Kooferstest1 - ISE 2204 — Manufacturing Processes(11:00 am T& Th Closed Book Closed Notes(one 8 1/2 X 11 in sheet allowed xam#1 Spring 2001

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Unformatted text preview: ISE 2204 — Manufacturing Processes (11:00 am, T & Th) Closed Book, Closed Notes (one 8 1/2 X 11 in. sheet allowed) xam #1 Spring 2001 Name: PART A: Filling Blanks and Multiple Choice Questions (70 points, 2 points for each blank and choice) 1. Fabrication is one of the four basic categories of manufacturing processes which changes an item /directly by applying force or energy. What are normally the changes made on an item via a fabricatio process: a) shape/features/appearance, b) dimensions/geometry, and c) racist ‘c a.) Pro Grits-é 2. Manufacturing is the backbone of any industrialized nation, accounting for20~30 % of GNP for all ’1/ industrialized nations, while primary industries (forestry, mining, farming...) accounting for 5“- 5’ % of GNP. y’( 0.7- )x UTS. It is important to know shear strength of a material in order to determine reorcg required in sheet metal cutting (e.g., punching holes in sheet metals). W 4. “Hardness” is an indicator of material strength and resistance to We», and 0 measure hardness of metals, use indenter pressed against surface with given forc indentation meaning éoCJer materials (harder or softer, choose one). ,, .1 - 3. Shear strength is the maximum shear stress material can withstand, which can be approximated by @ 5. , Swear-ft; Ami is the energy required to raise temperature of a unit mass of material by 1 degree, ' cal/g-°C (BTU/lbm-°F). behavior of metals: 7. 0) mu 5‘10“, / materials in contact. 8. itanium and tungsten have the B LC type lattice structure with good strength and moderate ductility characteristics. ”size leads to {mm-seal strength, new; hardness, and bettersurface finish. Ie correct one : 11. Cold working (circle correct one). V/ a) plastic deformation above recrystallization temperature, larger force required to deform c) poorer surface finish and dimensional integrity 10. Following plastic deformation, g ' a) has high ductility 9. Grain size (crystal surrounded by other crystals) affects mechanical properties of metals. Smaller grain @ CS “nub/‘40 he e three basic materials used in iron and steel making: a) iron ore, b) can-bah , and! 13. Di ' - v steels are obtained by varying amounts of secific elements to change properties (circle / i/‘correct one): add boron to impr - - add chromium to increase wear and corrosion @ ‘ chinability, resistance, 0) add lead, seleniu ‘o impro e hardenability. 14. Carbon steels (circle correct ) r’has carbon content < 0.30%, ' carbon. hi -carbon steels has carbon content > 6%,-carbon steel 0 o signation of 1040 metal means plain carbon el with 4.0% 15. Stainless steels (circle correct one): a) highly-alloyed steels with more than 15% nickel@ high ./ corrosion resistance and high strength, c) low ductility. 16. Nonferrous metals (circle correct one): a) generally less expensive than ferrous metals, b) titanium and flitanium alloys are lightest [email protected] and copper alloys have very high thermal and electrical conductivity. 17. Two most common copper alloys: a) brass is a copper— 21 he alloy, b) bronze is a cooper- “ +144 alloy. / room temperature used to restore properties of cold-worked or heat-treated alloy to its original properties, 0) an annealing temperature can never be higher than the material’s recrystallization temperature. 19. {Case hardening changes properties of workpieces at surface only. Name any two common case M hardening processes: Carbuvizibiq , /V£ Matti“) _ 20. Components 0 a typical casting mold (circle correct 0 i/pouring cu rs are reservoirs for compensating turbulences. 18. Annealing (circle cgect one): a) heat workpiece to a specific temperature and immediately cool it to @ @r nner is the vertical channel leading from 'o shri age, c) sprue minimizes splashing and / 21.VThree important factors in casting: a) fluidity, b) golgcll‘ifithiioh vqée , and c) Show (ca, a . 22. Sand casting (circle correct one): a) used primarily for producing large workpieces, b) only ferrous parts k/can be [email protected] most widely used casting process. 23. Investment casting (circle correct one): a) used for making only extremely large [email protected] parts l/with excellent dimensional tolerances, c) patterns can be reused, if necessary. {/chamber process is used for hig melting point metals only, m the cold-chamber process is used for low 24. Die casting (circle correct one) a process of injecting metal into mold under high pressure, 9‘) the hot- i . . ’L melting pornt metals only. 25. Power etallurgy (circle correct one): easy to produce scr Vpartsén produce net or near-net hape products. PART B - Problems (35 points, must show all work to receive full credits) 1. A test specimen in a tensile test has an initial (gage) length of 2.0 inches and an area of 0.60 inchz. At a certain point in the elastic region, the gage length is 2.083 inches at a load of 35,000 lb. The final gage length of the specimen is 2.65 inches. Determine A k a) Ductility of the material (3 pts) to 3' i [O i L. b) Modulus of elasticity (6 pts) <10 .: Q, 69 r 2? Hi“ (gfztéf‘wq b) E: E Q: L~Za ’Z.O<?Z~Z,O Q X0 2.0 : «Cc, 0‘ f 35* \0 Z “ _ goo Cr 53333.37: 4 ‘ as ’%33333 OHS)“ 3 ’f‘ V lHOSje22,L/a : 2. A disk-shaped (round) part is to be sand-casted out of a special alloy. The diameter of the disk is 20 inches and its thickness is 2.0 inches. The cross-sectional area at the top and bottom of the sprue is 1.0 inch2 and 0.64 inchz, respectively, and the pouring cup height is 1.5 inches. The mold constant is 9.5 min/inchz, and n = 2. Find: a) Velocity of flowing metal at the sprue base (6 pts) b) Mold filling time (6 pts) 7- :213 \vx “Helms: 2.0m Vo\:’ic2k : (923,33 42 ’ L. Préclj 2AM r . VI A 4 0 Qt; . l l ‘ 3t (0G2 : A IH " g Vi 1» VQKOLU)’ w- M62» x Q><>3iaeéfawi V ': 1 “3233"?"‘><irs’+2iez} Q~~ 3% my 0, .a-v ”W”M'““WMM~~~ . [M / ‘ g ~ ’- , ‘ h v1 : {3 MN r » 76 wee /‘ f : Mmmah‘WMML-M ’1 /V\.ET‘ : “0:25? 3:2 3. Suppose you are asked to design a rolling operation to reduce steel sheet from 1.0 inch to 0.9 inch in a single pass. The sheet width is 16 inches and has a strength coefficient of 45 ksi and a strain hardening exponent of 0.13. Given the equipment has rolls of radium 8.0 inches and N = 60 RPM. a) What is roll separation force ? (6 pts) b) What size of roll radius would be required to reduce this force by 20% (8 pts) mew saw, 54—Mayst L\ C cs 5 mm; 4-1» g" {1" .2 in a sick; .PQSS‘ sir-am k0 (ch/9‘3"»; eweawm‘ J; Or i 3 roédua : 3 3h NCBQQP/m a} me ‘45 ml! 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This note was uploaded on 02/20/2010 for the course ISE 2204 taught by Professor Rhsturges during the Spring '08 term at Virginia Tech.

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Kooferstest1 - ISE 2204 — Manufacturing Processes(11:00 am T& Th Closed Book Closed Notes(one 8 1/2 X 11 in sheet allowed xam#1 Spring 2001

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