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engineering
materials science engineering
Materials and process in manufacturing 9th edition E. Paul DeGarmo, J T. Black, Ronald A. Kohser - Solutions
How is the standard deviation of a distribution of sample means related to the distribution from which the samples were drawn?
In the last two decades, the quality in automobiles has significantly improved. What do vow think is the main cause for this marked quality improvement?
Suppose you have a "pistol-shooting" process that is accurate and precise. What might the target look like if, occasionally while shooting, a sharp gust of wind blew left to right?
Why don't standard tables exist detailing the natural variability of a given process, like rolling, extruding, or turning?
What are Taguchi or factorial experiments, and how might they be used to do a process capability study?
How does the Taguchi approach differ from the experimental method outlined in this chapter?
Why are Taguchi experiments so important compared to classical experiments?
Here are some common, everyday processes with which you are familiar. What variable or aspect to the process might dominate the process, in terms of quality, not output? a. Baking a cake (from scratch; from a cake mix). b. Mowing the lawn. c. Washing dishes in a dishwasher.
For the items listed in the following chart, obtain a quantity of 48. Measure the indicated characteristics and determine the process mean and standard deviation. Use a sample size of 4, so that 12 samples are produced. Item Characteristic(s) You Can Measure Flat washer
For the data given in Figure 12-3, compute Cp, D, and Cpk, making any assumptions needed to perform the calculations.
For the data given in Figure 12-4, compute Cp, D, and Cpk.
Calculate and and the control limits for the and R control charts shown in Figure 12-A. The sample mean, and range for the first nine subgroups and the data for each sample are given in the bottom of the figure. There are 25 samples of size 4. Therefore K = 25, n = 4. Complete the bottom part
For the data given in Figure 12-A, estimate the mean and standard deviation for the process from which these samples were drawn (i.e., the parent population) and discuss the process capability in terms of Cp, Cpk and D. The USL and LSL for this dimension are 0.9 and 0.5, respectively, and the
Compare the results from your analysis of Figure 12-A with the findings of problem 4.
Figure 12-B contains data from a process that produces holes (drilling) with limits of 6.00 to 6.70 mm. The control charts for and R using n = 5 and k = 25 are shown in the figure, also. (The numbers in the body of the table are 6.47, 6.19, 6.19,6.29, etc.)a. Using the data for n = 5, k = 25,
You have recently been hired by the BRC Company as the quality engineer. Your new boss, Abigail Crawford, brought in one of the leading textbooks in manufacturing engineering (NOT DeGarmo) to show you this problem. After reading the discussion and studying the figure, Abigail asked you the
What is materials processing?
What is draft and why is it used?
What are the two stages of solidification, and what occurs during each?
Why is it that most solidification does not begin until the temperature falls somewhat below the equilibrium melting temperature (i.e., undercooling is required)?
Why might it be desirable to promote nucleation in a casting through inoculation or grain refinement processes?
Why might directional solidification be desirable in the production of a cast product?
Describe some of the key features observed in the cooling curve of a pure metal.
What is superheat?
Discuss the roles of casting volume and surface area as they relate to the total solidification time and Chvorinov's rule.
What are the four basic families of shape-production processes? Cite one advantage and one limitation of each family.
What is the correlation between cooling rate and final properties of a casting?
What is the chill zone of a casting, and why does it form?
Which of the three regions of a cast structure is least desirable? Why are its properties highly directional?
How can we promote the formation of an equiaxed zone and minimize the size of the columnar zone?
What is dross or slag, and how can it be prevented from becoming part of a finished casting?
What are some of the possible approaches that can be taken to prevent the formation of gas porosity in a metal casting?
What is fluidity, and how can it be measured?
What is a misrun and what causes them to form?
What defect can form in sand castings if the pouring temperature is too high and fluidity is too great?
Describe the capabilities of the casting process in terms of size and shape of the product.
Why is it important to design the geometry of the gating system to control the rate of metal flow as it travels from the pouring cup into the mold cavity?
What is a choke and how does its placement affect metal flow?
What features can be incorporated into the gating system to aid in trapping dross and loose mold material that is flowing with the molten metal?
What features of the metal being cast tend to influence whether the gating system is designed to minimize turbulence and reduce dross, or promote rapid filling to minimize temperature loss?
What are the three stages of contraction or shrinkage as a liquid is converted into a finished casting?
Why is it more difficult to prevent shrinkage voids from forming in metals or alloys with large freezing ranges?
What type of flaws or defects form during the cooling of an already-solidified casting?
Why is it desirable to design a casting to have directional solidification sweeping from the extremities of the mold to the riser?
Based on Chvorinov's rule, what would be an ideal shape for a casting riser? A desirable shape from a practical perspective?
How might the desired production quantity influence the selection of a single- or multiple-use molding process?
Define the following riser-related terms: top riser, side riser, open riser, blind riser, live riser, and dead riser.
What assumptions were made when using Chvorinov's rule to calculate the size of a riser in the manner presented in the text?
What is the purpose of a chill? Of an insulating sleeve? Of exothermic material?
What types of modifications or allowances are generally incorporated into a casting pattern?
What is a shrink rule, and how does it work?
Why is it desirable to make the pattern allowances as small as possible?
What are some of the features of the casting process that are directly related to the location of the parting plane?
What types of problems can occur when sections of a casting intersect?
Why is it important to provide a means of venting gases from the mold cavity?
What is a casting pattern? Flask? Core? Mold cavity? Riser?
What are some of the components that combine to make up the gating system of a mold?
Using Chvorinov's rule as presented in the text with n = 2, calculate the dimensions of an effective riser for a casting that is a 2 in. by 4 in. by 6 in. rectangular plate. Assume that the casting and riser are not connected, except through a gate and runner, and that the riser is a cylinder of
Reposition the riser in Problem 1 so that it sits directly on top of the flat rectangle, with its bottom circular surface being part of the surface of the casting, and recompute the size and yield fraction. Which approach is more efficient? Problem 1 Using Chvorinov's rule as presented in the text
A rectangular casting having the dimensions 3 in. by 5 in. by 10 in. solidifies completely in 11.5 minutes. Using n = 2 in Chvorinov's rule, calculate the mold constant B. Then compute the solidification time of a 0.5 in. by 8 in. by 8 in. casting poured under the same conditions.
A cast iron, T-type fitting is being produced for the oil drilling industry, using an air-set or no-bake sand for both the mold and the core. A silica sand has been used in combination with a catalyzed alkyd-oil/urethane binder. Figure CS-13 shows a cross section of the mold with the core in place
What are some of the factors that influence the selection of a specific casting process as a means of making a product?
For what types of products might a loose-piece pattern be required?
What are the four primary requirements of a molding sand?
In what ways might a molding sand be a compromise material?
What is a muller, and what function does it perform?
What is a standard rammed specimen for evaluating foundry sands, and how is it produced?
What is permeability, and why is it important in molding sands?
How does the ratio of water to clay affect the compressive strength of green sand?
How does the size and shape of the sand grains relate to molding sand properties?
What is a sand expansion defect, and what is its cause?
What are the three basic categories of casting processes when classified by molds and patterns?
How can sand expansion defects be minimized?
What features can cause the penetration of molten metal between the grains of the molding sand?
What are hot tears and what can cause them to form?
Describe the distribution of sand density after compaction by jolting, squeezing, and a jolt-squeeze combination.
What is a slip jacket and how is it used?
How can the use of vertically parted flaskless molding reduce the number mold sections required to produce a series of casting?
What are some of the advantages and limitations of the sodium silicate-CO2 process?
What metals are frequently cast into products?
What material serves as the binder in the shell-molding process, and how is it cured?
Why do shell molds have excellent permeability and collapsibility?
What is the sand binder in the V-process? The Eff-set process?
What is the binder in the hot-box core-making process?
What is the primary attraction of the cold-box coremaking process?
Which type of casting is the most common and most versatile?
Why is it common for greater permeability, collapsibility, and refractoriness to be required of cores than for the base molding sand?
Why is it important that chaplets not completely melt during the pouring and solidification of a casting?
Why are plaster molds only suitable for the lower-melting-temperature nonferrous metals and alloys?
What is the primary performance difference between plaster and ceramic molds?
Why are investment casting molds generally preheated prior to pouring?
Why are investment castings sometimes called "lost-wax" castings?
What are some of the advantages of counter-gravity investment casting over the conventional gravity pour approach?
What are some of the benefits of not having to remove the pattern from the mold (as in investment casting, full-mold casting, and lost-foam casting)?
What is a casting pattern?
Since both use expanded polystyrene as a pattern, what is the primary difference between full-mold and lost-foam casting?
What are some of the attractive features of the evaporative pattern processes?
What are some of the objectives of a shakeout operation?
How might castings be cleaned after shakeout?
What are some of the materials used in making casting patterns? What features should be considered when selecting a pattern material?
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