Principle of Manufacturing Engineering sheet1

1) Answer all the following questions:

 

1. How do you classify the manufacturing processes?

products may be classified into six major groups as primary shaping processes, secondary machining processes, metal forming processes, joining processes, surface finishing processes and processes effecting change in properties.

2. Define the manufacturing engineering?

It is therefore a study of the processes required to make parts and to assemble them in machines.

3. List the advanced manufacturing engineering?

1. Process planning.

2. Process sheets.

3. Route sheets.

4. Tooling.

5. Cutting tools, machine tools (traditional, numerical control (NC), and computerized numerical control (CNC).

6. Jigs and Fixtures.

7. Dies and Moulds.

8. Manufacturing Information Generation.

9. CNC part programs.

10. Robot programmers.

11. Flexible Manufacturing Systems (FMS), Group Technology (GT) and Computer integrated manufacturing (CIM).

4. Distinguish between ‘primary’ and ‘secondary’ processes?

Primary shaping processes are manufacturing of a product from an amorphous material, As large number of components require further processing after the primary processes.

5. Define the product ion process?

The art of converting raw material into finished goods with application of different types of tools, equipment, machine tools, manufacturing set ups and manufacturing processes, is known as production

6. Discuss primary shaping processes. Give also a brief account of the primary shaping processes?

Some processes produces finish products or articles into its usual form whereas others do not, and require further working to finish component to the desired shape and size

7. Explain the secondary or machining processes. Give also a brief account of these processes?

The process of removing the undesired or unwanted material from the workpiece or job or component to produce a required shape using a cutting tool is known as machining. This can be done by a manual process or by using a machine called machine tool (traditional machines namely lathe, milling machine, drilling, shaper, planner, slotter).

8. How is the raw material converted into finished goods?

Forming processes encompasses a wide variety of techniques, which make use of suitable force, pressure or stresses, like compression, tension and shear or their combination to cause a permanent deformation of the raw material to impart required shape.

These processes are also known as mechanical working processes and are mainly classified into two major categories i.e., hot working processes and cold working processes.

In these processes, no material is removed; however it is deformed and displaced using suitable stresses like compression, tension, and shear or combined stresses to cause plastic deformation of the materials to produce required shapes

9. Define machining process?

The process of removing the undesired or unwanted material from the workpiece or job or component to produce a required shape using a cutting tool is known as machining. This can be done by a manual process or by using a machine called machine tool (traditional machines namely lathe, milling machine, drilling, shaper, planner, slotter).

10. Define forming processes and what is the classification of metal forming process?

Forming processes encompasses a wide variety of techniques, which make use of suitable force, pressure or stresses, like compression, tension and shear or their combination to cause a permanent deformation of the raw material to impart required shape.

*Hot working Processes

(1) Forging, (2) Rolling, (3) Hot spinning, (4) Extrusion, (5) Hot drawing and (6) Hot spinning. 

*Cold working processes

(1) Cold forging, (2) Cold rolling, (3) Cold heading, (4) Cold drawing, (5) Wire drawing, (6) Stretch forming, (7) Sheet metal working processes

11. What are the processes effecting change in properties? 

A few such commonly used processes are given as under: 

(1) Annealing, (2) Normalising, (3) Hardening, (4) Case hardening, (5) Flame hardening, (6) Tempering, (7) Shot peeing, (8) Grain refining and (9) Age hardening.

12.Describe and name the types of joining processes, surface finishing operations and the processes employed for changing the properties of manufactured components.

common joining processes are:

(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering, (4) Riveting, (5) Screwing, (6) Press fitting, (7) Sintering, (8) Adhesive bonding, (9) Shrink fitting, (10) Explosive welding, (11) Diffusion welding, (12) Keys and cotters joints, (13) Coupling and (14) Nut and bolt joints

commonly used surface finishing processes are:

(1) Honing,

(2) Lapping,

(3) Super finishing,

(4) Belt grinding,

(5) Polishing,

(6) Tumbling,

(7) Organic finishes,

(8) Sanding,

(9) deburring,

(10) Electroplating,

(11) Buffing,

(12) Metal spraying,

(13) Painting,

(14) Inorganic coating,

(15) Anodizing,

(16) Sheradising,

(17) Parkerizing,

(18) Galvanizing,

(19) Plastic coating,

(20) Metallic coating,

(21) Anodizing and

(22) Sand blasting.

13.How many atom per unit cell in the following crystals structure:

1- SC       2- BCC, and  3- FCC

1-n=1       2-n=2            3-n=4

 

(2)Complete the following statements:

 

1- Manufacturing and technical staff in industry must know 1. Safety of self

2. Safety of job3. Safety of machines tools.

2- Process planning consist of selection of means of production

1. Safety by construction or design.

2. Safety by position.

3. Safety by using fixed guards.

4. Safety by using interlock guards

5. Safety by using automatic guards.

6. Safety by using trip guards.

7. Safety by using distance guards.

8. Safety by workplace layout and proper working conditions.

9. Safety by proper material handling 

3-Joining process are carried out by 1- Process Safety System or Process Shutdown System, (PSS).

(PSS ) 2- Safety Shutdown System (SSS):    This includes Emergency Shutdown-(ESD) and        Emergency Depressurization-(EDP) Systems

 

2) State which of the following statements is true and which is false:

1- Manufacturing process is not concerned with the change of form or dimensions of part being produced. ( x )

2- Manufacturing process does not include the transportation, handling or storage of parts. ( √)

3- Manufacturing is the backbone of any industrialized nation. ( √ )

4- The process of removing the undesired or unwanted material from the work-piece or job or component to produce a required shape using a cutting tool is known as forming( 𝑥 )

 

3) Put a line under the correct answer: (MCQ)

 

1- Joining process is carried out by ………..

a) Riveting b) polishing c) forging

2- ………… affect the physical properties and also make a marked change in the internal structure of the metal.

a) Heat treatment b) rolling c) turning

3- The process of putting the parts together to form the product, which performs the desired function, is called ………….

a) Milling b) assembly c) extrusion

4- Metal Forming Processes are classified into ……….

a) One type b) two types c) three types