describe a broaching operation
A roughing operation is used to remove large amounts of material rapidly and to
produce a part geometry close to the desired shape. A finishing operation follows
roughing and is used to achieve the final geometry and surface finish. - ANSWER-
Explain the difference between roughing and finishing operations in machining.
Adhesives - ANSWER-generally use a rubber or polymer as the filler material, forms
include: liquid, paste, solution, emulsion, powder, tape, and film
Brazing - ANSWER-A joining process in which a filler metal is placed at the periphery or
between the interfaces of the faying (contacting) surfaces to be joined
, -The temperature is then raised sufficiently to melt the filler metal but not melt the base
metal
-Essential that surfaces in brazing are clean
calendering - ANSWER-This process is used to produce sheet and thin film stock out of
rubber or rubbery thermoplastics
carbon black - ANSWER-This is the most important reinforcing filler in rubber because it
increases tensile strength and resistance to abrasion
compression molding - ANSWER-A molding operation that uses sheet-molding
compound (SMC) is a form of which molding process?
contact molding and open mold process - ANSWER-Hand lay-up is classified in which
general categories of PMC shaping processes
continuous filaments - ANSWER-Filament winding involves the use of which fiber
reinforcements
cracks cavities, and inclusions. Surface conditions of the base metals can adversely
affect the operation. - ANSWER-Typical welding defects
curing - ANSWER-This process accomplishes cross - linking of the polymer,
transforming it from a liquid into a hardened product
die casting - ANSWER-This permanent mold process injects molten metal into the mold
cavity at high pressures
Dissimilar metals - ANSWER-pose special problems in welding when their physical
state and/or mechanical properties are substantially different. IF a filler metal is used, it
must be compatible with the base metals.
drawing - ANSWER-A bulk deformation process in which the cross-section of a rod or
wire is reduced by pulling it through a die opening
drawing - ANSWER-A sheet-metal forming operation performed by placing a sheet of
metal over a die cavity and then pushing the metal into the opening with a punch
electric discharge material removal process - ANSWER-This process removes metal by
a series of discrete electrical discharges that cause localized temperatures high enough
to melt or vaporize the metal in the immediate vicinity of the discharge
electrochemical machining - ANSWER-This process removes metal from an electrically
conductive workpiece by anodic dissolution
Final Exam Review (Accurate Solutions)
-Interfacial bond has sufficient strength for structural and non-structural applications
(sealing, insulation)
-Distributes load at interface → eliminates localized stresses resulting from joining with
mechanical fasteners (rivets, bolts) - ANSWER-Major Advantages of Adhesive Bonding
-Joint clearance (increase yields in tensile strength up and shear strength down)
-Joint area (larger joint area = larger joint strength)
-Nature of the bond at the interfaces between the filler metal and base metal -
ANSWER-Brazed joint strength depends on...
-Mechanical interlocking improves joint strength immensely
-Large contact surfaces (low strength of solders)
-Rarely used to make butt joints due to small faying surfaces required - ANSWER-Best
Practices for Effective Soldering
-Surface preparation is very important (clear of dirt, dust, oil, etc.) as they affect not only
the bond strength but also the wetting ability
-Joints only subjected to shear stresses; peeling should be avoided - ANSWER-Best
Practices for Effective Adhesion
-Torch Brazing (manual)
-Furnace Brazing (preassembled)
-Induction (coil) Brazing (for line brazing)
-Resistance Brazing (for spot brazing)
-Dip Brazing (molten bath of filler or salt which melts the filler material) - ANSWER-
Brazing Methods
a metal removal process in which a tool with multiple teeth moves linearly past a
stationary workpart. - ANSWER-Briefly describe a broaching operation
A roughing operation is used to remove large amounts of material rapidly and to
produce a part geometry close to the desired shape. A finishing operation follows
roughing and is used to achieve the final geometry and surface finish. - ANSWER-
Explain the difference between roughing and finishing operations in machining.
Adhesives - ANSWER-generally use a rubber or polymer as the filler material, forms
include: liquid, paste, solution, emulsion, powder, tape, and film
Brazing - ANSWER-A joining process in which a filler metal is placed at the periphery or
between the interfaces of the faying (contacting) surfaces to be joined
, -The temperature is then raised sufficiently to melt the filler metal but not melt the base
metal
-Essential that surfaces in brazing are clean
calendering - ANSWER-This process is used to produce sheet and thin film stock out of
rubber or rubbery thermoplastics
carbon black - ANSWER-This is the most important reinforcing filler in rubber because it
increases tensile strength and resistance to abrasion
compression molding - ANSWER-A molding operation that uses sheet-molding
compound (SMC) is a form of which molding process?
contact molding and open mold process - ANSWER-Hand lay-up is classified in which
general categories of PMC shaping processes
continuous filaments - ANSWER-Filament winding involves the use of which fiber
reinforcements
cracks cavities, and inclusions. Surface conditions of the base metals can adversely
affect the operation. - ANSWER-Typical welding defects
curing - ANSWER-This process accomplishes cross - linking of the polymer,
transforming it from a liquid into a hardened product
die casting - ANSWER-This permanent mold process injects molten metal into the mold
cavity at high pressures
Dissimilar metals - ANSWER-pose special problems in welding when their physical
state and/or mechanical properties are substantially different. IF a filler metal is used, it
must be compatible with the base metals.
drawing - ANSWER-A bulk deformation process in which the cross-section of a rod or
wire is reduced by pulling it through a die opening
drawing - ANSWER-A sheet-metal forming operation performed by placing a sheet of
metal over a die cavity and then pushing the metal into the opening with a punch
electric discharge material removal process - ANSWER-This process removes metal by
a series of discrete electrical discharges that cause localized temperatures high enough
to melt or vaporize the metal in the immediate vicinity of the discharge
electrochemical machining - ANSWER-This process removes metal from an electrically
conductive workpiece by anodic dissolution
