Materials processing can be broadly classified as either a shaping process, a joining process, or a finishing process: Advanced Engineering Materials Assignment, UOL, Ireland

Questions:

Q1: Materials processing can be broadly classified as either a shaping process, a joining process, or a finishing process. Provide a description of each of these processing groupings, highlighting the key differences between each. The stages of a systematic process selection are a translation of design requirements, screening using constraints, rank objectives, and seeking documentation. Provide a description of each of these stages.

Q2: Processing plays a central role in the manipulation of material properties. The Ashby chart shown in Fig. 1 illustrates the relationship between elastic modulus (𝐸) and strength (𝜎𝑓) for a range of metals. Comparing High Carbon Steel and Copper, what is suggested by the width and height of associated bubbles in the chart? What conclusion may be drawn from inspection of the variability in Young’s modulus for metals in general in relation to the influence of processing conditions?

Q3: The total cost to produce a component is a combination of the material cost and the cost of manufacturing/processing. Given the following mathematical description of processing costs:

provide a full description of each term in the equation, and how this equation may be used to model processing costs.

Q4: Briefly describe how the principles of Industry 4.0 may be applied to process selection during the design stage.