Industrial and Product Design Industrial and Product Design Materials & Manufacturing 2 — Questions and Answers
Question 1: What is the primary purpose of a 'design for assembly' (DFA) analysis?
- Improve color matching
- Reduce the number of parts and simplify assembly steps (Correct answer)
- Increase packaging size
- Lengthen product lifecycle
Correct answer: Reduce the number of parts and simplify assembly steps
DFA focuses on minimizing the number of components and simplifying how they fit together to reduce assembly time and cost.
Question 2: Which metal alloy is most commonly used in aircraft structures due to its high strength-to-weight ratio?
- Stainless steel
- Aluminum alloy (Correct answer)
- Copper alloy
- Titanium alloy
Correct answer: Aluminum alloy
Aluminum alloys, particularly 7075 and 2024 series, are widely used in aerospace because they offer excellent strength while remaining lightweight.
Question 3: What is 'tolerancing' in product design and manufacturing?
- Specifying acceptable variation in a part's dimensions (Correct answer)
- Approving a supplier's invoice
- Selecting paint finishes
- Defining product warranty terms
Correct answer: Specifying acceptable variation in a part's dimensions
Tolerancing defines the allowable range of dimensional variation for a part so it can be manufactured consistently and still function correctly.
Question 4: Which rapid prototyping technology builds parts layer by layer using a UV-cured liquid resin?
- Fused Deposition Modeling (FDM)
- Stereolithography (SLA) (Correct answer)
- Selective Laser Sintering (SLS)
- Direct Metal Laser Sintering (DMLS)
Correct answer: Stereolithography (SLA)
SLA uses a UV laser to cure liquid photopolymer resin layer by layer, producing highly detailed parts with smooth surfaces.
Question 5: What does 'anodizing' do to an aluminum part?
- Adds a layer of paint
- Electrochemically thickens the natural oxide layer for protection (Correct answer)
- Welds two aluminum pieces together
- Hardens the core of the metal
Correct answer: Electrochemically thickens the natural oxide layer for protection
Anodizing is an electrochemical process that grows a thicker, durable aluminum oxide layer on the surface, improving corrosion and wear resistance.
Question 6: In materials testing, what does a stress-strain curve primarily reveal?
- Surface finish quality
- Mechanical behavior including elasticity, yield point, and ultimate strength (Correct answer)
- Thermal conductivity
- Electrical resistance
Correct answer: Mechanical behavior including elasticity, yield point, and ultimate strength
A stress-strain curve shows how a material deforms under load, identifying key properties like Young's modulus, yield strength, and fracture point.
Industrial and Product Design Industrial and Product Design Materials & Manufacturing 2
What is the primary purpose of a 'design for assembly' (DFA) analysis?