Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 40, Problem 51SDP
Discuss the factors that influence the choice between the following pairs of processes to make the products indicated:
- a. Sand casting vs. die casting of a fractional electric-motor housing
- b. Machining vs. forming of a large-diameter bevel gear
- c. Forging vs. powder metallurgy production of a cam
- d. Casting vs. stamping a sheet-metal frying pan
- e. Making outdoor summer furniture from aluminum tubing vs. cast iron
- f. Welding vs. casting of machine-tool structures
- g. Thread rolling vs. machining of a bolt for high-strength application
- h. Thermoforming a plastic vs. molding a thermoset to make the blade for an inexpensive household fan
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1. Die casting is the process where molten metal is force into the die cavity at high pressures. There are two types of die casting; hot camber process and cold chamber process. Please describe and draw the schematic illustration to represent each of them.
2.
a) Flat rolling reduces the thickness of plates and sheets. It is possible, instead, to reduce their thickness simply by stretching the material? Would this be a feasible process? Explain.
b) Defects may be present on the surfaces of rolled plates and sheets, or there may be internal structural defects. Defects are undesirable not only because they adversely affect surface appearance, but also because they may affect strength, formability, and other manufacturing characteristics of the rolled sheets. Describes the typical defects in flat rolling by providing the schematic illustration for each of them.
1.1) Which Additive Manufacturing materials and processes (according to the ISO/ASTM 52900 standard) is mostly used during the manufacturing of patterns for the investment casting process?List the advantages and disadvantages of each of the AM processes
1.2) Which manufacturing process (listed in Question 1.1) will be most suitable to produce a pattern for the turbine rotor? Provide reasons for your selection
1.3 The use of additive manufactured patterns for the investment casting process are being used more frequently in industry. Using this technology, comment on production aspects such as cost savings, human resources, production rates, quality,and repeatability of patterns, as well as possible risks associated with the technology? Provide reasons for your statements
Consider the red aluminum tool holder shown in Figure 4. Your job shop has been contracted to make 10,000 pieces this year, with possibility of making 20,000 more each year in the future. Consider the process options below, which option is the best?
a)
using die casting, cast the holder
anodizing the holder to red color
b)
using injection molding, mold the holder without hole
using a mill or drill press, cut the hole
anodizing the holder to red color
c)
using sand mold, cast the holder without hole
using a mill, cut all planar surfaces (smooth surfaces)
using a mill or drill press, cut the hole
anodizing the holder to red color
d)
using a hacksaw, cut a piece of 3"X3" bar stock to length
using a mill, cut all planar surfaces
using a mill or drill press, cut the hole
anodizing the holder to red color
Chapter 40 Solutions
Manufacturing Engineering & Technology
Ch. 40 - Explain what is meant by manufacturing properties...Ch. 40 - Why is material substitution an important aspect...Ch. 40 - What factors are involved in the selection of...Ch. 40 - How is production quantity significant in...Ch. 40 - List and describe the major costs involved in...Ch. 40 - Why does material selection influence energy...Ch. 40 - Describe life-cycle assessment and life-cycle...Ch. 40 - Define what is meant by economic order quantity.Ch. 40 - Explain the difference between direct-labor cost...Ch. 40 - Describe your understanding of the following...
Ch. 40 - What is the difference between production...Ch. 40 - Is there a significant difference between...Ch. 40 - How would you define value? Explain.Ch. 40 - Define sustainable manufacturing.Ch. 40 - What is the meaning and significance of the term...Ch. 40 - Describe the major considerations involved in...Ch. 40 - What is meant by manufacturing process...Ch. 40 - Prob. 18QLPCh. 40 - Explain why the value of the scrap produced in...Ch. 40 - Prob. 20QLPCh. 40 - Prob. 21QLPCh. 40 - Explain why it takes different amounts of energy...Ch. 40 - Refer to Table 40.2 and explain why it is...Ch. 40 - Explain how the high cost of some of the...Ch. 40 - On the basis of the topics covered in this book,...Ch. 40 - What factors are involved in the shape of the...Ch. 40 - Describe the problems that may have to be faced...Ch. 40 - Prob. 28QLPCh. 40 - Prob. 29QLPCh. 40 - Prob. 30QLPCh. 40 - Prob. 31QLPCh. 40 - Review Table 40.2 and estimate the carbon...Ch. 40 - Explain why the larger the quantity per package...Ch. 40 - Prob. 34QLPCh. 40 - As you can see, Table 40.5 lists only metals and...Ch. 40 - Is it always desirable to purchase stock that is...Ch. 40 - Prob. 37SDPCh. 40 - Prob. 38SDPCh. 40 - Prob. 39SDPCh. 40 - Over the years, numerous consumer products (such...Ch. 40 - List and discuss the different manufacturing...Ch. 40 - Prob. 42SDPCh. 40 - Prob. 43SDPCh. 40 - Select three different products commonly found in...Ch. 40 - Prob. 45SDPCh. 40 - The cross-section of a jet engine is shown in Fig....Ch. 40 - Inspect some products around your home, and...Ch. 40 - Prob. 48SDPCh. 40 - Discuss the trade-offs involved in selecting...Ch. 40 - Discuss the factors that influence the choice...Ch. 40 - Prob. 52SDPCh. 40 - Figure P40.53 shows a sheet-metal part made of...Ch. 40 - The part shown in Fig. P40.54 is a carbon-steel...
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- Consider the red aluminum tool holder shown in Figure 4. Your job shop has been contracted to make 5 pieces this year, with possibility of making 5 more each year in the future. Consider the process options below, which option is the best? a) using sand mold, cast the holder without hole using a mill, cut all planar surfaces (smooth surfaces) using a mill or drill press, cut the hole anodizing the holder to red color b) using injection molding anodizing the holder to red color c) using die casting, cast the holder anodizing the holder to red color d) using a hacksaw, cut a piece of 3"X3" bar stock to length using a mill, cut all planar surfaces using a mill or drill press, cut the hole anodizing the holder to red colorarrow_forwardd) A common process for the assembly of compound cylinders is thermal shrink- fitting. In your own words, Describe briefly how this procedure may be performed. Explain with reference to solid mechanics concepts, how a thermal shrink-fit can generate forces which hold the cylinders together and enable higher pressure bearing capability (in comparison to a single cylinder). Considering the concepts/principles explained above, describe more generally an alternative method for achieving such improved performance and describe advantages/disadvantages, if any, over a thermal shrink-fitting procedure. (200 - 300 words).arrow_forward2. Assignment You are tasked to investigate the following and to compile your findings in a technical report: 2.1 What is the benefit of using investment casting for the production of a turbine rotor compared to other casting processes? 2.2 Which AM materials and processes (according to the ISO/ASTM 52900 standard) is mostly used during the manufacturing of patterns for the investment casting process? List the advantages and disadvantages of each of the AM processes. 2.3 What are the advantages and disadvantages of using AM techniques to produce patterns for the investment casting process, compared to conventional methods? 2.4 Show with a sketch, how the build orientation of the processes listed in Question 2.2 can have an influence on the accuracy and surface quality of a pattern. 2.5 Which manufacturing process (listed in Question 2.2) will be most suitable to produce a pattern for the turbine rotor? Provide reasons for your selection. 2.6 The use of additive manufactured patterns…arrow_forward
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