Design & Manufacturing - Short Answer Questions from AMIE Exams

Friction welding
Friction welding (FRW) is a solid-state welding process that generates heat through mechanical friction between workpieces in relative motion to one another, with the addition of a lateral force called "upset" to plastically displace and fuse the materials.

The function of dielectric in EDM
The dielectric fluid acts as an insulator between the electrode and the mould cavity.

Chip breakers
The function of a chip breaker is to improve chip control and reduce cutting resistance. A better balance between the two will increase the machining performance.

Reverse engineering
Reverse engineering is taking apart an object to see how it works in order to duplicate or enhance the object. The process often involves disassembling something (a mechanical device, electronic component, computer program, or biological, chemical, or organic matter) and analyzing its components and workings in detail.

Quality Function Deployment
Quality Function Deployment (QFD) is a structured approach to defining customer needs or requirements and translating them into specific plans to produce products to meet those needs. The “voice of the customer” is the term to describe these stated and unstated customer needs or requirements. 
The voice of the customer is captured in a variety of ways: direct discussion or interviews, surveys, focus groups, customer specifications, observation, warranty data, field reports, etc. This understanding of the customer needs is then summarized in a product planning matrix or “house of quality”. These matrices are used to translate higher-level “what’s” or needs into lower-level “how’s” - product requirements or technical characteristics to satisfy these needs.

Directional solidification
Directional solidification and progressive solidification are types of solidification within castings. Directional solidification is solidification that occurs from the farthest end of the casting and works its way towards the spine. The directional solidification rule is that "solidification of the molten metal in a casting should occur in such a manner that liquid feed metal is always available for that portion that is just solidifying."

Blanking
Blanking is a metal fabricating process, during which a metal workpiece is removed from the primary metal strip or sheet when it is punched. The material that is removed is the new metal workpiece or blank. 
Draw spikes
Draw spike tool is used to remove the pattern from the mould and also used for rapping the pattern gently the loosen it from the sand to assure a clean draw.

Magnetic arc blow
Arc blow is the undesirable effect of a wandering welding arc during arc welding. They are two kinds of arc blow: Magnetic and Thermal. Magnetic arc blow or "arc wander" is the deflection of welding filler material within an electric arc deposit by a build-up of magnetic force surrounding the weld pool.

Up-milling
Up-milling: hr up milling the cutter rotates clockwise when cutting the workpiece from right to left, hr this type of milling the tool spins against the direction of feed, hr this milling process, the cutting chips are carried upward by the tool.
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