060070103-Rifat Yılmaz- 1st week definitions

Rapid Prototyping (Previous)-GROUP: Manufacturing Method

Rapid prototyping is a technology which relies on CAD/CAM and on various manufacturing techniques (Using metallic or nonmetallic materials as work pieces) to produce prototypes rapidly and at low cost, in the form of a solid physical model of a part

(manufacturing engineering and technology-Serope kalpakjian, page 14)

Rapid Prototyping (New)

Rapid prototyping is a means of producing component parts or accurate replicas of them in a short lead time. These parts are made with special automatic non-traditional fabrication methods from sophisticated computerized designs, without the use of special dies, molds, jigs or other tooling. All common rapid prototyping methods build the parts with a layer-by-layer approach, under computer control. Parts thus made can be tested and evaluated much sooner than would be possible if traditional production methods were employed.

Rapid prototypes have the following uses: 1) as visual concept models - to visualize and verify appearance, fit and design features. 2) as casting patterns. Wax or plastic prototypes can be used as

patterns for the manufacture of investment, plaster or sand-mold cast metal prototypes. 3) for use as patterns for producing non-consumable short-run tooling of epoxy, rubber or other materials for plastic molding of prototypes or short-run production parts. 4) as functional prototypes. Sometimes, rapid prototypes can be made sufficiently strong that they can be used in operational testing of the product that uses the part.

(James G. Bralla, Handbook of Manufacturing Process, page  585)

New definition is better than previous one. New definition give good information.

Friction Stir Welding (FSW) (Previous)-GROUP: Manufacturing Method

Friction stir welding (FSW) is a solid-state welding process that is gaining wide acceptance in industry, especially the shipbuilding, aerospace, mass transportation and automotive industries. FSW is particularly suited to those industries that use aluminium and its alloys. This authoritative book provides a comprehensive review of the subject of friction stir welding and covers topics such as process basics, equipment, modelling, inspection and quality control and applications.

(Friction stir welding from basics to applications D. Lohwasser, Z. Chen 2009 p.1)

Friction Stir Welding (FSW) (New)

Friction stir welding is a solid-state joining process developed at the Welding Institute. As shown in Figure 15.23a, a rotating cylindrical tool with a probe is plunged into a rigidly clamped work piece and traversed along the joint to be welded. Welding is achieved by plastic flow of frictionally heated material from ahead of the probe to behind it. For welding aluminum alloys, the tool is usually made of tool steel. As shown in Figure 15.23b, the resultant weld consists of three zones: thermally affected zone, thermo mechanically affected zone, and dynamically recrystallized zone for aluminum welding.

(Sindo Kou, Welding Metalurgy, Second Edition, page 370-371.)

New definition is better than previous one. Because new one give us visual demonstration of welding method.

Total Quality Management (Previous)-GROUP: Quality control

TQM is a system that emphsizes the concept that quality must be desinged and built into a product. It is a systems approach in that both managements and employees make a concerted effort to consistently manufacture high-quality products. Defect preventation (rather than defect detection) is the major goal here.

Leadhership and teamwork in the organization are essential. They ensure that the goal of continuous improvement in manufacturing operations is imperative,be-cause they reduce product variability and they improve customer satisfaction. The TQM concept also requires us to control processes and not the parts produced, so that process variability is reduced and no defective parts are allowed to continue through the production line.

(Kalpakjian S., Schmid S.R.,Manufacturing engineering and technology, 5th Edition, p. 1113)

Total Quality Management (New)

Total Quality Management involves the understanding and implementation of quality management principles and concepts in every aspect of business activities. Total Quality Management demands that the principles of quality management must be applied at every level, every stage and in every department of the organization. The idea of Total Quality Management philosophy must also be enriched by the application of sophisticated quality management techniques. The process of quality management would also be beyond the inner organization in order to develop close collaboration with suppliers.

In general we will follow the definition of TQM by Kanji (1990). According to him ‘TQM is the way of life of an organization committed to customer satisfaction through continuous improvement. This way of life varies from organization to organization and from one country to another but has certain essential principles which can be implemented to secure greater market share, increase profits and reduce cost.

(Jens J. Dahlgaard, Kai Kristensen, Gopal K. Kanji, Fundamentals of Total quality Management, page 8,14)

New definition is more specific and widely used for TQM. So it is better.

Wire Cut (Previous)-GROUP: Manufacturing Methods

Wire cut or wire EDM : In wire electric discharge machining a wire (about 0.05-0.30 mm in diameter) is used as an electrode and deionized water as dielectric. A nozzle is employed to inject the dielectric in the machining area in wire EDM.

(Advanced machining processes Vijay k.jain 12 th edition 2010 p.165 )

Wire Cut (New)

Wire-cut EDM - uses a constantly-moving wire instead of a shaped electrode. The wire, of 0.00 1 to 0.013 in (0.025 to 0.33 mm) diameters, passes through the work, with a vertical axis, (though it may be set at an angle when required when cutting apertures for stamping tools.) Tungsten, copper, and brass are common wire materials. The wire or the work, is fed horizontally as the cut progresses, to cut a slit or shaped through-hole in the workpiece. Different wire material is constantly exposed to the spark, so wear of the wire is widely distributed and is not a problem. The process, shown in Fig. 3Ilb, is often used to cut die openings in hardened stock to produce dies and die components. A high level of accuracy and fine detail can be achieved.

(James G. Bralla, Handbook of Manufacturing Processes, page 120)

New definition is more obvious than previous one. It is better one.

High-Speed Steels (Previous)-GROUP: Material

High-speed steels are usually used for drilling, milling, broaching, sawing, and turning tools. Their hot hardness (up to approximately 600 ◦C) is far superior to that of tool steels Their hardness results from their basic martensitic structure and from interspersed carbides: tungsten carbides,
tungsten-molybdenum carbides, chromium carbides, and vanadium carbides.

(Grote Antonsson, Springer Handbook of Mechanical Engineering, pg.628)

High-Speed Steels (New)

The high-speed tool steels are very highly alloyed, with tungsten and molybdenum as the major alloying elements in the T and M grades, respectively. The tungsten, molybdenum, chromium, and vanadium in these steels produce very high densities of stable carbides. As a result, the high speed tool steels are capable of retaining hardness at temperatures as high as 600 ᵒC (1112 F) and are widely used for high-speed cutting and machining applications.

(George Krauss, Steels: Processing, Structure, and Performance, page 538)

New definition is better than previous.