MFE 432 - Course Review



ME 482 - Course Review

Fall, 2008

Some basics:

1. What is the difference between how manufacturing engineers consider the stress and strain curve, when compared to ME’s?

2. For the metals considered in this course, temperature of the metal influences strain rate? What happens to the strain rate as the temperature increases?

3. Many of the processes considered in the course use elevated temperatures. Which processes have we considered that might use elevated temperatures? And what are the accompanying advantages and disadvantages?

4. Why can many of the metal working processes use a constant volume assumption in the basic modeling investigations?

Rolling:

1. Rolling is a compressive process. What are the main parameters that govern the process? (coefficient of friction, plate temperature and roller radius)

2. What is the draft? Is there a limit to the draft?

3. What is the no-slip point? And where does it occur? Is it influenced by friction? By temperature?

Extrusion:

1. What is the difference between direct extrusion and indirect extrusion? Which requires more power to run the process? Why?

2. How do you solve for the extrusion force/power requirements when the cross-sectional shape is more complex?

Sheet Metal Bending:

1. What is the primary difference between sheet metal bending and plate rolling?

2. Explain why bending must compensate for springback.

3. What is the relationship between Strength of Materials and the V-bending forces used to bend sheet metal?

3. Is bending springback greater or less when the die radius is smaller? Why?

Metal Removal:

1. In metal removal, what are the primary cutting parameters? (feed, speed, and depth of cut)

2. What is the rake angle? What does an increase in rake angle do to the shearing force/power requirements? Why?

3. What is the friction angle? What does the increase in friction angle do to the force/power requirements? Why?

4. What is the orthogonal model in metal cutting?

5. Where does the machining energy go in the machining process?

6. What is the Merchant relation?

7. Machining is capable of what tolerances?

8. What is the surface finish? Machining is capable of what finishes?

Cutting Tools/Materials:

1. What is Taylor’s equation?

2. Is it true that there are basically two distinct types of cutting tool materials, depending on the application? What are they?

3. Is it true that almost all metals can be machined successfully?

Cutting Processes:

1. Why is it that tolerances get worse as part sizes go up?

2. What is machinability and how is it measured? (such as cutting speeds for a given tool life)

3. Explain the trade-off between production rates and production costs.

4. How can surface roughness in machining be mathematically predicted? (predicted by geometric factors that relate to the geometry of the tool profile and the feed rate)

Electronics Manufacturing (1/3rd of all manufacturing):

1. What are the two major IC assembly methods? (thru-hole and surface mount)

2. Distinguish between terms PCB, PWB, U, R, C, DIP.

3. On what type of IC assembly process is an axial inserter used?

4. Is it true that the new electronic assembly methods have eliminated the need for manual assembly? (Still need for manual stations for odd-form components)

5. Is it true that wave soldering is used for surface mount assembly? Explain .(for thru-hole, reflow oven for surface mount?

6. Specification processes well defined for assembly proceses.

7. Complicated fixturing, templates, tooling required for processes.

8. Newer technologies like ball-grid arrays provide both advantages and disadvantages. What are they?

9. What are via holes?

10. What are the primary SM assembly steps?

11. What is a board fiducial? How is it used?

12. What are the two types of reflow soldering?

13. In electronics the assembly tolerances have moved to what range?

14. Why is machine vision critical to electronics assembly? Explain some applications.

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