EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
expand_more
expand_more
format_list_bulleted
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
Expert Solution & Answer
Want to see the full answer?
Check out a sample textbook solutionStudents have asked these similar questions
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
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
Chapter 40 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
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...
Knowledge Booster
Learn more about
Need a deep-dive on the concept behind this application? Look no further. Learn more about this topic, mechanical-engineering and related others by exploring similar questions and additional content below.Similar questions
- A process currently services an average of 59 customers per day. Observations in recent weeks show that its utilization is about 90 percent, allowing for just a 10 percent capacity cushion. If demand is expected to be 70 percent of the current level in five years and management wants to have a capacity cushion of just 4 percent, what capacity requirement should be planned? The needed capacity requirement is nothing customers per day. (Enter your response rounded up to the next whole number.)arrow_forwardThe table below provides the parameters for a new current state value stream map for the family of retainers at the Jensen Bearings Inc. firm described in the chapter. This table depicts the value stream after Kline Steel agrees to accept daily orders for steel sheets and also agrees to deliver on a daily basis. Calculate each component of the new value stream's reduced lead time. Jensen Bearings operates 5 days per week. More Info Overall Process Attributes Average demand: 2,700/week (1,400 "L"; 1,300 "S") Batch size: 1,000 Number of shifts per day: 1 Availability: 8 hours per shift with two 30 minute lunch breaks Process Step 1 Press Cycle time=4 seconds Setup time=2 hours Uptime=90% Operators=1 Every Part Every=1 week WIP=1 day of sheets (before Press) Process Step 2 Pierce & Form Cycle time=23 seconds Setup time=30 minutes Uptime=100% Operators=1 WIP=1,100 "L", 1,250 "S" (before Pierce & Form) Process…arrow_forwardA manufacturer of plastic traffic cones sells the cones at a wholesale cost of £8 pounds per cone. The variable cost for each cone is £3. The annual overhead cost for the production line is £100,000. Current production is 30,000 cones/units per annum. What is the annual profit generated by this production line? £240,000 £50,000 £50,000 £150,000 £90,000 Hide hint for Question 14 The question is asking for the annual profit and not the contribution. Use Break-even theory.arrow_forward
- Evaluate the different manufacturing processes used to produce a component and recommend the most suitable process based on cost, quality and time constraints.arrow_forwardProcessing raw materials depends upon the kind of products and nature of the products to be produced. Name and briefly explain three processes used in making raw materials.arrow_forward2.1 What is the benefit of using investment casting for the production of a turbine rotorcompared to other casting processes?2.2 Which AM materials and processes (according to the ISO/ASTM 52900 standard) ismostly 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 producepatterns 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 2.2can 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 producea pattern for the turbine rotor? Provide reasons for your selection.2.6 The use of additive manufactured patterns for the investment casting process arebeing used more frequently in industry. Using this technology, comment onproduction…arrow_forward
- 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
- describe the sequences of five production steps and stages from the initial research and development idea to the launch of the product for a metal casing or a car engine block. Use descriptive diagrams and or images, data to support your answers.arrow_forwardBased on the table below, which of the statements below is/are correct regarding the 3D printing process shown in the schematic? Z AXIS X AXIS YAXIS LEGEND A: Extruder B: Nozzle C: Printed part D: Hot plate E: Filament Table 15.2 Melting and Glass Transition Temperatures for Some of the More Common Polymeric Materials Material Polyethylene (low density) Polytetrafluoroethylene Polyethylene (high density) Polypropylene Nylon 6,6 Polyester (PET) Poly(vinyl chloride) Polystyrene Polycarbonate Glass Transition Temperature [°C (°F)] -110 (-165) -97 (-140) -90 (-130) -18 (0) 57 (135) 69 (155) 87 (190) 100 (212) 150 (300) Melting Temperature [°C (°F)] 115 (240) 327 (620) 137 (279) 175 (347) 265 (510) 265 (510) 212 (415) 240 (465) 265 (510) a. This process is best suited for the low volume production of tubes, bars and beams due to the nature of the extrusion process b. Manufacturing a thermoplastic HDPE hose with an extrusion nozzle heated to 175C is possible with this process □c. You can…arrow_forwardWhich of the following qualifies as a precision-casting process: a. investment casting b. sand casting c. ingot casting d. die casting e. plaster-mold castingarrow_forward
arrow_back_ios
SEE MORE QUESTIONS
arrow_forward_ios
Recommended textbooks for you
- Elements Of ElectromagneticsMechanical EngineeringISBN:9780190698614Author:Sadiku, Matthew N. O.Publisher:Oxford University PressMechanics of Materials (10th Edition)Mechanical EngineeringISBN:9780134319650Author:Russell C. HibbelerPublisher:PEARSONThermodynamics: An Engineering ApproachMechanical EngineeringISBN:9781259822674Author:Yunus A. Cengel Dr., Michael A. BolesPublisher:McGraw-Hill Education
- Control Systems EngineeringMechanical EngineeringISBN:9781118170519Author:Norman S. NisePublisher:WILEYMechanics of Materials (MindTap Course List)Mechanical EngineeringISBN:9781337093347Author:Barry J. Goodno, James M. GerePublisher:Cengage LearningEngineering Mechanics: StaticsMechanical EngineeringISBN:9781118807330Author:James L. Meriam, L. G. Kraige, J. N. BoltonPublisher:WILEY
Elements Of Electromagnetics
Mechanical Engineering
ISBN:9780190698614
Author:Sadiku, Matthew N. O.
Publisher:Oxford University Press
Mechanics of Materials (10th Edition)
Mechanical Engineering
ISBN:9780134319650
Author:Russell C. Hibbeler
Publisher:PEARSON
Thermodynamics: An Engineering Approach
Mechanical Engineering
ISBN:9781259822674
Author:Yunus A. Cengel Dr., Michael A. Boles
Publisher:McGraw-Hill Education
Control Systems Engineering
Mechanical Engineering
ISBN:9781118170519
Author:Norman S. Nise
Publisher:WILEY
Mechanics of Materials (MindTap Course List)
Mechanical Engineering
ISBN:9781337093347
Author:Barry J. Goodno, James M. Gere
Publisher:Cengage Learning
Engineering Mechanics: Statics
Mechanical Engineering
ISBN:9781118807330
Author:James L. Meriam, L. G. Kraige, J. N. Bolton
Publisher:WILEY
Thermodynamic Availability, What is?; Author: MechanicaLEi;https://www.youtube.com/watch?v=-04oxjgS99w;License: Standard Youtube License