Questions: Bonding and Brazing / Soldering

1.) What kind of adhesives do you know (classes and 5 examples)?

Chemical Reactive adhesive

Physical Adhesive

Polyaddtiton

Polymerizati

Polycondensat

Melting

Adhesives

products

on products

ion products

adhesives

with

Epoxy

Anaerobe

Silicone

Polyamide

solvent
Rubber

polyurethan

ad..
Methacrylat

Phenolic

Saturated

acrylate

e
e
poly
2.) Bonding: Which types of loads should be avoided?
- Cleavage and Peel
3.) Bonding: Draw two examples of an optimized overlap design.
Tapered:
Tapered with fillet:

4.) Derive the relation to achieve an optimized overlap length (shear

-

load).
Increased

surface

for

bonding

material
- Optimized load distribution
5.) In
which
way
could

T K=
you

compensate

F
F
=
KB
A K bl S

peel

loaded sheet connection (two examples: drawing).

???
6.) Describe the differences between bonding and brazing/soldering.
- Both are non-removable
Brazing/Soldering:
Bonding:
- Different types of metals
- Different types of materials
- Compound is formed by a
- Glue
represents
the
liquidly

applied

metallic

additive material wich acts as

a
-

bridge

between

the

compounds
Temperature: ~450 C
Just heating up, no melting of

connection by adhesion
No
material-connection

(Stoffverbindung)
Almost all materials
bondable

are

metal

Questions: Riveting / Welding

7.) What kind of rivets do you know (3 examples)?

- Rivet, blind rivet, spread rivet, high strength rivet

8.) Describe advantages / disadvantages between blind riveting and the
shear bolt joint.
Blind Rivet
- Accresability
- Filling of the hole

Shear Bolt
- Defined pre tension
- Repair friendly

9.) Compare threaded fastening with rivet technologies (advantages /

limitations)

???

10.)
Welding: describe the abbreviations MIG and TIG.
- MIG = Metal Inert Gas
- TIG = Tungsten Inert Gas
11.)
What is the meaning of LASER, which type which type is
better to weld aluminum alloys?
- LASER = Light amplification by stimulated emission of radiation
- Steel:: CO2-Laser
Aluminum: Nd-YAG Laser
12.)
What is the main advantage of laser welding compared to MIG-

welding?
Higher welding speed (up to 10x higher, depending on sheet

thickness)
Smaller weld width and heat affected zone HAZ
Lower heat input -> less distortion
Less danger of lacks of fusion at the start
Less danger of crater cracks at the end (with filler metal)
New possibilities of construction -> tailored blanks or tubes

13.) Compare the stress distribution of a welded / riveted / bonded

sample in form of a sketch.
???

Questions: Gears
14) Belt drive: name three advantages and three disadvantages of a
belt drive compared to a chain drive.

Advantages:

Disadvantages:

- Very quiet in service

- Simple and efficient
- No
lubricant
->

- Strain behavior of belt

low

maintenance

(slip)
- No constant gear ratio
- High
loads
in
the
shafts/axles

15) Belt drive: describe the construction of a modern belt

- Composite set-up: high strength fibers embedded in an elastomeric
structure
15b.) Belt drive: describe the difference of the flat belt compared to a VBelt (advantages / disadvantages).

Advantages:
- Large

Disadvantages:
transmission

forces -> less bearing

loads
- Service reliability

- Heating

of

the

V-belt

during service -> less

efficiency

16) Belt drive: what is the main advantage of a synchronous belt?

-

nearly constant gear ratio

17) Belt drive: describe significant criteria to choose the right belt drive
(one for each)?
-

-flat belt: large shaft distances, very high belt velocity (max. v=100

m/s), transmission of high forces

V-belt: large gear ratios, less shaft distances
Synchronous belt: constant gear ratio, position accuracy (industrial
robots), high power transmission, less loads on bearings

18) Belt drive: describe the gear ratio of a one-step belt drive in
dependency of the revolution and the gear wheel diameters (formula).
i = n1 / n2 = d2 / d1
19) Chain drive: give three advantages of a chain drive.
-

Positive engaged (formschlssig) and no slip -> constant gear ratio

Low bearing loads (no pre tensioning)
No dust and temperature sensitivity

20) Chain drive: name the gear ratio in dependency of the number of teeth
(two chain wheels: z1 and z2).
i = z2 / z1
21) Gear wheel / gear box: why do you need a clutch between an electric
motor and a gear?
-

compensation of misalignment, damping of vibrations

22) Gear wheel: what is the main advantage of a helical toothing

compared to a spur toothing?
-

smooth running
better for higher rotational speed
for higher loads

23) Gear wheel: what is the module of a gear?

m=p/

24) Gear ratio: calculate the total gear ratio of a three step gear.
i = i1 * i2 * i3

Questions: Product Development

25) Name the five steps for product development according the guideline
VDI 2222.
-

Planning => concept design => embodiment des. => Detail des.
=> manufacturing

26) Name the three (four) design rules.

-

safe, simple, , (unique)

27) Give one example for the so called clear design.

-

fixed / loose bearing

28) Give one example for the so called safe design.

-

Activation of a tooling machine with two switches

29) Which principles are used in engineering design?

Achieve direct force flow through a product, minimize stresses: e.g.

avoid

sharp

edges / notches / boreholes, optimize changes in stiffness

30) Explain the fundamental steps of reverse engineering
-

1. Analyze existing product: understand function => sub functions,

study

the

systematic

approach e.g. the morphological box => define one concept

3. Define the structure: new material combinations, variations of
geometrical

details

(make the opposite)

4. Describe the new product

31) Explain TRIZ (engl. TIPS) in simplified keywords.

-

geometry, define the materials which are used

2. Develop alternative ideas based on the function => sub function:
use

shape

Theory of inventive problem solving:

Understand the problem => contradictions
Identify the principle(s) using the 40 inventive principles
Indicate the system features (list of 39)
Solve the problem