Manufacturing Processes & Techniques Flashcards
7 cards from real CMS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Manufacturing Processes & Techniques flashcards as text
In chemical mechanical planarization (CMP), used in semiconductor manufacturing, material removal is achieved by:
Answer: Combined mechanical abrasion from slurry particles and chemical reaction with the workpiece surface
CMP simultaneously uses abrasive particles in a chemical slurry for mechanical removal and chemical reactions to soften/dissolve the surface, achieving global planarization of wafers.
Which casting process is best suited for producing thin-walled, complex aluminum parts in high volumes with excellent dimensional accuracy?
Answer: High-pressure die casting
High-pressure die casting forces molten metal into steel dies at high pressure, enabling thin walls, tight tolerances, and high production rates ideal for aluminum automotive components.
In additive manufacturing, what is the primary limitation of Fused Deposition Modeling (FDM) compared to Selective Laser Sintering (SLS)?
Answer: FDM produces parts with visible layer lines and anisotropic mechanical properties due to the layer-by-layer extrusion method
FDM's layer-by-layer extrusion creates visible stair-stepping, anisotropic strength (weaker in the Z-direction), and may require support structures for overhanging features.
The purpose of normalizing a steel part after hot forging is to:
Answer: Refine grain structure and relieve internal stresses caused by the forging operation
Normalizing heats steel to above the upper critical temperature then air-cools it, refining the coarse, non-uniform grain structure produced during hot forging.
In a broaching operation, each successive tooth on the broach is designed to:
Answer: Remove a small additional increment of material, with each tooth being slightly larger than the previous one
Each broach tooth is incrementally larger (by the rise per tooth) so that the complete broach progressively roughs, semi-finishes, and finishes the feature in a single linear stroke.
During electroplating, the workpiece (cathode) is coated when:
Answer: Metal ions from the electrolyte solution are reduced and deposited onto the negatively charged workpiece surface
In electroplating, the DC current causes positive metal ions in the electrolyte to migrate to the negatively charged cathode (workpiece), where they are reduced and deposited as a metal coating.
Which machining parameter has the greatest effect on surface roughness (Ra) in a turning operation?
Answer: Feed rate
Feed rate has the dominant effect on surface roughness in turning because the theoretical roughness is proportional to the square of the feed rate divided by the tool nose radius (Ra ∝ f²/8r).