INSY Final Exam
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Complete list of Terms and Definitions for INSY Final Exam

Terms Definitions
Piercing ...
Wire Cutting - ...
Dimensional Precision ...precision with dimensions
Glass High strength; dimensional stability; translucence.
lapping an abrasive surface-finishing process where fine abrasive particles are charged (or embedded) into a soft material (called a ___). The material can range from cloth to cat iron or copper.
Sleeves insulates risers to slow cooling
duplicators produce forms in 3 dimensions
lattice regular geometric array, describable through a unit cell
Cermet combinations of metals and ceramics (usually oxides, carbides, nitrides, or carbonitrides), united into a single product by procedures of powder metallurgy that provide high hardness, toughness, and thermal shock resistance
Flow Shop: Characterized by larger lots, special-purpose machines and equipment, less variety, and more mechanization. These layouts are typically either continuous or interrupted and can be for manufacturing or assembly
Tows 471 - Untwisted assemblies of fibers.
Chemical blanking Through-etching of the workpiece. Typically performed using double-sided etching to increase production rates and minimize taper on the etched walls of the feature.
Inserts can be electrical heating elements, threaded studs, etc
Pneumatic-mechanical 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
Spinning 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
Microstructure another level of structure produced by, the size, shape, and arrangement of multiple crystals, or the mixture of two or more different structures within a material.
Tailstock assembly containing three parts, a lower casting fits on the inner ways of the bed, an upper casting fits on the lower one, and the third major component of the assembly is the tailstock quill.
slab milling usually performed on horizontal milling machines. The tool rotates at some rpm while the work feeds past the tool at a table feed rate in inches per minute
flash oxides and other surface impurities are dispaced into this, can be removed by subsequent machining
Hardness A very important but hard-to-define property of engineering materials. There are several tests to test the hardness of a material.
Particulate Composite A composite material composed of particles embedded in a matrix.
Clay many ceramic materials have been based on this material to which various amounts of quartz and feldspar have been added. Selected proportions of this material are mixed with water, shaped, dried and fired to produce products of brick, tiles, pipe, etc. and whiteware products (ex: toilets)
Whiteware Ceramic products based on clay. Things like toilets, sinks, and bathtubs.
Machining Refers to the removal of certain selected areas from a part in order to obtain a desired shape or finish
Stellite (523) also called cast cobalt alloys are cobalt rich, chromium-tungsten-carbon cast alloys and retain their hardness at high temperatures, so they can be used at higher cutting speeds.
Isostatic Pressing 467 used in fabricating crystalline ceramics. Exhibits features and limitations similar to those discussed in ch 16.
Boring Always involve the enlarging of an existing hole, which may have been made by a drill or may be the result of a core in a casting. Essentially, ______ is internal turning. _____ can use single-point cutting tools to produce internal cylindrical or conical surfaces.
staggered-tooth milling cutter narrow cylindrical cutters having staggered teeth, and with alternate teeth having opposite helix angles
cut-and-peel- simplest method of applying a maskant, usually neoprene, polyvinyl chloride, or polyethylee, is appplied to the entire surface of the workpiece by dipping or spraying. Once the coating dries, it is then selectively removed in those areas where etching is desired by scribing he maskant with a knife and peeling away the unwanted portions.
Electroforming metal is deposited by plating, when the desired thickness has been attained, plating is stopped and the product is stripped from the mandrel
Pop-rivet Used to expand a tubular shank. 415
Heat checking rate of temperature change causing cracks in a die
Squeeze casting metal introduced slowly to avoid turbulence, then pressure is applied
Burn-off 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
Intermetallic compound alloy systems where the bonding attraction of the component materials is strong enough to form compounds. These compounds are single-phase solids and tend to break the diagram into recognizable subareas. If components A and b form a compound AxBy, and the compound cannot tolerate any deviation from that fixed atomic ratio, the product is known as a stoichiometric intermetallic compound. If compound can tolerate some degree of chemical deviation, the compound is known as a nonstoichiometric intermetallic compound. IN GENERAL, INTERMETALLIC COMPOUNDS tend to be HARD, BRITTLE MATERIALS, SINCE THESE PREPERTIES ARE A CONSEQUENCE OF THEIR IONIC OR COVALENT BONDING.
Eutectic One common type of the three-phase reaction, known as EUTECTIC, is when a liquid mixture transitions into solid 1 + solid 2. -Liquid  Solid 1 + Solid 2The eutectic structure is an intimate mixture of 2 single-phase solids.- All alloys containing more than 2.11% carbon will experience the eutectic reaction and are classified by the general term cast irons.
Dislocation deformation as a result of progressive slippage of a localized disruption. 3 types: edge, screw, mixed.
flux-cored arc welding overcomes shielded metal arc limitations by moving powdered flux to the interior of a continuous tubular electrode
Hot-isostatic Pressing 467 common technique in fabricating crystalline ceramics because crystalline ceramics cannot be formed by techniques requiring either plasticity or melting. Exhibit features and limitations similar to those discussed in ch 16.
Thermoforming 460 thermoplastic sheet material is heated to a working temperature and then formed into a finished shape by heat, pressure, or vacuum.
Cermets (528) ceramic material in a metal binder
Planing (Pg 632-635) Among the oldest single-point machining processes, work is moved past one or more stationary single-point cutting tools and can be used to produced horizontal, vertical, or inclined flat surfaces on large workpieces (too large for shapers), as well as for producing long flat cuts like those in the way of machine tools
Channel Jigs derive their name from the cross-sectional shape of the main member. Can only be used with parts having fairly simple shape
Mandrels Workpieces that must be machined on both ends or are disk-shaped are often mounted on ______________ for turning between centers. There are three common types: Gang, Solid, and Cone.
vibration welding relative movement between the two parts is used to generate heat in the direction parallel to the interface
Location determine the position or location of geometrc shapes with respect to each other
work hardening plastically deforming a metal to become harder
Plastic deformation Elongation past the elastic limit becomes unrecovable and becomes plastic deformation.
Condensation Polymerization a process that needs heat, pressure, or catalysts to drive the reaction, and occurs when reactive molecules combine with one another to produce a polymer plus small, by-product molecules, such as water (structures often are linear chains or 3D framework in which all atoms are linked by strong, primary bonds)
Absolute Requirement Requirements where there can be no compromise. The consequence of not meeting them is product failure. Materials that fall short can be automatically eliminated.
Station Is a position or location in a machining (or process) where specific operations are performed.
Chip Velocity the velocity of the chip being sheared.
Adhesive bonding (470) attractive means of joining the various layers and can be applied to both metallic and nonmetallic materials. The lamination of polymer matrix composites often utilizes films of unpolymerized resin that are introduced between the layers. Pressing at elevated temperature then cures the resin and completes the load
face milling done on both horizontal and vertical spindle machines
silicon carbide made by charging an electric furnace with silica sand, petroleum coke, salt, and sawdust. By passing large amounts of current through the charge, a temperature of over 4000 F is maintained for several hours, and a solid mass of silicon carbide crystals results.
electrical discharge machining- process removes metal by discharging electric current from a pulsating DC power supply across a thin interelectrode gap between the tool and the workpiece.
Centerless grinding makes it possible to grind both external and internal cylindrical surfaces without requiring the workpiece to be mounted between centers or in a chuck. This eliminates the requirement of center holes in some workpieces and the necessity for mounting the workpiece, thereby reducing the cycle time.
Hand ramming 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
Transfer Die 432 - When individual parts are mechanically moved from die to die within a single press.
Hydrostatic Extrusion 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.
Flashless forging forging where the die provides total confinement.
Strain Hardening strengthening of a metal by plastic deformation.
Annealing 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.
Upset forging 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.
Nonstoichiometric a compound in which some degree of chemical deviation is tolerable in it’s fixed atomic ratio and the vertical line expands into a single phase region in the phase diagram
Brittle fracture failure that occurs before the onset of plastic deformation; more common in metals have the BCC or HCP crystal structures
Vacancy missing atom that is a barrier to dislocation
Oblique Machining In _______ machining, the cutting edge and cutting motion are not perpendicular to each other.
Broaching In this the cutting tool moves into the work while the work remains stationary. This operation uses a teethed tool to do work.
capillary action used to distribute the filler material between the closely fiitting surfaces of the joint
Cementation (469 This is an alternative method of producing strength that does not require elevated temperature. A liquid binder material is used to coat the ceramic particles, and a subsequent chemical reaction converts the liquid to a solid, forming strong, rigid bonds
Annealing (467) in dealing with tempered glass, this can be used to reduce unfavorable residual stresses that might lead to cracking
Etch Factor/Etch Radius Something to consider in chemical machining. Etch Factor (E) describes the relationship between undercut (U) and depth of cut (d). See picture.
Emery a mixture of alumina and magnetite is another natural abrasive still in use today and is used on coated paper and cloth.
flux used to clean the surfaces and remove contaminating oxide
amorphous structure (ex. Glass) atoms have a certain degree of local order
Drilling is a cutting process that uses a bit to cut or enlarge a hole in solid materials. It cuts by applying pressure and rotation to the workpiece, which forms chips at the cutting edge.
Roll bonding 477 - A means of producing fiber-reinforce metal products. Clad metals are joined by a roll bonding and thermal treatment process that produces a metallurgical bond as the lattice structures of the metals are forced into conformance with each other. High pressure, producing massive deformation of the metals, causes a sharing of electrons at the interface, which produces a bond on the atomic level. No intermediate layers such as adhesives or braze metal are involved.
countersinking makes a beveled section at the end of a drilled hole to provide a proper seat for a flat -head screw or rivet
multiple spindle drilling machines mass-production machines with as many as 50 spindles driven by a single powerhead and fed simultaneously into the work
Kerf (Pg 646) From the viewpoint of strength, large teeth are desirable. Second, tooth spacing determines the space (gullet) available to contain the chip that is formed. The chip cannot drop from this space until it emergers from the slot cut in the workpiece, called _____. The _____ gullet space must be such that there is no crowding of the chip & no tendency for chips to become wedged between the teeth & not drop out when the saw emerges from the cut
High definition plasma also called precision PAC or fine plasma cutting. Uses a special nozzle, where either a high flow vortex or a magnetic field causes the plasma to spin rapidly and stabilizes the plasma pressure.
Roll Straightening 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
Elastic Springback 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."
Hydraulic press move in response to fluid pressure in a piston
Electrical conductivity the net movement of charge through the material.
shear angles The onset of the shear process takes place along the lower boundary of the shear zone defined by this?
duty cycle- the on-time as a percentage of the total cycle time (inverse of the frequency)
twist drills most common type of drill with 3 parts: body, point, and shank
assist gas used to blow molten metal through the cut, cool the workpiece, and assist in the combustion of the material
Circular saw- 645, 647 These saws necessarily differ somewhat from straight blade forms. Because they must be relatively larger in comparison with the work, only the sizes up to about 19 inches in diameter have teeth that are cut into the disk.
nonconsumable electrode process employs a tungsten electrode which is not consumed by the arc, except by relatively slow variation. A separate metal wire is required to supply the filler metal
plasma arc welding the arc is maintained between either the welding gun or the workpiece
Tensile test An impact test in which the specimen is subjected to a uniaxial impact loadings applied through drop weights, modified pendulums, or variable-speed flywheels.
Rockwell hardness test A hardness test similair to the Brinell hardness test in which a minor load and then a major load are applied to the surface of a material and the depth of the permanent indentation is meaured.
Heat Treatment: The heating and cooling of a metal for the specific purpose of altering its metallurgical and mechanical properties.
Cast Cobalt Alloy(515, 523) Popularly known as steelite tools. Are cobalt rich, chromium tungsten carbon cast alloys having properties and applications in the intermediate range between high-speed steel and cemented carbides. Retain their hardness to a much higher temperature than high-speed steel tools. Are hard as cast, and can not be softened or heat treated. The casting provides a tough core and elongated grains normal to the surface. The structure is not however homogeneous. The tools made of cast cobalt alloys are generally cast to shape and finished size by grinding. They are only available in simple shapes such as single point tools, and saw blades because of limitations in the casting process and expense involved in the final shaping (grinding). Materials machinable with this tool material include plain carbon steels, alloy steels, non-ferrous alloys, and cast iron.
Transfer Molding 457 - Is sometimes used to reduce the turbulence and uneven flow that can result from the high pressures of hot-compression molding. Transfer molding combines elements of both compression molding and injection molding and enables some of the advantages of injection molding to be utilized with thermosetting polymers.
Follow Rest p 580 This is bolted to the lathe carriage. It has two contact fingers that are adjusted to bear against the workpiece, opposite the cutting tool, in order to prevent the work from being deflected away from the cutting tool by the cutting forces.
Pulse-echo method (p. 238) 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.
Shallow Drawing used when the depth of a product is less than its diameter 437
Van der Waals forces weak or secondary bonds; can form between molecules that possess a nonsymmetrical distribution of charge.
Cutoff When the tool is fed all the way to the axis of the workpiece, it will be cut in two. Also known as parting.
Crater wear wear on the rake face of the tool Think of wearing on the threads of a screw.
Plasma Arc Cutting (PAC) (714) Uses a superheated stream of electrically ionized gas to melt and remove material. 20,000 to 50,000 deg F.plasma is created inside a water cooled nozzle by electrially ionzing a suitable gas such as nitrogen, hydrogen, argon, or mixtures of these gases. The process can be used on almost any conductive metal.
Polycrystalline diamond tools(530) consists of a thin layer of diamond particles sintered together and metallurgically bonded to a cemented carbide substrate.
Offset yield strength The value of the stress that will produce a given, but tolerable, amount of permanent strain. For most components, the amount of offset strain is set at 0.2%. It is determined by drawing a line parallel to the elastic line, but displaced by the offset strain.
Depth of cut p550 Roughing cuts may be as heavy as proper chip thickness, cutting dynamics, tool life, lathe horsepower, and the workpiece permit. Large _______ and smaller feeds are preferred to the reverse procedure, because fewer cuts are required and less time is lost in reversing the carriage and resetting the tool for the following cut.
Cope and drag pattern patterns that are in cope and drag section to allow easier formation of large molds
Ductile Cast Iron (Nodular Cast iron) if a high-carbon-equivalent cast iron is sufficiently low in sulfur (either by original chemistry or desulfurization), the addition of certain materials can promote graphite formation and change the morphology (shape) of the graphite product. Inoculation with ferrosilicon will promote the formation of graphite. If magnesium (in the form of MgFeSi or MgNi alloy) is also added just prior to solidification, the graphite will form as smooth-surface spheres. The latter addition is known as a Nodulizer and the product is known as Ductile or Nodular Cast Iron.
short circuit transfer The lowest currents and the use of CO2 shield gas promotes ________________.
electrical discharge wire cutting- in this, the electrode is a wire used for cutting through-cut features driving the workpiece with a CNC table.
Equilibrium (as in Equilibrium Phase diagram) the natural tendencies of a material or material system.
Reaction injection molding 455 459 - P Process, in which two or more liquid monomers are metered into a unit where they are intimately mixed by the impingement of liquid streams that have been pressurized to a value between 13 and 20 MPa (2000 and 3000 psi).