Gökhan GÜNGÖR 514101006 (10th Week Terms)

        1. Hydrogen embrittlement
2. Hardox
3. Business Plan
4. Superalloys
5. Single Crystal Casting
6. Directional Solidification
7. Continous Flow Conveyors
8. Tube Sinking
9. Trimming
10. Extruder

Berk Korucu - 030080104 - 10th Week Definitions Part-2

3) Compliance-Based Fracture Toughness Testing (Material Testing)

There is no previous definition.

      Compliance-Based Fracture Toughness Testing. Laboratory testing for fracture toughness has become increasingly reliant on servohydraulic equipment, and a synthesis of mechanical test apparatus with sophisticated computer data acquisition and controls is becoming the fracture toughness test standard. Compliance-based fracture testing employs a displacement (CMOD) gage. DC signals are amplified and conditioned to control and monitor the test, as shown schematically in Fig. 11. The load is generally monitored by the use of a load cell, mounted within the test frame in the load train.

     

      

     Compliance-based fracture testing employs the relationship between compliance, which is the reciprocal of the loaddisplacement plot generated during testing, and the crack length. For example, the equation for the crack mouth opening compliance of a compact tension specimen for LEFM (following ASTM E 399) can be expressed as follows (Ref 20):

      

      where C is the compliance, v is the displacement of the clip gage, B is the specimen thickness, and P is the load.The relationship between compliance and crack length has been verified in the literature (Ref 64), and these relationships are generally good for specific specimen geometries, such as compact tension (C(T)) and single-edged notch bend specimens (SE(B)), as found in ASTM E 399, E 813, and E 1737 (Ref 20, 26, 17). With reference to Fig. 12, and using the C(T) specimen for an example, the elastic compliance relationship (following ASTM designation E 399) works as follows:

      1. The clip gage records a displacement and the load cell records the load, both values of which are input into the compliance equation (Eq 26).

      2. The compliance is input into an equation of the form:

      

      3. where ux is a value to use for a polynomial expression.

      4. Continuing, ux is input into a fifth-order polynomial expression with various constants as follows:

      

      5. where W is the specimen width and ci are various constants. Multiplying both sides of the equation by W obtains the crack length.

      6. Finally, the stress intensity factor can be determined by the following expression:

      7.                                     

      It should be noted that the compliance-based procedure just developed describes only LEFM testing in detail. For EPFM testing the procedure is essentially the same, except that plasticity must be accounted for in the determination of J and CMOD.

       (P. Andresen et al. , ASM Handbook Vol 20 Materials Selection And Design , p.1273-1274)

4) Design for Wear Resistance (Design)

There is no previous definition.

Wear is damage to a solid surface as a result of relative motion between it and another surface or substance. The damage usually results in the progressive loss of material. The scientific measure used for wear is volume loss. However, in engineering the concern with wear is usually associated with dimensional or appearance changes that eventually affect performance and not with volume loss. As a result other measures are often used in practice, such as depth of the wear scar on a mechanical component or the degree of haze with optical components.


For any material, wear can occur by a variety of mechanisms, depending on the properties of the material and the situation in which it is being used. Wear resistance is, therefore, not an intrinsic material property like hardness or elastic modulus. Both wear and wear resistance are system properties or responses.


Collection of all the mechanical, chemical, and environmental elements that can affect wear and wear behavior is referred to as the tribosystem. Typical factors that can affect wear behavior are the properties of the materials, the nature of the relative motion, the nature of the loading, the shape of the surface(s), the surface roughness, the ambient temperature, and the composition of the environment in which the wear occurs. Tribosystem design parameters are those parameters that affect wear and that the designer can specify and alter. Designing for the control of wear involves selecting values for tribosystem design parameters in order to obtain acceptable wear behavior or life. The process for doing this is called wear design.


Fundamentally, wear design consists of identifying those design factors that can affect wear and then determining values for them on the basis of their effect on wear rate. The aim is to achieve an acceptably low wear rate. Common tribological design parameters are materials, surface contours, lubrication, and roughness. However, these are not the only ones that can be considered design parameters. For example, loading, type of relative motion, and various environmental parameters may be utilized as design parameters in some situations.


Different design parameters influence wear rate in different ways. There are four fundamental ways to reduce wear rates: by modifying the surface to make it more wear resistant, by using a more wear-resistant material or material pair, by increasing the separation between the surfaces, and by reducing the severity of the contact (i.e., by modifying those features of the wear situation that tend to increase wear rate). Often, the wear rate reduction associated with a design parameter comes from a combination of these methods.


For example, one common method for reducing wear rate is to use a lubricant. A lubricant can reduce wear rate by reducing surface shear forces, by reacting with the surface to form a more wear-resistant surface layer, or by acting as an interposing layer that decreases the amount of contact between the contacting surfaces. In most situations all three elements are present. A lubricant can also conduct heat away from the contact region. In situations where temperature of the contacting surfaces is a factor in wear behavior, this is another way by which a lubricant can affect wear.


(R. G. Bayer, ASM Handbook Vol 20 Materials Selection And Design, p.1424)

Erdem Özdemir - 030070307 - 10th Week Definitions

Emery

 Manufacturing

In the ordinary process, the lumps of emery ore arc broken up in the same mantel as stone is for repairing macadamized roads, and into lumps of similar size. These lumps then crushed under stampers, such as are used for pounding metallic ores, driven by water or by steam power. It is supposed that the stampers leave the frag­ments more angular than they would be if they were ground under runners, a mode which is sometimes employed. The coarse powder is then sifted through sieves of wire cloth, which are generally cylindrical, like the bolting cylinders of corn-mills hut the sieves are covered with wire cloth, which vary from ninety to sixteen wires to the inch. No. 16 sieve gives emery of about the size of mustard-seed ; and coarser fragments, extending nearly to the size of pepper-corns, are also occasionally prepared for the use of engineers. The sieves have sometimes as many as 120 wires in the inch ; but the very fine sizes of emery are most commonly sifted through lawn sieves. The finest emery that is obtained from the manufacturers is that which floats in the atmosphere of the stamping-room, and is deposited on the beams and shelves, from which it is occasionally collected. The manufacturers rarely or never wash the emery ; this is mostly done by the glass-workers, and such others as require a greater degree of precision than can be obtained by sifting.

The following table shows the number of wires usually contained in the sieves, and the names of the kinds respectively produced by them:

Washing emery by hand is far too tedious for those who require very large quanti­ties of emery, such as the manufacturers of plate glass and some others, who generally adopt the following method:—Twelve or more cylinders of sheet copper, of the common height of about two feet, and varying from about three, five, eight, to thirty or forty inches in diameter, are placed exactly level, and communicating at their upper edges, each to the next, by small troughs or channels; the largest vessel has also a waste-pipe near the top. At the commencement of the process, the cylinders are all filled to the brim with clean water; the pulverized emery is then churned up with abundance of water in another vessel, and allowed to run into the smallest or the three-inch cylinder, through a tube opposite the gutter leading to the second cylinder. The water during its short passage across the three-inch cylinder, deposits in that vessel such of the coarsest emery as will not bear suspension for that limited time ; the particles next finer are deposited in the five-inch cylinder, during the somewhat longer time the mixed stream takes in passing the brim of that vessel; and so on. Eventually the water forms a very languid eddy in the largest cylinder, and deposits therein the very fine particles that have remained in suspension until this period; and the water, lastly, escapes by the waste-pipe nearly or entirely free from emery. In this simple arrangement, time is also the measure of the particles respectively deposited in the manufacture to which the emery is applied. When the vessels are to a certain degree filled with emery, the process is stopped, the vessels are emptied, the emery is care­fully dried and laid by, and the process is recommenced.

Holtzapffel informs us that he has been in the habit, for many years, of employing emery of twelve degrees of fineness, prepared by himself by washing over.

For optical purposes, Mr. Ross mixes four pounds of the flour of emery of com­merce, with one ounce of powdered gum-Arabic, and then throws the powder into two gallons of clear water; and he collects the deposit at the end of 10" and 30", and 2' 10/ 2Cr* and GO⁷, and that which is not deposited by one hour's subsidence is thrown away as useless for grinding lenses.

L;; .ii v paper is prepared by brushing the paper over with thin glue, and dusting the emery-powder over it from a sieve. There are about six degrees of coarseness. Sieves with thirty and ninety meshes per linear inch, are in general the coarsest and finest sizes employed. When used by artisans, the emery-paper is commonly wrapped round a file or a slip of wood, and applied just like a file, with or without oil, accord­ing to circumstances. The emery-paper cuts more smoothly with oil, but leaves the work dull.

(Ures̓ dictionary of arts, manufactures and mines, 1867, Andrew Ure, P201)






There is no previous definition.

Single-Spindle Automatic Lathes

Machining

The illustration shows a sin­gle-spindle, automatic, screw ma­chine designed for bar work of small diameter and arranged so that it is completely automatic in operation. 60-3(A). Bar stock of various shapes is fed auto­matically through a hollow spin­dle against a bar stop and held during the operation by a collet. 60-3(B).The tools are mounted around a six-station turret which is in a vertical plane. The ma­chine has a cross-slide which can carry tools on both front and rear. The turret indexes around a horizontal axis and is moved forward and backward on a slide which is controlled by a disc cam located at the right-hand end of the machine. 60-3(C). The cross-slide is controlled by two disc cams driven by the front drive shaft.

The front, rear, and right end of the machine are equipped with feed shafts for dog carriers, clutches, and cams that control operation.

Cams, clutches, levers, stops, and trip dogs are used to actuate and control the cutting tools without the attention of the op­erator. The stock is automatically fed and advanced the correct amount until the stock is used up. The control of the turret ro­tation, reverse spindle rotation to withdraw threading tools, and other operations are all done by self-acting mechanisms.

The camshaft usually rotates at a fixed rate of speed through­out the cycle. The cams that con­trol the various motions are designed so that each motion starts and stops at a suitable time.

End-working tools are mounted on the turret which feeds toward the headstock.

All the common machining operations, such as drilling, reaming, turning, boring, and threading, can be done on these machines.

Many types of accessories can be used.

(21st Centuty Manufacturing, 1994, DIANE Publishing Company, P280)

 There is no previous definition.

Hakan YORULMUŞ 030070111 week10 part2

4) Horn press   (Group: Manufacturing machine)

There is no old definition. 

(new)
A horn press is a special type of gap-frame press where a heavy cylindrical shaft or "horn" appears in place of the usual bed. Curved or cylindrical work pieces can be placed over the horn for such operations as seaming, punching, and riveting. On some presses, both a horn and a bed arc provided, with provision for swinging the horn a side when not needed.


(J. T. Black,Ronald A. Kohser, DeGarmo's Materials and Processes in Manufacturing, 2012, page 475)


5) Direct-acting valves (Group: Pneumatic Unit)


(previous)
The direct-acting valve, is the simplest and least costly design.A reduction in pressure at the inlet acts on the underside of the diaphragm, which in turn, opposes the pressure exerted by the main spring, allowing the closure member to open, thereby increasing pressure.This type of valve is suitable where accurate control is not essential and where the steam flow rate is small and reasonably constant.İt has some fluctuation of steam pressure and a relatively low capacity for its size.

(Facility piping systems handbook 2nd edition Michael Frnkel p.11.16)

(new)- Better

When the solenoid is energised in a direct-acting valve, the core directly opens the oriiicc of a normally-closed valve or closes the orifice of a normally-open valve.

The force needed 10 open the valves is proportional to the orifice size and fluid pressure. As the orifice size increases, so does the force required. To open large orifices while keeping the solenoid size small, internal pilots are used.

(T. Christopher Dickenson, Valves, Piping, and Pipelines Handbook,1999,page 151)

Halil_kayhan_030070090_10thweek_definitions

1. Capture pumps
Capture pumps operate on the principle of having the molecules of the gas retained in the pump itself by sorption or condensation on internal surfaces.Examples are diffusion pump,sorption pump,sublimation pump,sputterion pump,and the cryopump.Capture pumps are typically low volume ultrahigh vacuum producing pressure pumps.They find application mostly in semiconductor and unique research facilities.
(Facility Piping Systems Handbook:For industrial,Commercial and Healthcare,Michael Frankel,p:15-13)

Capture pumps (New) (Machine)
All capture pumps share one common feature: they store gases which arc pumped. Because of this, all capture pumps have a finite capacity for the amount of gas they can pump. This capacity differs depending on the species of gas being pumped, and the pressure at which it is being pumped. Once this capacity is exceeded, the pump must either be replaced, or refurbished by some process unique to the type of pump. The refurbishment process might require a complete rebuild-ing of the pump, as in the case of sputter-ion pumps, or merely executing some sort of pump warm-up cycle as in the case of cryopumps.
You have a significant advantage as a user of capture pumps if you have a quantita-tive feel for the capacity and throughput limitations of your pump. Without this insight, problems of misapplication occur, and there will often be misinterpretation of pump performance. Also, you are at an advantage if you arc able to predict when the pump has exceeded its finite storage capacity, and you arc able to recognize these symptoms. Better yet, if you can anticipate when this storage capacity will be exceeded, you sill have control over your equipment rather than the equipment controlling you. This system insight requires the ability to make estimates of the rate at which gas is being pumped. These are simple concepts, which I refer to as counting mole-cules. They require a basic understanding of the behavior of gases, and the models or devices of man used to describe the behavior of gas in a vacuum system (e.g., pump speed, conductance, etc.) . If you have mastered these concepts, go on to Chapter 2. If not, take the time to study this material, as it will afford you a better understanding and control of your equipment.
(Kimo M. Welch, Capture Pumping Technology, page 1-2)
The new one is better.

2. Fuse (New) (Device)
A fuse is a device that, by the fusion of one or more of its specially designed and proportioned components, opens the circuit in which it is inserted and breaks the current when this exceeds a given value for a sufficient time. The fuse comprises all the parts that form the complete device (BS 88). We see in the definition that the fuse is the complete device, consisting of a fuse-holder (which comprises a fuse base and fuse carrier) and a fuselink.
A fuselink is a device comprising a fuse element or several fuse elements connected in parallel enclosed in a cartridge, usually filled with an arc-extinguishing medium and connected to terminations, the fuselink is the part of a fuse which requires replacing after the fuse has operated. (BS 88) We see from this definition that the 'fuselink' is the part of the fuse popularly but incorrectly referred to as 'a fuse', and that the internal part which melts is called the 'element'. Other definitions relating to fuses can be found in the British Standards referred to in the bibliography.
(Electricity Training Association, Power System Protection: Principles and components, page 307)
There is no old definition


3. Pilot operated valves(Old)
The nozzle sealed by a piston which is loaded by the process pressure. The differantial area between the nozzle bore and the back of the piston creates an unbalanced force which holds the piston down on the nozzle.As the process pressure increases unbalanced force increases which increases the sealing pressure on nozzle face.Pilot operated valves can operate extremely close to the set pressure similar to pilot assisted and supplementary loaded valves without tending to leak.Most pilot operated valves have resillient seats to further reduce seat leakage.When the pilot valve senses the set pressure normally in the nozzle the pilot vents the process fluid above the piston and the fluid forces from the nozzle bore open the valve.
(Guide to European valves:for control,isolation and safety,Brian Nesbitt,p:76)

Pilot operated valves(New) (Valves)
In order to overcome the various problems encountered when using spring-operated SRVs and also at NASA's request, the industry started looking for ideal SRV characteristics and tried to design a valve that came as close as possible to these characteristics. Thus, the POSRV was born.
'Ibe main objectives achieved with some pilot-operated valves on the market were:
• Compensation for variable backpressure up to 90% to 100% without the use of vulnerable bellows
• Tightness up to set pressure (98%)
• Rated capacity at set pressure, not requiring any overpressure
• Opening and blowdown independently adjustable
• Large range of blowdown adjustment to overcome inlet piping losses
• Possibility of installing the valve further away front the process
• Easy maintenance
• In-line It, 11(1k mality testing possibilities
• Reducing the unnecessary loss of material during opening (cost and environmental considerations)
• Reducing the weight of the valves in order to reduce mechanical supports and effects of reaction forces on the valve during opening
• Reducing the noise during the opening cycle • Stable and reliable operation in case of dual flow (flashing) applications
Unfortunately, a lot of the operational objectives for the POSRV described above could not be achieved as economically as with a spring valve; the use of soft seats was imperative to obtain all advantages, which limits the use of most POS10,1s in high temperatures (typically up to 300° maximum). There are now POSIZVs in the market with metal-to-metal seats, hut here tightness, especially after a few operations, decreases much more than with resilient-seated valves and even traditional spring-operated metal-to-metal valves. Due to its somewhat more complicated design, in the early days All did not recommend its use on dirty service or polymerizing fluids. However, since then some renowned manufacturers have found solutions to overcome these problems. The advantage of soft seats is also that they are very suitable for cryogenic applications.

(Marc Hellemans, The Safety Relief Valve Handbook: Design and Use of Process Safety Valves to ..., page 110-111)
The new one is better.

4. Evolutionary Algorithms (Old)
Evolutionary algorithms are a set of heuristics simulating the process of natural evolution (Figure 6.10). Although the underlying mechanisms are simple, these algorithms have proven them as a general, robust and powerful search tool. In particular, they are especially convenient for problems involving multiple conflicting objectives and large and complex search spaces.
In spite of the wide diversity in the proposed approaches, an evolutionary algorithm can be characterized by three features:
• A set of candidate solutions is maintained.
• A competitive selection process is performed on this set.
• Several solutions may be combined in terms of recombination to generate new
solutions.
There are two main evolutionary heuristics: the German school of evolution strategies (ES), and the American school of GAs. The main differences between these two approaches are summarized in Table 6.1. Some papers have shown the application of evolutionary techniques in hardmachining optimization [26, 33].(Davim. J. P., Machining of Hard Materials, 2011, p. 191)


Evolutionary Algorithms(New)(Programming)
Evolutionary algorithms (EAs), which are based on a powerful prin-ciple of evolution: survival of the fittest, and which model some natural phenom-ena: genetic inheritance and Darwinian strife for survival, constitute an interesting category of modern heuristic search. This introductory article presents the main paradigms of evolutionary algorithms (genetic algorithms, evolution strategies, evo-lutionary programming, genetic programming) and discusses other (hybrid) meth-ods of evolutionary computation. Also, various constraint-handling techniques in connection with evolutionary algorithms are discussed, since most engineering prob-lems includes some problem-specific constraints. Evolutionary algorithms have been widely used in science and engineering for solving complex problems. An important goal of research on evolutionary algorithms is to understand the class of problems for which EAs are most suited, and, in particular, the class of problems on which they outperform other search algorithms.
(Dipankar Dasgupta,Zbigniew Michalewicz, Evolutionary Algorithms in Engineering Applications, page 3)

New one is better.

5.Lap Joint (Previous)

A lap joint is made by overlapping the edges of the two plates.The joint can be welded on one side or both sides with a fillet weld.
As the fillet weld is made on the lap joint, the buildup should equal the thickness of the plate.A good weld will have a smooth transition is abrupt, it can cause stresses that will weaken the joint.
Penetration for lap joint does not improve their strength. complete fusion is required.The root of fillet welds must be melted to ensure a completely fused joint.İf the molten weld pool shows a notch during the weld, this is an indication that the root is not being fused together.
(Welding principles and applications 3rd edition LARRY JEFFUS P.76)

Lap Welding  (New)  (Manufacturing type)
Well do the easiest type of weld—called a lap n eld-11 rst . Cut your practice panel into six-inch coupons and dress the edges square. Lay two coupons out so they overlap by about 1/2". Hook up the ground cable so it grips both pieces and holds them in alignment. Check the thickness of your coupons. then adjust the wire feed ratc and amperage to the specifications that came with your welder. You are ready to try welding. Extend the wire at the tip to about 3/8" to 1/2". If it ends up longer. cut it off to that length using a pair of wire cutters. Touch the electrode to the work and depress the trigger. Just make a small spot weld. then reposition the ground strap out of your way. Tack a spot weld at the other end or your work to hold it in position. Holding the nozzle at about a 45 degree angle. try to run a bead of weld between the two tack welds. It is very important to keep the gap from the nozzle to the work at the correct distance. You'll know when it is right because the sound of the welding will be sort of like that of frying eggs. If you hold the nozzle too far away from the work you will hear a hollow Mussing or hissing sound. And, if you hold the nozzle too close, your wire electrode will stick in your work or to the nozzle. Instead of watching the spark from the electrode while you work, watch the puddling behind the weld. The ridge of the puddle where the metal solidifies should be about 311C behind the electmde spark. I like to move the electrode from side to side a tiny amount as I weld in order to draw the weld in toward the center. Other ...elders move the electrode in tiny circles to do the same thing. However you do it, keep practicing until you get a nice clean-looking weld with good penetration.
(Jim Richardson,Tom Horvath, Pro Paint & Body, page 44-45)

The new one is better.

Metin Atmaca 030080007 10th week part 4

5. Design Process Reengineering (Organization):

There is no previous definition.

Definition:

Organizational and procedural changes have been made to enhance communication between functions, encourage DFM, and simplify and optimize work flow. Many companies have adopted concurrent engineering practices and are using the team approach effectively. In some cases, design and manufacturing engineering have been located on the same premises, while in other situations technologies such as teleconferencing, E-mail, and the World Wide Web are used to overcome wide geographical separations. Many companies are also working to improve their product realization process so that the design team knows exactly what to do during each step of the process. Gate or design reviews have been instituted to ensure economic viability of design projects and to facilitate simultaneous achievement of product manufacturability and tight schedule commitments.

(ASM Handbook vol 20 Materials Selection and Design, p. 1578)

514111014 Hayrullah İlter 10th Week Terms

1.chip pan

2.pneumatic gage

3.knurled nut

4.grub screw

5.emery

6.etching

7.fuse

8.horn press

9.lap welding

10.malleable iron

Fatih GÜNDÜZ 030060144 10th week Answers (Part 3)

 Steam separators : (New) (Boiler Appurtenances and Accesories)
The function of the boiler is to create the necessary amount of steam required for the load, whether it is for process, heating, or hot water. The steam produced must also be of a certain quality and purity. Steam quality refers to the moisture content of steam; for example, steam with 98% quality would have 2% moisture. Steam purity refers to the amount of contamination in the steam and is often a result of impurities entrained in boiler water that is carried over with the steam. The contamination in steam is often given as the amount of solids in parts per million or parts per billion. Water and impurities carried over with the steam is aptly known as carryover. Steam for heating and hot water service normally docs not have to meet very stringent purity requirements, and the small amounts of impurities carried over with the boiler water do not pose a problem. More sensitive to carryover and impurities are certain manufacturing processes that can be contaminated by impurities in steam and facilities that utilize superheat and certain steam turbines that require very clean dry steam. The contaminants carried over may form deposits on superheater tube surfaces that act as insulation, impeding heat transfer and resulting in superheater tube overheating and tube failure. Additionally, the contaminants carried over deposit inside steam piping and valves as well as on the mechanisms and turbine blades in steam turbines, causing premature shutdown for service and overhaul and, in extreme cases, failure of the turbine or turbine parts. Steam separators are devices installed in the boiler steam space designed to separate out moisture and impurities from the steam as it exits the boiler.
(Steam and Hot Water Primer, Chris Langley, Andrew Sacks, p.79)

THERE IS NO OLDER DEFİNATİON !!!

Ramazan Rıdvan SEKMEN, 030080083, 10th week words

1-Three-Dimensional Printing (Group: Design)

This RP technology was developed at Massachusetts In­stitute of Technology. Three-dimensional printing (3DP) builds the part in the usual layer-by-layer fashion using an ink-jet printer to eject an adhesive bonding material onto successive layers of powders. The binder is deposited in areas corresponding to the cross sections of the solid part, as determined by slicing the CAD geometric model into lay­ers. The binder holds the powders together to form the solid part, while the unbonded powders remain loose to be removed later. While the loose powders are in place during the build process, they provide support for overhanging and fragile features of the part. When the build process is completed, the part is heat treated to strengthen the bonding, followed by removal of the loose powders, To further strengthen the part, a sintering step can be applied to bond the individual powders.

The part is built on a platform whose level is controlled by a piston. A layer of powder is spread on the existing part-in-process. An ink-jet printing head moves across the surface, ejecting droplets of binder on those regions that are to become the solid part. When the printing of the current layer is completed, the piston lowers the platform for the next layer.

(Mikell P. Groover,Fundamentals of Modern Manufacturing,4th Edition,pg.793)

New and better explanation

The 3DP (three-dimensional printing) is a rapid prototyping technology, used to create complex three-dimensional parts directly from a computer model of the part, with no need for tooling [4, 5]. This method (Figure 12) combines a 3D printer, CAD development software and special materials from which the prototype will be created. Computer software splits the 3-D CAD data into a series of thin horizontal cross-sections (slices). Each new layer is fabricated through lowering of the piston by a layer thickness and tilling the resulting gap with a thin distribution of powder. An inkjet printing head then selectively prints a binder solution onto this layer of powder to form a slice of the 3-D CAD file. This method can produce high accuracy filler structures for the fabrication of complex 3D prototypes [17].

        Using the Rapid Prototyping 3D Zcorp 310 Printer system, we manufactured the prototypes for human bones (Figure 13) and one can finally obtain functional assemblies which can be used in the future work in different experiments [2, 16].

(Pisla, D. (2010). 3DP technology Used to Prototype the Knee Joint Components.  New Trends in Mechanism Science: Analysis and Design (p. 315) )

2-Wave Soldering (Group:Manufacturing) Wave soldering is a mechanical technique in which printed circuit is boards containing inserted components are moved by conveyor over a standing wave of molten solder.The position of the conveyor is such that only the underside of the board ,with component leads projecting through the holes, is in contact with the solder.The combination of the capillary action and the upward force of the wave cause the liquid solder to flow into the clearances between leads and through-holes to obtain a good solder joint.The tremendous advantage of wave soldering is that all of the solder joints on a board are made in a single pass through the process.

(Fundamentals of Modern Manufacturing.Materials,processes and system 3rd edition, Mikell Groover, p. 844) 00.49

New and better explanation

The basic principles of wave soldering:

          • contact of a fluxed solderable printed wiring board and component terminations with a continually refreshed surface of molten solder,

         • heat transfer,

         • welting and flow, and

         • drainage of excess solder

are the same for lead-(Pb)-free solder as for tin-lead (Sn-Pb) solder. The differences arise largely from the fact that:

        1.The difference between the melting point of lead-free solders that are suitable for wave soldering and the maximum temperature that the printed board assembly and the wave soldering machine itself can accommodate without damage is much smaller than it is for Sn-Ph solder.

       2. The wetting and spread properties of lead-free alloys suitable for wave soldering are not quite as good as those of Sn-Pb solder.

Despite these differences, it has been confirmed on many hundreds of wave soldering machines that have successfully soldered tens of  millions of a wide range of printed board assemblies that lead-free wave soldering is a viable process that can produce reliable products economically.

        The key to this success is process optimization, which takes into proper account the differences between lead-free and Sn-Ph wave soldering.

( Suganuma, K. (2004).Introduction. Lead-Free Soldering in Electronics: Science,Technology and Environmental Impact (p.275)

3-Design for Corrosion Resistance ( Group: Design)

There is no old explanation

New explanation The life of equipment subjected to corrosive environments can be increased by proper attention to design details. Equipment should be designed to drain freely and completely. The internal surfaces should be smooth and free from crevasses where corrosion products and other solids can accumulate. Butt joints should be used in preference to lap joints. The use of dissimilar metals in contact should be avoided, or care taken to ensure that they are effectively in to avoid galvanic corrosion. Fluid velocities and turbulence should be high enough to avoid the deposition of solids, but not so high as to cause erosion-corrosion.

( Coulson, J.M.,  Sinnott, R. K., Richardson, J.F. (). Design for corrosion resistance. Coulson & Richardson's Chemical Engineering: Chemical engineering design (p.305)

4-Integrated Design Systems ( Group: Design)
There is no old explanation

New and better explanation

To perform process automation and integrate the PSG and the FE modeling support system, an integrated design system was implemented based on the JADE [12] platform. This system meets the standard specifications of FIPA (Foundation for Intelligent Physical Agent) [13] and has various types of agents; Interface Agent, Monitoring Agent, Engineering Server Agent, Job Management Agent, and Process & Analysis Server (PAS) Agents. This system also has EDM (Engineering Data Management) to manage the data required for an engineering process and for system information. The Job Management Agent and the Engineering Server Agent enable the management of engineering jobs. which are executed with specified design parameters. On the other hand, the PAS Agents manage the engineering tasks, which are sub-processes for executing a job. There are four tasks: Task 1, CATIA modeling: Task 2, Pre-processing for CAE: Task 3, Structural analysis: and. Task 4, Durability analysis. Task 1 is performed in the PSG via ParaCAT developed as an in-house

code. The other Tasks accomplished with the FE modeling support system are integrated with corresponding PAS Agents. Fig. 7 shows the architecture of the integrated design system.                

          XML-based Resource Wrappers [10] are utilized to link the PAS Agent to the dis-tributed engineering tools, such as Tasks 1-4. The architecture of the Resource Wrapper consists of Paralnput.xml, Wrapper.xml and ParaOutput.xml, as shown in Fig.8. In the first step, the Paralnput.xml is generated using EDM data. In the Wrapper.xml the input data required for executing the engineering program are generated using a

tag, <Generate>. The engineering program, based on a batch process, then runs defined in the tag of <Run>. Consequently, the necessary data are extracted from the results obtained after running the engineering program in a tag of <Parse>, and the ParaOutput.xml is then generated. The data from the engineering results and the ParaOutput.xml are saved in the EDM.

(Yong, J. (2008). Integrated Design Systems. Computer Supported Cooperative Work in Design (pp.148-150))

5-Pneumatic gage ( Group: Tool)
There is no old explanation

New explanation
A pneumatic gage is an instrument for measuring, comparing, or checking dimensions by sensing the flow of air through the space between the gage head and workpiece surface. The gage head is applied to each workpiece in the same way, and the clearance between the two varies with the size of the piece. The amount the airflow is restricted depends on the clearance. There are four basic types of air gage sensors, shown in Figure 8.3a, b, c, and d. All have a controlled constant-pressure air supply.

       The back-pressure gage (a) responds to the increase in pressure when the air-flow is reduced. It can magnify from 1000:1 to over 5000:1, depending on range, but is somewhat slow because of the reaction of air to changing pressure.

       The differential gage (b) is more sensitive. Air passes through this gage in one line to the gage head and in a parallel line to the atmosphere though a setting valve. The pressure between the two lines is measured.

        There is no time lag in the flow gage (c), where the rate of airflow raises an indicator in a tapered tube. The dimension is read from the position of the indicating float. This gage is simple, does not have a mechanism to wear, is free from hysteresis, and can amplify to over 500,000:1 without accessories.

        The venturi gage (d) measures the drop in pressure of the air flowing through a venturi tube. It combines the elements of the back-pressure and flow gages and is fast, but sacrifices simplicity.

        A few of the many kinds of gage heads and applications are also shown in Figure 8.3 (e through i). Practically all inside and outside linear and geometric dimensions can be checked by air gauging.

        Air match gauging, depicted in Figure 8.3i, measures the clearance between two mating parts. This provides a means of controlling an operation to machine one part to a specified fit with the other. A multidimension gage has a set of cartridge or contact gage heads (Figure 8.3h) to check several dimensions on a part at the same time. The basic gage sensor can be used for a large variety of jobs, but a different gage head and setting master are needed for almost every job and size.

        A major advantage of a pneumatic gage is that the gage head does not have to tightly fit the part. A clearance of up to 0.08 mm (.003 in.) between the gage head and workpiece is permissible, and even more in some cases. Thus, there is

no pressure between the two, which causes wear, and the gage head may have a large allowance for any wear that does occur. The flowing air also helps keep surfaces clean.

      The lack of contact makes air gauging particularly suitable for checking highly finished and soft surfaces. Because of its loose fit, a pneumatic gage is easy and quick to use. An inexperienced inspector can measure the diameter of a hole to 25 µm (.000001 in.) in a few seconds with a pneumatic gage. The same measurement (to 25 µm or .001 in.) with a vernier caliper by a skilled inspector may take up to one minute. The faster types of pneumatic gages are adequate for high-rate auto-matic gauging in production.

( Walker, H.F. (2008). Pneumatic gaging. The Certified Quality Inspector Handbook (pp.80-82))