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2010 Exam 2.pdf - University of Wesson-Columbia 3c...

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Unformatted text preview: University of Wesson-Columbia + 3c! . Department of Mechanicai- and Aerospace Engineering I W Manufacturing Methods Spring 2010 MAE 4500 Midterm Exam #2 REMEMBER: Make engineering quality sketches Identifyali coordinates and curves Use brief} clearly worded explanatory sentences. fl . In preparation of a large-gear blank, a 1045 steel billet of ZOO-mm diameter and 400— mm height is upset at ”300°C to a IUD—mm thick “pancake" .a: . hydraulic press with 3mfmin. A graphite lubricant reduces friction {m a part of your e (138' , _ 4:" 24- ‘i "ELF—.4 ' proc ss Ign . . etc" \_, ii W‘- ‘i (a) Make a sketch of the operation. ff,— 1 , --*—) (71 r a gain- - n o (b) Calculate the average the pressure. P“.— Cff Q“. (C) Calculate the force required to forgo the part. PP L. Pa 148ml Express the end result aiso in USC units. A small, shallow U channei of Cu~5Sn bronze is coldcolled. The shape is shallow enough "to regard it as a w m 20 mm wide, It ~7- l.5 mm thick strip of rectangular cross section. According to. a preliminary process design, a 40% reduction in height is taken in a single pass, on a mill with lSO-mm-diameter rolls, at v = 0.8 this speed, with a minerahoil lubricant (,u = 0.1). (a) Check whether the reduction is feasible; if not, take two reductions, then calculate (b) the roll force and (0) power requirement. A steel connection rod (figure 1) is to be made by sand casting. The small end is cast solid, the big end is cored. Melt i-s fed-at the big end. (a) Draw a sketch of the mold, identifying the top and bottom halves and showing the important parts of the metal supply system. (b) Show on the sketch what remedy Would cure a shrinkage cavity in the small end. (c) Distributed porosity (micropo‘tosity) of ragged configuration is found in the stem. Make a sketch to show what caused it; show on the sketch of (a) two methods of eliminating the problem. Fig. l (a) A bolt is cold extruded from .a bar of 30mm diameter. Make a sketch of the process. All dimensiOns in mm efects. What kind of defect (b) The bolt in Problemta) is found to have internal 6 fy. Use sketches to explain would you expect to see? SuggeSt. a remedy and justi your answers. (c) The bolt produced is annealed to get good ductility without loosing the high strength obtained in coid working. Make diagrams showing the effects of cold working and annealing process on the properties of the produced bolt. _ W ,3 a) 75W: 9r 1.7%": 87777077 0072775" ‘ " ’77 “W: 7779.615 W R W xii/'0) .- . V”. g SSE xi . _ gs- _ :1 ._ . 3w?“ ”1/ Wfiilmffe wxmmia, 4.33%10 L. "' 6.77? ...
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