Manufacturing Processes

Use this for “A 10 cm cube casting (M = 1.667 cm, B = 2 min/cm²) needs a side riser with H = D. How wide?”

Use this for “A 25 mm slab is rolled to 20 mm with 250 mm rolls and μ = 0.15. Can one pass do it?”

Use this for “Steel with K = 275 MPa, n = 0.15 is rolled to ε = 0.223 over 300 × 35.4 mm at 50 rpm. Find the roll force and power.”

Use this for “Is extrusion casting, bulk forming, sheet forming, material removal or joining?”

Use this for “A carbide tool has n = 0.25 and C = 400 m/min. How long does it last cutting at 200 m/min?”

Use this for “An 80 mm cutter with 6 teeth runs at 120 m/min and 0.1 mm/tooth, 40 mm wide and 3 mm deep. Find the spindle speed, table feed and removal rate.”

Use this for “Turning steel at 150 m/min, 0.25 mm/rev and 2 mm deep needs 2.8 J/mm³. Find the cutting power, and the motor power at 85 % efficiency.”

Use this for “A tool with 0.8 mm nose radius turns at 0.25 mm/rev. Find the ideal roughness Rₐ and the cusp height.”

Use this for “0.2 mm layers on a face at 30° from the build plate. How high is the cusp?”

Use this for “A 0.4 mm wide, 0.2 mm tall bead at 60 mm/s. How long does 12 cm³ of plastic take?”

Use this for “Which additive family is SLS? Which is wire-and-arc DED?”

Use this for “Put these in order for a metal powder-bed part: slice, stress-relieve, add supports, cut from the plate.”

Use this for “Four parts in a row are ±0.05, ±0.10, ±0.05 and ±0.02 mm. Find the gap’s worst-case and RSS tolerance.”

Use this for “A shaft is 25.000 ± 0.030 mm. The process runs at a mean of 25.006 mm with σ = 0.008 mm. Find Cₚ, Cₚₖ and the share outside.”

Use this for “A 25.000–25.021 mm hole takes a 25.002–25.015 mm shaft. Which kind of fit is it?”

Use this for “A 5/16 in fillet weld 6 in long has an allowable shear of 21 ksi on the throat. What load can it carry?”

Use this for “A spot weld runs 10 kA through 0.1 mΩ for 0.2 s; 30% of the heat goes into the nugget (Uₘ = 10 J/mm³). Find the heat and the nugget’s volume.”