What is a sand slinger?

feeds the sand to the molding board and molding line

Chaplets

internal cavities or passages

Hot Spots

Isolated pools of liquid form inside solidified metal

Fillets and Rounds

radial edge features

Draft

taper or slope given to cores or other parts

Shrink

Metal shrinks as it transforms from liquid to solid

sprue

the entry point and vertical passage for molten plastic material

riser

a reservoir built into a metal casting mold to prevent cavities due to shrinkage

runner

channels in a mold through which molten metal is poured to fill the mold cavity

cavity

the portion of a cast which forms the external shape

pouring basin

funnel-shaped inlet, situated atop the system

Precision/Investment Casting

wax to make the mold and then replaced with metal to create complex and intricate parts

what the precision of the instruments is

Degree of repeatability of the instrument

How does temperature affect measuring instruments?

Temperature control is very important to maintain high accuracy. 20ºC±0.3ºC(68ºF±0.5ºF) is the standard measuring temperature

Drilling for taps

drill a smaller hole than the tap

Starting Drills

make sure drill is not touching piece

Drill and boring round holes

drill a smaller hole then bore it to the correct size

Continuous Chips

not ideal can cause defects. to stop increased rotation or slow-cutting speed

Welding rod designations

1st = Electrode 2nd= Min. tensile (in KSI) 3rd=position, 4th=type of current and coating

Brazing (Bronze Welding)

process of joining two pieces of bronze using a third metal alloy with a lower melting point than the base metals

MIG

wire fed

TIG

rod fed

Where would you use submerged arc welding?

Limited to flat and horizontal welding. Used in big projects like ship building.

Can you weld aluminum to steel [other than with friction welding]?

yes, explosive welding

DCEN (Straight Polarity)

good for fillet welding in the flat position, flats, and vertical up welding

DCEP (Reverse Polarity)

The metal flow is from the work-piece to the electrode

Stick saftey

protective wear

Oxyacetylene Welding Saftey

acetylene must be below 15 psi

What DC stick welding process do we use for overhead welding?

DCEP-reversed

What DC stick process do we use for horizontal – flat welding?

DCEN

Flash Welding – How they make bandsaw blades

Uses heat and pressure as this is another type of resistance welding

Resistance Seam Welding

like overlapping spot welding

Inertial Welding

friction welding

Welding Dissimilar Metals

combining different types of metals

Welding Thin Metal

typically done with mig

electron beam welding

AUTOGENOUS in that it used the base metal to create the weld

Types of rolling

cold, hot

Cambering, spreading

roll a piece flat by rolling with round rollers

Rolling defects

Wavy edges – roll bending

Cracks – low material ductility at the rolling temperature

Types of forging

cold, hot

Grain alignment

smashed together

Sheet-metal forming

process is performed on a press using a set of tools called die and punch

broaching

tool removes material from a workpiece in a consistent, continuous, and accurate way

TiN [titanium nitride]

It is used as wear protection in cutting tools

Define a properly knurled part

sharp diamond points

Surface Plate

the main horizontal reference plane for precision inspection, marking out (layout), and tooling setup

Angle plate

plate that is set to an angle that is used as a reference

Micrometer Use

precision measuring tools used to measure very small objects

Burning

utilizes a high temperature for removing material

Types of Grinding

Surface, Center, Center-less,

Mohs Scale

Used to determine hardness

Grit Sizes

based on screen mesh size

Precision

highly precise and efficient manufacturing process

Snag Grinding

Rough grind

What abrasive is the hardest?

Synthetic Diamonds