Master Manufacturing Processes: Processes in Design Technology for Year 13

Question 1

Which factor is LEAST likely to influence the selection of a manufacturing process?

Accepted Answer

Historical preference of the manufacturer

Answer

Product design

Answer

Availability of materials

Answer

Cost and efficiency of the process

Question 2

Identify the step that is NOT involved in the casting process.

Accepted Answer

Welding

Answer

Pattern making

Answer

Mold making

Answer

Gating and risering

Question 3

Which welding technique is most appropriate for joining thin metal sheets?

Accepted Answer

TIG welding

Answer

Arc welding

Answer

MIG welding

Answer

Plasma welding

Question 4

What is the fundamental distinction between a butt joint and a lap joint?

Accepted Answer

Orientation of surfaces being joined

Answer

Type of adhesive used

Answer

Strength of the joint

Answer

Number of surfaces being joined

Question 5

Identify the property that is NOT characteristic of ductile materials.

Accepted Answer

Low tensile strength

Answer

High yield strength

Answer

Significant elongation before failure

Answer

Ability to undergo cold-working

Question 6

What is the central concept behind design for manufacture (DFM)?

Accepted Answer

Optimizing designs for ease of production

Answer

Minimizing material waste

Answer

Reducing production costs

Answer

Enhancing product quality

Question 7

Which of the following factors is NOT considered when selecting a manufacturing process?

Accepted Answer

Product aesthetics

Answer

Material properties

Answer

Design complexity

Answer

Production volume

Question 8

How has the integration of CAD and CAM technologies revolutionized manufacturing?

Accepted Answer

Enhanced precision and accelerated production

Answer

Increased production costs and reduced flexibility

Answer

Eliminated the need for skilled workers

Answer

Led to more complex and demanding manufacturing processes

Question 9

Which of the following is NOT a key consideration when aiming to minimize waste and promote sustainability in manufacturing processes?

Accepted Answer

Overproducing goods in anticipation of potential demand

Answer

Prioritizing the use of recycled materials

Answer

Designing products with disassembly in mind

Answer

Adopting lean manufacturing principles

Question 10

Which of the following is NOT a type of casting process used in manufacturing?

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Die casting

Answer

Investment casting

Question 11

Which of the following materials is NOT suitable for forging due to its properties?

Accepted Answer

Plastic

Answer

Steel

Answer

Aluminum

Answer

Copper

Question 12

Which machining process is primarily used for creating precise holes in workpieces?

Accepted Answer

Drilling

Answer

Turning

Answer

Milling

Answer

Grinding

Question 13

Which of the following joining methods is NOT considered permanent in nature?

Accepted Answer

Adhesive bonding

Answer

Welding

Answer

Soldering

Answer

Mechanical fastening

Question 14

Which of the following is NOT a characteristic of sustainable manufacturing practices?

Accepted Answer

Increasing production output

Answer

Minimizing waste generation

Answer

Utilizing renewable resources

Answer

Optimizing energy efficiency

Question 15

Which manufacturing process is commonly employed to create intricate patterns on metal surfaces?

Accepted Answer

Chemical etching

Answer

Forging

Answer

Casting

Answer

Machining

Question 16

Which factor is NOT relevant when selecting a manufacturing process?

Accepted Answer

Environmental impact

Answer

Material properties

Answer

Production volume

Answer

Design complexity

Question 17

Which casting process is best suited for producing intricate shapes with smooth surfaces?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Centrifugal casting

Question 18

Which joining method involves fusing metals with electricity?

Accepted Answer

Welding

Answer

Brazing

Answer

Soldering

Answer

Adhesive bonding

Question 19

Which of the following is NOT a fundamental principle of ergonomics?

Accepted Answer

Focusing on aesthetic appeal and pleasing appearance

Answer

Ensuring comfort and well-being of users

Answer

Prioritizing safety and preventing harm

Answer

Optimizing efficiency and productivity

Question 20

How does 'design for manufacture' (DFM) enhance manufacturing efficiency?

Accepted Answer

Simplifies designs and production methods, enabling faster assembly and reduced production time.

Answer

Minimizes material usage, prioritizing sustainability and waste reduction.

Answer

Enhances product aesthetics by prioritizing visual appeal over functionality.

Answer

Increases production costs by incorporating intricate design features.

Question 21

Which of the following is NOT a casting process?

Accepted Answer

Forging

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 22

What is the primary purpose of annealing in metalworking?

Accepted Answer

To release internal stresses

Answer

To enhance hardness

Answer

To increase strength

Answer

To improve corrosion resistance

Question 23

What is the main function of a jig in manufacturing?

Accepted Answer

To secure and position workpieces accurately

Answer

To guide cutting tools precisely

Answer

To enhance productivity and efficiency

Answer

To reduce manufacturing lead times

Question 24

What is the main purpose of using a mandrel in casting?

Accepted Answer

To create hollow sections or cavities within the casting

Answer

To support and reinforce thin sections of the casting

Answer

To remove excess material and improve surface finish

Answer

To facilitate the removal of the casting from the mould

Question 25

Forging produces stronger components compared to casting due to:

Accepted Answer

Elimination of voids and defects

Answer

Increased grain size

Answer

Improved surface finish

Answer

Lower material strength

Question 26

Which machining operation is commonly used to create holes?

Accepted Answer

Drilling

Answer

Turning

Answer

Milling

Answer

Grinding

Question 27

Annealing in metalworking is primarily used to:

Accepted Answer

Soften the material

Answer

Harden the material

Answer

Increase the material's strength

Answer

Improve the material's corrosion resistance

Question 28

Which material is not suitable for casting processes?

Accepted Answer

Glass

Answer

Aluminum

Answer

Steel

Answer

Copper

Question 29

The process of joining two metal pieces by melting their surfaces together is called:

Accepted Answer

Welding

Answer

Soldering

Answer

Brazing

Answer

Adhesive bonding

Question 30

Identify the process that is **not** considered a primary manufacturing process.

Accepted Answer

Assembly

Answer

Casting

Answer

Forging

Answer

Machining

Question 31

Which joining process involves fusing the base metal and adding a filler metal to form a bond?

Accepted Answer

Welding

Answer

Soldering

Answer

Brazing

Answer

Adhesive bonding

Question 32

Forging is ideally suited for producing components that require:

Accepted Answer

Exceptional strength

Answer

Precise dimensional accuracy

Answer

Complex geometric features

Answer

Thin cross-sectional walls

Question 33

Which machining process is commonly employed to create cylindrical surfaces?

Accepted Answer

Turning

Answer

Milling

Answer

Drilling

Answer

Grinding

Question 34

Which of the following is NOT a subtractive manufacturing process?

Accepted Answer

Casting (Additive)

Answer

Milling

Answer

Turning

Answer

Drilling

Question 35

What is a key advantage of forging over casting?

Accepted Answer

Increased strength

Answer

Reduced cost (Casting is generally less expensive)

Answer

Improved surface finish

Answer

Greater dimensional accuracy

Question 36

Which type of joint is commonly used to connect two pieces of metal perpendicular to each other?

Accepted Answer

T-joint

Answer

Butt joint

Answer

Edge joint

Answer

Corner joint

Question 37

What is the primary purpose of heat treatment in metalworking?

Accepted Answer

To modify the material's mechanical properties

Answer

To eliminate impurities

Answer

To enhance corrosion resistance

Answer

To increase electrical conductivity

Question 38

Which factor is typically NOT considered when selecting a manufacturing process?

Accepted Answer

Teacher preference

Answer

Material properties

Answer

Production volume

Answer

Cost

Question 39

Which casting process is generally best suited for producing complex shapes with high accuracy?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Centrifugal casting

Question 40

What is the main purpose of a jig in manufacturing?

Accepted Answer

To hold and guide a workpiece during machining

Answer

To measure and inspect parts

Answer

To join two pieces of material

Answer

To apply finishes to surfaces

Question 41

What is the primary function of a lubricant in machining?

Accepted Answer

To reduce friction and heat

Answer

To cool the workpiece (coolant is used for this purpose)

Answer

To improve surface finish

Answer

To protect the cutting tool

Question 42

Which casting process involves pouring molten metal into a mold and allowing it to solidify under gravity?

Accepted Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Answer

Centrifugal casting

Question 43

What is the fundamental distinction between forging and rolling?

Accepted Answer

Forging involves shaping the workpiece by hammering, while rolling involves passing it between rollers.

Answer

Rolling involves shaping the workpiece by hammering, while forging involves passing it between rollers.

Answer

Forging involves heating the workpiece, while rolling involves working it at room temperature.

Answer

Rolling involves heating the workpiece, while forging involves working it at room temperature.

Question 44

Which machining operation is employed to create precise holes in materials?

Accepted Answer

Drilling

Answer

Turning

Answer

Milling

Answer

Grinding

Question 45

In manufacturing, which of the following is NOT a significant consideration when selecting a process?

Accepted Answer

Student age

Answer

Cost

Answer

Quality

Answer

Availability of materials

Question 46

What is the significance of a design specification in manufacturing?

Accepted Answer

It outlines the product's requirements and restrictions.

Answer

It provides step-by-step instructions for manufacturing the product.

Answer

It specifies the materials to be used in production.

Answer

It outlines the quality control procedures to be followed.