Term
| Acoustic emission (p. 242)— |
|
Definition
| involves listening for indications of failure because almost all materials emit high frequency sounds when stressed. |
|
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Term
| Acoustic holography (p. 243) |
|
Definition
| computer reconstruction technique, that is time based on ultrasound reflections from within the part. |
|
|
Term
| Computed tomography (p. 243)— |
|
Definition
| an inspection technique that provides a cross-sectional view of the interior of an object along a plane parallel to the X-ray beam. |
|
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Term
|
Definition
| in ultrasonic inspection, because air is a poor transmitter of ultrasonic waves, this is required to link the transducer to the piece to be inspected and transmit the vibrations into the part; generally a liquid such as oil or water; |
|
|
Term
| • Critical flaw (p. 244)— |
|
Definition
| larger defects, or defects of a more undesirable geometry that may grow or propagate under the same conditions of loading, often causing sudden or catastrophic failure. |
|
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Term
|
Definition
| )- a chart that acts as a control indicator of a process. The range and average are plotted for each sample group and the chart is analyzed. If the chart does not have a distinct pattern or the average, range, or standard deviation fall outside a certain region, then there is a problem with the process. |
|
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Term
| • Fishbone Diagram (p264)- |
|
Definition
| )- a diagram that shows the causes of an event. It can be used in conjunction with the control chart to root out the causes of problems. It is useful in identifying the primary obstacles that effect performance. |
|
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Term
|
Definition
| )- a graph of a frequency distribution that shows raw data and the desired value as well as upper and lower specification limits. The width of the bars corresponds to the class intervals while the height corresponds to frequencies. |
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Term
|
Definition
| (book doesn't give definition) a value that is used as the name for an actual value which is close but not exactly the same; theoretical value?? |
|
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Term
| • Parent Population (p254)- |
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Definition
| the set of individuals, items, or data from which a statistical sample has been taken. |
|
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Term
|
Definition
| the set of individuals, items, or data from which a statistical sample has been taken. |
|
|
Term
| • Process Capability (PC) (p246)- |
|
Definition
| )- the ability of a process to consistently reach the goals it is aiming for. Capability is measured through output. |
|
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Term
| • Quality Control (QC) (p246) |
|
Definition
| the product is examined to determine whether or not the processing accomplished was what was specified by the designer in the design, usually the nominal size and tolerance. |
|
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Term
| Specification Limit (p248)- |
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Definition
| )- boundaries or parameters on a histogram that define acceptable performance for a process expressed as upper and lower limits (USL and LSL). |
|
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Term
| • Standard Deviation (p249)- |
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Definition
| measure of variability; =sqrt((((Xi^2))/n)-Xbar^2). |
|
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Term
| • Statistical process control (p259 |
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Definition
| Sampling(looking at some percentage of the whole) requires the use of statistical techniques that permit decisions about the aceptablilty of the whole based on the quality found in the sample. Know as SPC. |
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Term
|
Definition
| drive for superior quality led to introduction of _________________ for improvement in products, product design, and processes. The consumer is the central focus of sttention on quality, and the methods of quality design and controls have been incorporated into all phases of production. (7 general features p256) |
|
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Term
|
Definition
| )-(inherent uniformity) variability to which no cause can be assigned and which cannot be eliminated is said to be inherent in the process and is therefore its nature. |
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|
Term
| Acoustic emission (p. 242)— |
|
Definition
| involves listening for indications of failure because almost all materials emit high frequency sounds when stressed |
|
|
Term
| Acoustic holography (p. 243)— |
|
Definition
| computer reconstruction technique, that is time based on ultrasound reflections from within the part. |
|
|
Term
| Computed tomography (p. 243) |
|
Definition
| an inspection technique that provides a cross-sectional view of the interior of an object along a plane parallel to the X-ray beam. |
|
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Term
|
Definition
| in ultrasonic inspection, because air is a poor transmitter of ultrasonic waves, this is required to link the transducer to the piece to be inspected and transmit the vibrations into the part; generally a liquid such as oil or water; |
|
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Term
|
Definition
| larger defects, or defects of a more undesirable geometry that may grow or propagate under the same conditions of loading, often causing sudden or catastrophic failure. |
|
|
Term
| Destructive testing (p. 232 |
|
Definition
| a product assessment where components or assemblies are selected and then subjected to conditions that induce failure. |
|
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Term
|
Definition
| an allowable flaw that is sufficiently small and will remain the same size and shape throughout its lifetime. |
|
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Term
| Eddy-current testing (p. 241) |
|
Definition
| can be used to detect surface and near-surface flaws, such as cracks, voids, inclusions, and seams. When an electrically conductive material is brought near an alternating-current coil that produced an alternating magnetic field, surface currents (eddy currents) are generated in the material. These surface currents generate their own magnetic field, which interacts with the original, modifying the impedance of the originating coil. Various material properties and/or defects can affect the magnitude and direction of the induced eddy currents and can be detected by electronics. |
|
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Term
| Electrical resistivity (p.243) |
|
Definition
| is a function of a material's chemistry, processing history, and structural soundness. Measurement of resistivity can therefore be used to alloy identification, flaw detection, or the assurances of proper processing |
|
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Term
|
Definition
| There was a time when the detection of a flaw was considered to be sufficient cause for rejecting a material or component, and material specifications often contained the term flaw-free. Such a criterion, however, is no longer practical because the sensitivity of detection methods has increased dramatically. |
|
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Term
| Hardness testing (p. 232) |
|
Definition
| can be used to provide insight into the quality of a product; With the correct material and proper heat treatment, the resulting hardness values should fall within a well-defined range of values. Abnormal results usually indicate some form of manufacturing error, such as improprer material, missed operations or poorly controlled processes. Hardness tests can be performed quickly, and the surface indentations are often small enough that they can be concealed or easily removed from a product. |
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Term
|
Definition
| the ratio of the voltage phasor to the electric current phasor, a measure of opposition to time-varying electric current in an electric circuit; a change in the magnetic field causes a change in the __________ of the coil, which in turn changes the magnitude of the current flowing through it; |
|
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Term
|
Definition
| a form of nondestructive testing designed to determine the existence of absence of leak sites and the rate of material loss through the leaks |
|
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Term
| Liquid penetrant testing (p. 234) |
|
Definition
| also called dye penetrant inspection; an effective method of detecting surface defects in metals and other nonporous materials. |
|
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Term
| Magnetic particle inspection (p. 235) |
|
Definition
| based on the principle that ferromagnetic materials (such as the alloys of iron, nickel, and cobalt), when magnetized, will have distorted magnetic fields in the vicinity of material defects. |
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Term
| Nondestructive testing (aka nondestructive inspection) (P. 232 |
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Definition
| the product is examined in a manner that retains its usefulness for future services. Tests can be performed on parts during or after manufacture, or even on parts that are already in service. |
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Term
|
Definition
| a standard test piece used that is often included in a radiographic exposure; made of the same or similar material as the specimen and contain features with known dimensions. |
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Term
|
Definition
| a liquid material capable of wetting the entire surface and being drawn into fine openings; used in liquid penetrant inspecting |
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Term
|
Definition
| a means of assuring product quality where a product is subjected to a load or pressure of some determined magnitude (generally equal to or greater than the designer capacity or the condition expected during operation). |
|
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Term
| Pulse-echo method (p. 238) |
|
Definition
| an ultrasonic pulse is introduced into the piece to be inspected, and the echoes from opposing surfaced and any intervening flaws are detected by a receiver. |
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Term
| Radiographic Inspection (p238) |
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Definition
| a shadow pattern is created when certain types of radiation penetrate an object and are differentially absorbed due to variations in thickness, density, or chemistry, or the presence of defects in a specimen. The transmitted radiation is permanently registered on photographic film. |
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Term
|
Definition
| used to determine the thickness of a plate or sheet from one side of the material using ultrasonic waves. Input pulses of varying frequencies are fed into the material. Thickness is detected by the speed of sound and time of transverse.used to determine the thickness of a plate or sheet from one side of the material using ultrasonic waves. Input pulses of varying frequencies are fed into the material. Thickness is detected by the speed of sound and time of transverse. |
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Term
| Through Transmission Technique (p238) |
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Definition
| a technique of ultrasonic inspection in which a pulse is emitted by a sending transducer and is detected by a receiver transducer on the opposite surface. Flaws in the material decrease amplitude of the transmitted signal because of back-reflection and scattering. |
|
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Term
|
Definition
| (not in book) imaging by sections or sectioning, through the use of any kind of penetrating wave. |
|
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Term
|
Definition
| a device that transforms electrical energy into mechanical vibrations. It is used in Ultrasonic Inspection. |
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Term
| Ultrasonic Inspection (p237) |
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Definition
| involves sending high-frequency waves through a material and observing the response. Within the specimen, sound waves can be affected by voids, impurities, changes in density, delamations, and other imperfections. |
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Term
|
Definition
| the simplest and most widely used nondestructive testing method in which a person is trained to visually look for defects. Sometimes mirrors, magnifying glasses, and microscopes are used. |
|
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Term
|
Definition
| aim; the ability to hit the target or reach a goal. |
|
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Term
|
Definition
| in contrast to bottoming dies, these produce the bend geometry by simple three-point bending. Since the resulting angle is controlled by the bottoming position of the upper die, a single set of tooling can produce a range of bend geometries from 180 degrees through the included angle of the die and the pressure required to form the bends is the lowest of three options |
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Term
|
Definition
| In this process, the material flows in the other direction of the punch displacement. The billet, which is enclosed in die, is forced to flow in the backward direction from the annular region that resides amidst the die and punch |
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Term
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Definition
| a type of machine that can be used to make angles bends up to 150 degrees in sheet medal under 1.5 mm (1/16 in) thick, which is manually operated and can be used to produce linear bends up to about 3.5 m (12 ft) in length |
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Term
|
Definition
| the plastic deformation of metals about a linear axis with little or no change in the surface area. Each axis of the material must be linear and independent of the others |
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Term
|
Definition
| once the process has been designed and the tooling manufactured, the primary variable for process adjustment is this (AKA holddown force) |
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Term
|
Definition
| a shearing operation where the shear blades are closed, curved lines along the edge of a punch and die. Done on a press, the piece being punched out in this process becomes the workpiece and any major burrs or undesirable features should be left on the remaining strip |
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Term
|
Definition
| in contrast to air-bend die, this contracts and compresses the full area within the tooling. The angle of the resulting of the resulting bend is set by the geometry of the tooling, and subsequent springback. |
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Term
|
Definition
| in this, fluid or rubber is used to transmit the pressure required to expand a metal blank or tube outward against a split female mold or die. |
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Term
|
Definition
| involves rubbing a smooth, hard object (under considerable pressure) over the minute surface irregularites that are produced during machining or shearing |
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Term
|
Definition
| If bottoming dies continue to move beyond the bottoming position, the material between the upper and lower die is plastically deformed, and the operation extends into this. This term also refers to the cold squeezing of metal while all of the other surfaces are confined within a set of dies. |
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Term
|
Definition
| large quantities of products are now being made by this (AKA cold forming) a family of processes in which slugs of material are squeezed int shaped die cavities to produce finished parts of precise shape and size |
|
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Term
|
Definition
| is used for making enlarged sections on the ends of rods or wire, such as the heads of nails, bolts, rivets or other fasteners. |
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Term
|
Definition
| the dominant cold-working process in terms of product tonnage. Sheets, strips, and rods are cold-rolled into products that have smooth surfaces and accurate dimensions. Because of smaller size and higher strength of the material (compared to hot rolling) most of ______ is performed on four-high or cluster-type rolling molls |
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Term
|
Definition
| processes that have been developed to perform a wide variety of deformations that can be classified into four basic categories: squeezing, bending,shearing, and drawing. These processes can also be used to improve or alter surfaces of metal products |
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Term
|
Definition
| in this process, piercing and blanking, or other combinations of operations, occur sequentially during a single stroke of the ram - usually a more precise process, by more expensive to do and are susceptible to breakage |
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Term
|
Definition
| in this process, the bending form remains stationary and the pressure tool moves along the surface of the workpiece |
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Term
|
Definition
| in terms of commercial application, the most significant for creating deformation is probably this process in which continuous feedstock is inserted into agrooved wheel and is driven by surface friction into a chamber created by a mating die segment. Upon impacting a protruding abutment, the material upsets to conform to the chamber, and the increased wall contact further increases the driving friction |
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Term
|
Definition
| if the pushing force could be applied to the periphery of h feedstock, rather than the back, continuous feedstock could be converted into continuous product, and the process could become one of ___ ( hich was first performed in 1970) |
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Term
|
Definition
| a punch and die operation used to separate a stamping or other product from a strip of stock - quite common in progressive die sequence |
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Term
|
Definition
| as opposed to shallow drawing, this term is used when the depth is greater than the diamete |
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Term
|
Definition
| metal or plate (often one of a pair) so cut or shaped as to give a certain desired form to, or impress any desired device on, an object or surface, by pressure or by a blow; used in forging metals, coining, striking up sheet metal, etc. |
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Term
|
Definition
| a modified shearing operation that is used to blank shapes from low-strength materials, such as rubber, fiber, or cloth |
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Term
|
Definition
| a technique that can provide variable constraint is the use of ____, rib-like projections and matching grooves in the die and blankholder. The added force of bending and unbending restricts the flow of material, and the degree of constraint can be varied by adjusting the height shape and size of the bead and bead cavity. |
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Term
|
Definition
| Since the product cannot be readily bent or coiled, straight-pull ____ are generally employed with finite length feedstock. |
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Term
|
Definition
| where the workpiece is clamped against a bending form and the entire assembly is rotated to draw the workpiece under a stationary pressure tool |
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Term
|
Definition
| key variables in deep drawing process include the blank diameter and the punch diameter which combine to determine this. |
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Term
|
Definition
| When the axes of deformation are not linear, or are not independent, the process is often called this______; the combination of tension and compress; Cold working process developed to perform a wide variety of deformations. This is a classification of one of the 4 major coldworking operations, 8 different processes according to their primary form of deformation: Bar and tube, wire, Spinning, Embossing, Stretch forming, sheet metal, Ironing, Superplastic forming |
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Term
|
Definition
| metal is deposited by plating, when the desired thickness has been attained, plating is stopped and the product is stripped from the mandrel |
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Term
|
Definition
| a conductive coil is positioned within a cylinder of conductive material, around the cylinder, or adjacent to a flat sheet. when a large capacitor bank is discharged, producing a current surge through the coiled conductor, the electromagnetic forces cause the material to be repelled from the coil. |
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Term
|
Definition
| is a press working process in which raised lettering and other designs are impressed in sheet material |
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Term
|
Definition
| Forming by use of explosive charges; examples: Free forming,cylinder Forming, and bulkhead forming; Shaping metal parts in dies by using an explosive charge to generate forming. |
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Term
|
Definition
| This is a type of rivet; when there is access to only one side of the assembly, this is one type of rivet that can be used for one-sided operations; The shank on the "blind" side of ________ expands to form a retaining head when a heated tool is touched against the exposed segment and detonates a charge. |
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Term
|
Definition
| in this process, a V-shaped protrusion is incorporated into the hold-down or pressure plate a a location slightly external to the contour of the cut, as pressure is applied to the hold down or pressure plate, the protrusion is driven into the material compressing the region to be cut; Shearing Operation |
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Term
|
Definition
| Flanges can be rolled on sheet metal in essentially the same manner as seams, however, the forming of both flanges and seams is a drawing operation, since the bending occurs along the curved axis |
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Term
|
Definition
| If a controlled internal diameter must be produced in a long-length product, this is utilized; This must be designed for the specific conditions of the material, reduction, and friction |
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Term
|
Definition
| (AKA Shear forming) Cones, hemispheres, and simular shapes are often formed by this; a modification of the spinning process in which each element of the blank maintains its distance from the axis of rotation. |
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Term
|
Definition
| when multiple bends are made with a single die it is often called this. |
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Term
|
Definition
| a quick and economic way to evaluate the severity of deformation in a formed part; a pattern or grid, like figure 19-84, is placed on the surface of a sheet by scribing, printing, or etching. |
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Term
|
Definition
| Type of impact extrusion; can be done with an open or closed die; In this process, the material flows in the direction of the punch displacement. Also, the rod / tube diameter is reduced by forcing it in a die, through an orifice. |
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Term
|
Definition
| (AKA rubber-die forming) based on the phenomenon that rubber of the proper consitency ,when totally confined, acts as a fluid and transmits pressure uniformly in all directions |
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Term
|
Definition
| method developed to form metals through the application of large amounts of energy in a very short time interval (high strain rate) HERF |
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Term
|
Definition
| once the process has been designed and the tooling manufactured, the primary variable for process adjustment is this (AKA blankholder force) |
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Term
|
Definition
| this is a cold working proccess that is used to plastically form recessed cavities in a workpiece. After hardening the hub is pressed into an anneal block until the desired impression is produced |
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Term
|
Definition
| produce motion as a result of the piston movement, and longer or variable-length strokes can be programmed within the limitations of the cylinder |
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Term
|
Definition
| This is another type of cold extrusion; High pressure fluid surrounds the workpiece, and applies the force necessary to extrude it through the die. The product emerges into either atmospheric pressure or a lower-pressure fluid filled chamber. |
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Term
|
Definition
| This is a family of processes that are are also known as cold extrusion. There are several variations, like forward and backward using both open and closed dies. This process was first used to shape low-strength metals (pb,Sn,Zn,AL) but in recent years has been applied to the forming of mild steel parts; often used in combination with cold heading; |
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Term
|
Definition
| This is created when punches and dies are mounted on a separate punch holder and die shoe, the holder and shoe are permanently aligned and guided by two or guide pins |
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Term
|
Definition
| process that thins the walls of a drawn cylinder by passing in between a punch and die whose separation is less than the original wall thickness |
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Term
|
Definition
| Manually operated presses such as foot operated or kick presses are generally used for very light work such as shearing small sheets. 446 |
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Term
|
Definition
| A piercing operation that forms either a lin cut (slit) or an actual hole in themetal, like those shown i n the left-hand portion of Figure 19-42. THe purpose of lancing is to permit the adjacent metal to flow more readily in subsequent forming operations.427 |
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Term
|
Definition
| Mechanical drives tend to provide fast motion ad positive control of displacement. The flexibility of a mechanical press is limited, since the length of the stoke is set by the design of the drive. Mechanical presses are preferred for operations that require the maximum pressure near the bottom of the stroke, such as cutting, shallow forming, drawing, and progressive and transfer die operations. 447 |
|
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Term
|
Definition
| The smallest bend radius that can be formed without metal cracking. 420 |
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|
Term
| Modular Tooling (AKA subpress dies) |
|
Definition
| A wide variety of standardized, self-contained die sets that have been developed. Can often be assembled an combined on the bed of a press to pierce or blank large parts that would otherwise require large and a costly complex die sets.429 |
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|
Term
| Multi-side Press or Four-slide machines(Fig19-91) |
|
Definition
| extremely versatile presses that are designed to produce small, intricately shaped parts from wire or coil feeds. Has four power-driven slides (or motions) set 90degrees apart. Set up times are long, used for products such as hinges, links, clips, and razor blades at high rates. 450 |
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|
Term
|
Definition
| The location that is neither stretched nor compressed 418 |
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Term
|
Definition
| In _____________, a contour is cut by producing a series of overlapping slits or notches (Fig. 19-43). In this manner, simple tools can be used to cut a complex shape from thick sheets of metal.428 |
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Term
|
Definition
| Used to remove segments from along the edge of an existing product. 428 |
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Term
|
Definition
| When a press is used, the rivet is usually headed in a single squeezing action, although the heading punch may also rotate so as to shape the head in a progressive manner, an approach known as ____________. 415 |
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Term
|
Definition
| Can be adapted produce thin, spray-formed products. Molten metal flows through a nozzle, atomized and carried by high velocity nitrogen jets. Tubes plates and simple forms can be produced from a variety of materials. Layered structures can also be produced by sequenced deposition. 446 |
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|
Term
| Parallel-Plate Hydroforming (AKA pillow forming) |
|
Definition
| Extends the hydroforming process to the simultaneous production of upper and lower contours. Two sheet metal blands are laser welded around the periphery or are strongly clamped between upper and lower dies. (You can continue reading on page 440 for more) |
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Term
|
Definition
| The mechanical working of surfaces by repeated blows of impelled shot or a round-nose tool. 417 |
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Term
|
Definition
| Consists of piercing a large number of closely spaced holes. 427 |
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Term
|
Definition
| Shearing operations where the shear blades are closed, curved lines along the edges of a punch and die. In piercing the punch-out is the scrap and the remaining strip is the workpiece. Blanking: the piece being punched out becomes the workpiece and any major burrs or undesirable features should be left on the remaining strip.427 |
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Term
|
Definition
| Same as Parallel Plate Hydroforming - Extends the hydroforming process to the simultaneous production of upper and lower contours. Two sheet metal blands are laser welded around the periphery or are strongly clamped between upper and lower dies.440 |
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Term
|
Definition
| Preferred when HERF methods are applied to mass production of forged-type products. In a _______________ press a sudden application of high pressure gas propels the upper die onto the workpiece.443 |
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Term
|
Definition
| Used to expand a tubular shank. 415 |
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Term
|
Definition
| Utilizes a downward descending bend die, which pushes into the center of material that is supported on either side by wind dies.422 |
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Term
|
Definition
| Mechanical or hydraulic presses with a long, narrow bed and short, adjustable strokes. 418 |
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|
Term
| Pressure Induced Ductility |
|
Definition
| Voids are suppressed in a compressed environment, resulting in a phenomenon known as such. 413 |
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Term
| Pressure to Pressure Extrusion |
|
Definition
| A product emerging from one pressurized chamber into a second high-pressure chamber. In effect, the metal deformation is performed in a highly-compressed environment. 413 |
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Term
|
Definition
| Consists of two or more sets of punches and dies mounted in tandem. The strip stock is fed into the first stock...431. Can be used for many combinations of piercing, blanking, forming, lancing, and drawing. |
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Term
|
Definition
| Basic component of a piercing a dn blanking die set. The punch descends, fitting within the die with uniform clearance. See pg 428 and figure 19-45 for clarification |
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Term
|
Definition
| (AKA shear)reduces cutting force substantially by tilting the punch face at an angle 428 |
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Term
|
Definition
| an expanded head is formed on the shank end of a fastener to permanently join sheets or plates of material. 415 |
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Term
|
Definition
| continuous form of 3-point bending where plates, sheets, beams, pipe, and even rolled shapes and extrusions are bent to a desired curvature using forming rolls |
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Term
|
Definition
| produces thin walled cylinders from thicker wall material with internal rollers expanding the inner diameter, and external rollers reducing the outer diameter 414 |
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Term
|
Definition
| process involves the progressive bending of a metal strip as it passes through a series of forming rolls at speed up to 80 m/min, only bending takes place and all bends are parallel to one another |
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Term
|
Definition
| subjects the material to a series of reverse bends, material passes through a series of rolls and bends up and down to stress surface beyond elastic limit, and replace any permanent set with a flat or straight profile 424 |
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Term
|
Definition
| the hardened rolls of a burnishing tool press against the surface a deform protrusions to more-nearly flat geometry. Can be used to improve the size and finish of internal and external cylindrical and conical surfaces 417 |
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Term
|
Definition
| used in Guerin process; designed to decrease tooling costs and/or setup time and expense; based on phenomenon that rubber of proper consistency, when totally confined, acts as a fluid and transmits pressure uniformly in all directions 439 |
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Term
|
Definition
| a bending operation that can be used to join the ends of sheet metal in some form of mechanical interlock |
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Term
|
Definition
| used when the depth of a product is less than its diameter 437 |
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Term
|
Definition
| - a finishing operation in which a small amount of metal is sheared away from the edge of an already blanked part; primary used to obtain greater dimensional accuracy, also to produce square or smooth edge 428 |
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Term
|
Definition
| (AKA rake angle) reduces cutting force substantially by tilting the punch face at an angle 424 |
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Term
|
Definition
| modification of the spinning process in which each element of blank maintains its distance from the axis of rotation; forms shapes such as cones and hemispheres 435 |
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Term
|
Definition
| mechanical cutting of materials without formation of chips or the use of burning or melting; when two cutting blades are straight 424 |
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Term
|
Definition
| can be obtained through cold rolling process in various conditions, and include skin rolled, quarter-hard, half-hard, and full-hard 408,414 |
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Term
|
Definition
| family of processes in which a rubber bladder backed by oil pressure, or pockets of pressurized fluid, replace either a solid punch, or female die of the traditional tool set |
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Term
|
Definition
| involves squeezing all or selected regions of forgings, ductile casting or powder metallurgy products, to achieve a prescribed thickness or enhance dimensional precision 414 |
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Term
|
Definition
| length-wise shearing process used to cut rolls of sheet metal into several rolls of narrower width 427 |
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Term
|
Definition
| method uses energy of electrical discharge to shape the metal 443 |
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|
Term
|
Definition
| cold forming operation where a rotating disk of sheet metal is progressively shaped over a male form, or mandrel, to produce rotationally symmetrical shapes such as cones, hemispheres, cylinders, bells, or parabolas |
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Term
|
Definition
| small amount of "unbending" that results from elastic recovery when the bending load is removed |
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Term
|
Definition
| used when sheets of metal need to be sheared along a straight line; while metal is firmly held in place by clamping bar or clamping fingers, a moving blade comes down upon a fixed blade and shears the metal |
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Term
|
Definition
| formed by spray deposition; one method is to inject powdered material into a plasma torch, where particles melt and are propelled onto a shaped form, or mandrel 446 |
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Term
|
Definition
| method of permanently joining parts together when a segment of one part protrudes through a hole in the other 415 |
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Term
|
Definition
| 430 - A technique that can be used to cut metal and a wide variety of softer materials. Also known as the "Cookie-cutter" die. Here the cutting die is fashioned from hardened steel strips, known as _________. |
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Term
|
Definition
| 445 - A quick and economical means of evaluating the severity of deformation in a formed part. |
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Term
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Definition
| 436 - An attractive means of producing large sheet metal parts in low or limited quantities. |
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Term
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Definition
| 424 - When sheets are straightened. Here the material is gripped mechanically and stretched beyond the elastic limit to produce the desired flatness. |
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Term
|
Definition
| When the axes of deformation are not linear, or are not independent, the process is often called this______ (AKA Drawing) |
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Term
|
Definition
| 408,427 - Cold rolled into products that have smooth surfaces and accurate dimensions. A cold-rolled strip can be obtained in various conditions. |
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Term
|
Definition
| 428 - The basic component of a piercing and blanking die set. It is attached above the die to keep the strip material from ascending with the retracting punch. |
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Term
|
Definition
| 429 - A type of self-contained die set. These can often be assembled and combined on the bed of a press to pierce or blank large parts that would otherwise require large and costly complex die sets. |
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Term
|
Definition
| 444 - A type of behavior that can be used to form material into large, complex-shaped products with compound curves. |
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Term
|
Definition
| 408 - uses external hammering to reduce the diameter, taper, or point round bars or tubes. (Also know as rotary swagging or radial forging) |
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Term
|
Definition
| 408 - A more specialized cold-rolling operation that is an alternative to the cutting of threads. |
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Term
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Definition
| 432 - When individual parts are mechanically moved from die to die within a single press. |
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Term
|
Definition
| 449 - Have a long moving slide that enables multiple operations to be performed simultaneously in a single machine. |
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Term
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Definition
| 438 - Used to establish both the size and uniformity of the final part. |
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Term
|
Definition
| 423 - Key parameters in ___________ are the outer diameter of the tube, the wall thickness, and the radius of the bend. |
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Term
|
Definition
| 433 - Can be used to produce high-quality tubing where the product requires the smooth surfaces, thin walls, accurate dimensions, and added strength (from the strain hardening) that are characterisitic of cold forming. |
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Term
|
Definition
| 442 - Has emerged as a significant process for manufacturing strong, lightweight, one-piece automotive components, which frequently replace an assembly of welded stampings. |
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Term
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Definition
| 433 - Thick-walled tubes and those less than 12mm (1/2 in) in diameter are often drawn without a mandrel in this process. |
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Term
|
Definition
| 432 - Used when many holes of varying sizes and shapes are to be placed in sheet components. In these machines, as many as 60 separate hole punches and dies are contained withing a turret. |
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Term
|
Definition
| Is used to make a relatively complex part during cold forming to make the part specific to close tolerances. |
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Term
|
Definition
| Is essentially the same process as bar drawing except that it involves smaller diameter material. Because the material can be coiled, the process can now be conducted in a somewhat continuous manner on rotating draw blocks. |
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Term
|
Definition
| ceramic slurry formed around metal or wood patterns that can produce thin sections and fine detail |
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Term
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Definition
| third segment, along with cope and drag, used to make specific angles and shapes in a casting. |
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Term
|
Definition
| the ability to retain a given shape when packed into a mold |
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Term
|
Definition
| Any core binder process that uses a gas or vaporized catalyst to cure a coated sand[mold] while it is in contact with the core box at room temperature |
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Term
|
Definition
| the ability to permit the metal to shrink after it solidifies and ultimately to free the casting by disintegration of the surrounding mold |
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Term
|
Definition
| determined by sifting loose sand into a steel cylinder, leveling off the column, striking it three times with a standard weight, and measuring the final height |
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Term
|
Definition
| measure of the material's ability to withstand handling and avoid erosion during a pour |
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Term
|
Definition
| patterns that are in cope and drag section to allow easier formation of large molds |
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Term
|
Definition
| Process that uses a vegetable or synthetic oil binder and water with cereal or clay to develop green strength |
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Term
| Counter-gravity investment casting |
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Definition
| aka hitchiner process, uses vacuum to suck metal into the mold |
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Term
|
Definition
| long-lasting mold made by baking off almost all the moisture within the sand |
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Term
|
Definition
| liquid nitrogen is sprayed on the mold surface and becomes a binder. Like a shell. |
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|
Term
| Evaporative pattern casting |
|
Definition
| type of casting process that uses a pattern made from a material that will evaporate when the molten metal is poured into the molding cavity. The most common evaporative-pattern material used is polystyrene foam. |
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Term
|
Definition
| creates a parting surface for a simple casting, where the cope is the entire mold cavity |
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Term
|
Definition
| process that uses a expendable pattern to produce a closed mold system |
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Term
|
Definition
| inexpensive casting process using sand, clay, water, and additives |
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Term
|
Definition
| often the preferred method of mold making when only a few castings are to be made from any given design. Focused on application in the making of sand molds |
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Term
|
Definition
| determined by the resistance of the sand to penetration by a .2inch diameter spring-loaded steel ball |
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Term
|
Definition
| sand containing a liquid thermosetting binder and catalyst is packed into a core box that has been heated to around 230⁰C. When the sand contacts the hot surface, the catalyst is heated, and the initial stages of curing occur within 10 to 30 seconds. The core can then be removed from the pattern and will hold its shape during further handling. For some materials, the cure completes through an exothermic curing reaction. Others require further baking to complete the process. |
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Term
|
Definition
| contracting metal during shrinkage may develop tensile stresses and crack while it is still weak |
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Term
|
Definition
| mold is dropped several times to pack the sand around the pattern |
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Term
|
Definition
| separate pieces are held to a primary pattern segment by beveled grooves or pins |
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Term
|
Definition
| uses pins to align cope and drag |
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Term
|
Definition
| device that kneads, rolls, and stirs the sand |
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Term
|
Definition
| consists of sand molds created using a wood, metal or plastic pattern. Sand is mixed with a urethane binder and deposited into a box containing the pattern (and all necessary formers and inserts) for pouring. The sand mixture sets hard in a short time, and the mold is then removed from the pattern. Cores for forming internal passages in the castings are made using the same process. |
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Term
|
Definition
| a measure of how easily gases can pas through the narrow voids between the sand grains |
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Term
|
Definition
| a white powder that forms a paste when it is mixed with water and then hardens into a solid, used in making casts, molds, and sculpture. Aka Plaster of Paris |
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Term
|
Definition
| the ability to withstand high temperatures |
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Term
|
Definition
| buckling or folding at the surface of the mold cavity due to uneven heating |
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Term
|
Definition
| used to produce large mold with uniform compaction throughout |
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|
Term
| Shaw (Osborn-Shaw) process |
|
Definition
| A precision casting technique in ceramic molds which do not require wax or plastic investment. |
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Term
|
Definition
| process using fine silica sand that offers good surface finish |
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Term
|
Definition
| mold made by drying only the surface of the sand adjacent to the mold cavity |
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Term
|
Definition
| metal band placed around the mold to hold the sand in place |
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Term
|
Definition
| process used to pack sand in a mold using an air-operated squeeze head and a diaphragm or other individual squeeze heads |
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|
Term
|
Definition
| More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. |
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Term
|
Definition
| sections containing a cope impression on the bottom and a drag impression on the top are piled vertically on top of each other |
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Term
|
Definition
| sand placed in 2in diameter steel tube, 14 lb weight dropped from 2in 3 times, used for permeability and strength tests |
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|
Term
| V process (Vacuum molding) |
|
Definition
| vacuum performs the role of sand binder using a sheet of softened plastic |
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|
Term
| Vertically parted flaskless molding |
|
Definition
| used in mass production molding. Figure 14-15 on pg 305. |
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|
Term
|
Definition
| electrodes create an arc between themselves and the metal charge, located in a pool of metal at the bottom |
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|
Term
|
Definition
| inertial forces of rotation or spinning are used to distribute the molten metal into the mold cavity |
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Term
|
Definition
| uses centrifugal action to force the metal from a central pouring reservoir, through runners, into separate mold cavities that are offset from the axis of rotation |
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Term
|
Definition
| used for materials that are not suitable for hot-chamber die casting |
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|
Term
|
Definition
| usually employed in the solidification of basic shapes that become a feedstock for deformation processes such as rolling and forging (like a roll of cookie dough) |
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Term
|
Definition
| a refractory-lined, vertical steel shell where mixtures are melted and the molten material collects at the bottom of the cupola |
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Term
|
Definition
| molten metal forced into metal molds under pressures of several thousand psi and held under this pressure during solidification |
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Term
|
Definition
| (AKA reverberatory furnaces) |
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|
Term
|
Definition
| metal is contained and solidified in an electromagnetic field designed to counteract the gravitation forces and hydrostatic pressure of the metal column |
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Term
|
Definition
| rate of temperature change causing cracks in a die |
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|
Term
| Heated manifold direct injection casting |
|
Definition
| Used to cast zinc, metal is forced through mininozzels which eliminate the need for gates and runners. |
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Term
|
Definition
| aka gooseneck design, gives fast cycles times |
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|
Term
| Indirect fuel-fired furnaces |
|
Definition
| used for small-batches, i.e. crucibles, holding pots |
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|
Term
|
Definition
| uses a high-frequency electric current around a crucible to induce secondary currents within the metal that results in a rapid rate of heating |
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|
Term
|
Definition
| can be electrical heating elements, threaded studs, etc |
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|
Term
| Low-pressure permanent mold casting |
|
Definition
| low-pressure 3-15psi gas acts on the surface of a molten metal bath. In response, the metal rises up a refractory tube and enters the mold from the bottom |
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|
Term
|
Definition
| eliminates gas porosity by injecting oxygen into the mold before each die casting |
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|
Term
|
Definition
| cores made of metal than can be retracted from the mold to produce complex castings |
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Term
|
Definition
| aka direct fuel-fired, much like an open hearth, heat is transferred through radiant heating from the refractory roof and walls and convective heating from the hot gases |
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|
Term
|
Definition
| centrifugal force assists the flow of metal from a central reservoir the the extremities of a rotating symmetrical mold |
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|
Term
|
Definition
| injection of semisolid materials into reusable metal dies under high pressures |
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|
Term
|
Definition
| shell of metal is allowed to solidify in a mold, then the remaining liquid metal is poured out |
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|
Term
|
Definition
| metal introduced slowly to avoid turbulence, then pressure is applied |
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|
Term
|
Definition
| high number of cycles resulting in cracks in a die |
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|
Term
|
Definition
| semisolids that can be handled mechanically like a solid, but flow like a liquid when agitated or squeezed |
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|
Term
| Vacuum permanent mold casting |
|
Definition
| a vacuum is used to draw material into a mold cavity |
|
|
Term
|
Definition
| since molds are not permeable, small vent holes or cracks between mold halves must permit the escape of trapped air |
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|
Term
|
Definition
| noncrystalline, glassy metals that form if the cooling rate approaches or exceeds 10 degrees Celsius |
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|
Term
|
Definition
| a measure of a powder's ability to fill available space without application of external pressure |
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|
Term
|
Definition
| where a liquid is fragmented into molten droplets which then solidify into particles |
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|
Term
|
Definition
| first stage of sintering, combusts any air, volatizes and removes any lubricants or binders that would interfere with a good bonding, and slowly raises the temperature of the compacts in a controlled manner |
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|
Term
|
Definition
| powder in a flexible isolating medium |
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|
Term
|
Definition
| an operation to restore or improve dimensional precision |
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|
Term
|
Definition
| loose powder is compressed and densified into a shape known as a green compact |
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|
Term
|
Definition
|
|
Term
|
Definition
| tests evaluate the effectiveness of applied pressure in raising the density of a powder |
|
|
Term
|
Definition
| the measure by which powder can be fed and distributed into a die |
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|
Term
|
Definition
| strength imparted by compaction to permit a reasonable amount of handling |
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|
Term
|
Definition
| combines powder compaction and sintering into a single operation that involves gas-pressure squeezing at elevated temperature |
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|
Term
|
Definition
| forcing of oil or other liquid into the porous network |
|
|
Term
|
Definition
| in the process a metal or alloy with a lower melting temperature than the P/M constituent flows into the interconnected pores of the product by pressure or capillary action |
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|
Term
|
Definition
| process to make extremely complex shapes, powder is encapsulated in a flexible mold and immersed in a pressurized gas or liquid |
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|
Term
|
Definition
| process when the product is composed of more than one material, and the sintering temperature is above the melting temperature of one or more of the components which causes those liquid particles to flow and fill in the voids between the remaining particles |
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Term
|
Definition
| powder is injected and then melted in the mold |
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Term
|
Definition
| called this if massive metal deformation takes place in the second pressing |
|
|
Term
|
Definition
| name of the process by which fine powdered materials are blended, pressed into a desired shape, and then heated (sintered) to establish desired properties |
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Term
|
Definition
| mixtures that already contain the desired alloy concentration |
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|
Term
| Pressure-assisted sintering (sinter HIP) |
|
Definition
| process to produce full-density powder products without the expense of canning and decanning |
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Term
|
Definition
|
|
Term
|
Definition
| process by which two or more pieces are joined by brazing while also being sintered |
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|
Term
|
Definition
| pressed powder compacts are heated in a controlled atmosphere environment to a temperature below the melting point but high enough to permit solid-state diffusion and bonding of the particles |
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|
Term
| Spray forming (osprey process) |
|
Definition
| droplets are sprayed onto a collecting container |
|
|
Term
|
Definition
| by preheating the powder prior to processing, the metal is softened and responds better to applied pressures |
|
|
Term
|
Definition
| The softer interior portion of an alloy piece that has been surface (case) hardened; or, that portion of a forging removed by trepanning or punching. |
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|
Term
|
Definition
| Portions of a pattern that locate and anchor the core in the proper position in the sand. |
|
|
Term
|
Definition
| A foamed styrene plastic; has high resistance to heat flow; mechanical strength relatively high for such a light material. |
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|
Term
|
Definition
| A frame for holding a sand mold in a foundry |
|
|
Term
|
Definition
| The end of a runner in a mold where molten metal enters the mold cavity |
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|
Term
|
Definition
| Casting metal into a mold produced by surrounding (investing) an expendable pattern with a refractory slurry that sets at room temperature after which the wax, plastic, or frozed mercury pattern is removed through the use of heat. Also called precision casting, or lost-wax process. |
|
|
Term
|
Definition
| is a type of evaporative-pattern casting process that is similar to investment casting except foam is used for the pattern instead of wax. |
|
|
Term
|
Definition
| aka Investment Casting. Casting metal into a mold produced by surrounding (investing) an expendable pattern with a refractory slurry that sets at room temperature after which the wax, plastic, or frozed mercury pattern is removed through the use of heat. |
|
|
Term
|
Definition
| Solid pattern, not necessarily made from one piece of material. May have one or more loose pieces |
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|
Term
|
Definition
| A channel through which molten metal or slag is passed from one receptacle to another; in a mold, the portion of the gate assembly that connects the downgate or sprue with the casting ingate or riser. |
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|
Term
|
Definition
| The operation of removing castings from the mold or a mechanical unit for separating the molding materials from the solidified metal casting. |
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|
Term
| Sodium Silicate -CO2 molding |
|
Definition
| Instead of using an oil or resin that requires heat for bonding or curing, this process uses a sand which has been mixed with sodium silicate |
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|
Term
|
Definition
| The hole through which molten material is channelled into a mold. |
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|
Term
|
Definition
| The water glass is mounted to the water column and has a series of vertical buttons which change color from green to red to indicate the level of water in the column. Green represents water and red indicates steam. This allows for visual observation of the water level in the boiler at all times. |
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|
Term
|
Definition
| An attractive means of altering properties while retaining the shape of the product. |
|
|
Term
|
Definition
| Porosity that is at or connected to free surfaces can be filled with resinous material, such as polyester. |
|
|
Term
|
Definition
| while not as flexible as sand castings in allowing the use of different patterns (different part designs), lower the cost of producing a part. At a production run of 1000 or more parts, permanent mold castings produce a lower piece cost part. Of course, the break-even point depends on the complexity of the part. More complex parts being favored by the use of permanent molds. |
|
|
Term
|
Definition
| Determined largely by the size and number of castings to be poured. Used to transfer the metal from the melting surface to the molds. |
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|
Term
|
Definition
| A dry-sand, graphie, or metal mold rotates about either a horizontal or vertical axis speeds of 300 to 3000rpm |
|
|
Term
|
Definition
| a substance for holding compacted metal powder together while it is being sintered (Internet). Binders produce the reverse effect of Lubricants. Most lubricants or binders are not wanted in the final product and are removed (volatilized or burned off) in the early stages of sintering, leaving holes that are reduced in size or closed during subsequent heating. (From Book) |
|
|
Term
|
Definition
| Done either dry or wet, where water or other solvent is used to enhance particle mobility, reduce dusting, and lessen explosion hazards. |
|
|
Term
|
Definition
| a substance capable of reducing friction by making surfaces smooth or slippery. Lubricants such as graphite or stearic acid improve the flow characteristics and compressibility at the expense of reduced green strength. |
|
|
Term
|
Definition
| Done either dry or wet, where water or other solvent is used to enhance particle mobility, reduce dusting, and lessen explosion hazards. |
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|
Term
| Particle Shape, Particle size, and Size Distribution |
|
Definition
| Important properties and characteristics of the starting powder by which the products of powder metallurgy depend. |
|
|
Term
|
Definition
| The rate of flow of a liquid or gas through a porous |
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|
Term
|
Definition
| The ratio of the volume of all the pores in a material to the volume of the whole |
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|
Term
| Rapidly solidified Powder |
|
Definition
| Microcrystalline and Amorphous; increased cooling rate |
|
|
Term
| Repressing (coining or sizing) |
|
Definition
| May be required to restore or improve dimensional precision |
|
|
Term
| Sizing (coining or repressing) |
|
Definition
| May be required to restore or improve dimensional precision |
|
|
Term
|
Definition
| A characteristic of the powder being compressed. |
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|
Term
|
Definition
| process with high production speed but high setup cost |
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|
Term
|
Definition
| is a metal welding process in which round or profile stock is welded end to end. |
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|
Term
|
Definition
| smaller than a bloom and has a square of circular cross section |
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|
Term
|
Definition
| intermediate forging impressions that approximate a piece's final shape |
|
|
Term
|
Definition
| has a square or rectangular cross-section, thickness greater than 6in, and a width no greater than twice the thickness |
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|
Term
| Bulk deformation processes |
|
Definition
| processes where the surface area of the workpiece changes significantly |
|
|
Term
|
Definition
| Butt welding can be used to run a processing machine continuously, as opposed to having to restart such machine with a new supply of metals. Usually, the seams (or abutment sections) are cleaned and prepared, and set on an automated piece of equipment which then welds the two materials together. Afterward, the material is usually ground down to a smooth finish and either sent on its way to the processing machine, or sold as a completed product. |
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|
Term
|
Definition
| uses backup rolls to support smaller work rolls |
|
|
Term
|
Definition
| A hot rolling process in which the temperature of the steel is closely controlled, particularly during the final rolling passes, to produce a fine-grain microstructure. |
|
|
Term
|
Definition
| two horizontal hammers that simultaneously impact a workpiece placed between them |
|
|
Term
|
Definition
| a solid ram drives the entire billet through a stationary die |
|
|
Term
|
Definition
| plastic deformation process in which a flat sheet or plate is formed into a recessed, three-dimensional part with a depth more than several times the thickness of the material (like punch) |
|
|
Term
|
Definition
| a specialty forging machine that may be powered by air, hydraulics, or mechanics. Depending on how the machine is powered, the mass of the ram, and the drop height, the striking force can be anywhere from 11,000 to 425,000 pounds. |
|
|
Term
|
Definition
| metal is compressed and forced to flow through a suitably shaped die to form a product with a reduced but constant cross section |
|
|
Term
|
Definition
| temperature at which hot rolling is terminated, about 50-100 degrees above the recrystallization temperature |
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|
Term
|
Definition
| excess metal squeezed around the periphery of the die cavity |
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|
Term
|
Definition
| forging where the die provides total confinement. |
|
|
Term
|
Definition
| a family of processes where the deformation is induced by localized compressive forces |
|
|
Term
|
Definition
| a tool meant to deliver an impact to an object. |
|
|
Term
|
Definition
| move in response to fluid pressure in a piston |
|
|
Term
|
Definition
| same as counterblow machine. two horizontal hammers that simultaneously impact a workpiece placed between them |
|
|
Term
|
Definition
| uses shaped dies to control the flow of metal during forging |
|
|
Term
|
Definition
| a hollow ram pushes a die back through a stationary, confined billet |
|
|
Term
|
Definition
| process that thins the cup wall in a drawing process |
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|
Term
|
Definition
| used for tubular products |
|
|
Term
|
Definition
| can produce tubing up to 12 inches in diameter |
|
|
Term
|
Definition
| use means such a cams, cranks, or toggles to produce a preset and repeatable stroke |
|
|
Term
|
Definition
| a tenacious high temperature oxide that covers the surfaces of hot-rolled products |
|
|
Term
|
Definition
| processes that form parts close enough to final dimensions so that little or no final machining is required |
|
|
Term
|
Definition
|
|
Term
|
Definition
| a process in which two or more layers of metal are rolled simultaneously as a means of providing thicker input material |
|
|
Term
|
Definition
|
|
Term
|
Definition
|
|
Term
|
Definition
| the simplest and easiest way to join sections of pipe. |
|
|
Term
|
Definition
| thin flat sheet of metal. |
|
|
Term
|
Definition
| slow squeezing action that produces more uniform deformation and flow |
|
|
Term
|
Definition
| when the initial drawing is followed by a further reduction in diameter and concurrent increase in wall height. |
|
|
Term
|
Definition
| The process of shaping weldless rings from pierced disks or shaping thick-wall ring-shaped blanks between rolls that control wall thickness, ring diameter, height, and contour. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| round or flat bar stock reduced in thickness and increased in length |
|
|
Term
|
Definition
| usually the first process that is used to convert material into a finished wrought product |
|
|
Term
|
Definition
| billet is rolled axial through a mandrel to produce "rolled" tubing |
|
|
Term
|
Definition
| Long products are made of either blooms or billets, which are, like slabs, considered a semifinished product and are cast by a continuous caster or rolled at a blooming mill. Billets have a cross section 50 to 125 millimetres square, and blooms are 125 to 400 millimetres square. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| operations where the deformation of a material where the thickness and surface area remain relatively constant |
|
|
Term
|
Definition
| long steel strips of specified width, thickness, and edge configuration |
|
|
Term
|
Definition
| a rectangular solid where the width is greater than twice the thickness |
|
|
Term
|
Definition
| the "spider" holds the mandrel in place |
|
|
Term
|
Definition
|
|
Term
|
Definition
|
|
Term
|
Definition
| The shape of a member especially adapted to structural purposes, esp. in giving the greatest strength with the least material. |
|
|
Term
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Definition
| process to reduce the diameter of a rod or tube by hammering or compression. The term swaging is also applied to a process where material is forced into a confining die to reduce its diameter, and this process is often performed hot. |
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Term
| Thermomechanical processing |
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Definition
| consists of integrating deformation and thermal processing into a single process that will both produce the desired shape and desired properties |
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Definition
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Definition
| to beat a material on the end making it shorter and thicker. |
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Definition
| involves increasing the diameter of a material by compressing its length. In terms of the number of pieces produced, it is the most widely used of all forging processes. |
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Definition
| The process of rubbing, grinding, or wearing away by friction |
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Definition
| the condition in which a material sticks to itself or another material |
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Definition
| where properties vary with direction |
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Definition
| Heating to and holding at a suitable temperature and then cooling at a suitable rate, for such purposes as reducing hardness, improving machinability, facilitating cold working, producing a desired microstructure, or obtaining desired mechanical, physical, or other properties. |
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Definition
| The forming of a metal part, by pressure, into a curved or angular shape, or the stretching or flanging of it along a curved path. |
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Definition
| (from the book) The deformation may be ________ in three dimensions. |
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Definition
| A unitless number indicating the mechanical or molecular interaction between two surfaces in contact. 1 represents immovable, 0 would represent a lack of friction. |
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Definition
| plastic deformation of metals below the recrystallization temperature. |
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Definition
| the mathematical description of material behavior as a function of the process conditions |
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Definition
| processes designed to exploit the property of plasticity |
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Definition
| aspects of a process for which control is totally indirect |
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Definition
| ...precision with dimensions |
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Definition
| crystallographic defect or irregularity |
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Definition
| If a material is strained beyond its elastic limit, it is strained both elastically and plastically. When the strain is relieved, the plastic deformation will remain, but the elastic deformation will "springback." |
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Definition
| When a metal is plastically deformed, the impurities tend to flow along with the base metal, or fracture into rows of fragments that are aligned in the direction of working. These nonmetallic impurities do not recrystallize with the base metal but retain their distorted shape and orientation. The product exhibits a flow structure, and properties tend to vary in different directions. |
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Definition
| A force that resists the relative motion or tendency to such motion of two bodies or substances in contact. Note that in metalworking conditions this is constantly changing due to changes in pressure, temperature, area, surface finish, and lubricant. |
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Definition
| the plastic deformation of metals at a temperature above the recrystallization temperature. |
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Definition
| those aspects of a process for which control is direct and immediate |
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Definition
| annealing to restore ductility |
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Definition
| constant-temperature forming |
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Term
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Definition
| These are generally selected for their ability to reduce friction and suppress tool wear. Secondary considerations may include the ability to act as a thermal barrier, the ability to act as a coolant, and the ability to retard corrosion. |
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Term
| Luders bands (stretcher strains) |
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Definition
| defect resulting from yield point runout where some parts of the material retain shape and others thin out. |
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Definition
| using the grain structure/strain deformations/crystal structure to give a material strength in a specific direction/orientation. |
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Definition
| the ability to flow as solid without a deterioration of properties |
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Definition
| When a metal has experienced a sufficient amount of deformation, the distorted structure will be rapidly replaced by new strain-free grains.. The process of reducing the internal energy by the formation of new crystals. |
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Definition
| is a metalworking process which cuts stock without the formation of chips or the use of burning or melting. |
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Definition
| materials that appear to be stronger when deformed at higher speeds |
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Definition
| the small elastic portion of the stress-strain curve that remains after a material has been deformed |
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Term
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Definition
| strengthening of a metal by plastic deformation. |
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Term
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Definition
| When a metal is plastically deformed, the impuritiues tend to flow along with the base metal, or fracture into rows of fragments, ________ , that are aligned with the direction of crack propagation. |
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Definition
| A dependent variable of forming processes. Dependent on the specific details of the process. |
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Definition
| (simple definition) stuff used to mold and shape stuff |
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Definition
| the study of friction and lubrication |
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Definition
| deformation produced at temperatures in between hot and cold working |
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Definition
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Definition
| where a material may strain up to several percent without addition force applied |
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Definition
| a narrow band of randomly oriented crystals that forms on the surface of a casting |
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Definition
| smallest cross-sectional area that serves to control the rate of metal flow |
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Definition
| equation that computes total solidification time |
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Definition
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Definition
| long, thin columnar grains |
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Term
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Definition
| the rate at which the liquid or solid is cooling, also the slope of the cooling curve |
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Definition
| mold or die used to produce casting cores |
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Term
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Definition
| risers that fill with metal that has already flowed through the mold cavity |
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Term
| Directional solidification |
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Definition
| where the solidification interface sweeps continuously through the material |
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Term
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Definition
| a.k.a Slag, metal oxides that form in the melt that impair surface finish |
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Definition
| the interior of a casting, filled with spherical, randomly oriented crystals |
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Definition
| material placed adjacent to the casting to accelerate cooling of various regions |
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Definition
| the ability of a metal to flow and fill a mold |
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Definition
| the difference between the liquidus and solidus temperatures |
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Definition
| process that passes small bubbles of inert or reactive gas through the melt |
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Definition
| dissolved gas that tends to form bubbles within the casting |
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Term
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Definition
| occurs as the heat of fusion is extracted from the liquid material |
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Definition
| thick sections of casting where sections meet that cool more slowly than other parts |
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Definition
| the act of intentionally introducing impurities into the pour |
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Definition
| pieces of metal that are placed within the mold cavity to absorb heat and promote more rapid solidification |
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Term
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Definition
| risers that receive the last hot metal that enters the mold |
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Term
| Local solidification time |
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Definition
| time from the start of solidification to the end of solidification |
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Definition
| allowance for the surface of the casting to undergo machining |
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Definition
| when a stable particle of solid forms from within the molten liquid |
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Definition
| model of the part being cast used to make molds |
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Definition
| defect where the metal fills the small voids between the particles of a sand mold |
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Definition
| the temperature of the melt when it first enters the mold cavity |
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Definition
| an increase in temperature brought about by local solidification |
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Definition
| rulers that are larger than a standard rule by the approximate shrink allowance |
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Definition
| volumetric decrease in material as it cools |
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Term
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Definition
| insulates risers to slow cooling |
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Definition
| dissipates the kinetic energy of metal coming down the sprue |
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Term
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Definition
| the difference between the pouring temperature and the freezing temperature of the material |
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Term
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Definition
| the plateau in the cooling curve that occurs during the solidification of a material with a fixed melting point |
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Term
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Definition
| insulates riser to slow cooling |
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Term
| Total solidification time |
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Definition
| time from the start of the pouring to the end of solidification |
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Term
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Definition
| tends to promote absorption of gases, oxidation, and erosion of the mold |
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Definition
| difference between the pouring temperature and the actual temperature of nucleation |
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Term
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Definition
| process that sprays the molten metal through a low-pressure environment |
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