11exam-final-key-K - Name E Y UFID Number EML 4321 Student...

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Unformatted text preview: Name: E Y '- UFID Number: EML 4321 Student Number: EML 4321: Manufacturing FINAL EXAM 4—- 28 April 11 The time limit of 120 minutes will be strictly enforced. It is your responsibility to complete this long exam within that time frame. Please work efficiently and accurately. Choose the best or closest answer. Open book, open notes. (However, waste time with written materials at your own risk!) Calculators are the only'type of electronic devices which may be used. the correct answer. You will be graded solely upon what you circle. You should a ve one circle for each “*”. You should have a total of sixty circles. IGNORE THIS PAGE --- EXAM STARTS ON THE NEXT PAGE --- Lorem ipsum dolor sit amet, consectetur adipiscing elit. Integer lacinia egestas laoreet. Nullam et mi et lectus dapibus dignissim vel quis lacus. Duis et sapien sem. Praesent at neque libero, at auctor nibh. Integer nec risus ac odio ullamcorper aliquam ac non dui. In convallis lectus quis felis dapibus sodales. Vivamus odio odio, egestas ac bibendum ut, condimentum feugiat quam. Etiam molestie neque Vitae neque facilisis eu semper nunc varius. Suspendisse ut bibendum metus. Nunc lacus dui, sodales vitae semper ac, dignissim ut orci. In condimentum nisl vitae ipsum tristique in placerat lectus tristique. Suspendisse commodo, lorem eu tristique sollicitudin, lacus libero sagittis nisl, et ultricies tellus est vel mauris. Duis felis neque, pharetra sit amet convallis ac, molestie quis quam. Etiam ac purus mi, at rutrum mauris. Curabitur auctor, magna sed malesuada malesuada, neque arcu volutpat neque, sit amet varius lectus magna eget libero. Cras uma nisi, mattis et eleifend at, condimentum auctor neque. Class aptent taciti sociosqu ad litora torquent per conubia nostra, per inceptos himenaeos. Class aptent taciti sociosqu ad litora torquent per conubia nostra, per inceptos himenaeos. Vivamus ac eleifend massa. Cum sociis natoque penatibus et magnis dis parturient montes, nascetur ridiculus mus. Class aptent taciti sociosqu ad litora torquent per conubia nostra, per inceptos himenaeos. Cras facilisis massa ut purus mattis sed mollis magna commodo. Quisque condimentum diam sed justo adipiscing pharetra ultrices mi gravida. Mauris lacinia, elit ut bibendum imperdiet, massa arcu aliquet mi, quis accumsan tellus est sit amet neque. In hac habitasse platea dictumst. Lorem ipsum dolor sit amet, consectetur adipiscing elit. Pellcntesque pellentesque Viverra nisl sed tincidunt. Aenean at lacinia mi. Duis orci mi, imperdiet eu feugiat nec, Viverra vel dui. Morbi consectetur dui id velit mollis et pellentesque mauris cursus. Mauris ac leo magna, ut elementum lacus. Etiam interdum auctor nisi ut fringilla. Suspendisse mollis lectus sed metus ullamcorper auctor. Integer lorem velit, porttitor ut lacinia eget, blandit eget sem. Praesent ultricies nunc pellentesque ligula adipiscing Vitae lacinia nunc fermentum. In pellentesque, justo ut elementum fringilla, velit leo aliquet dui, a pretium nulla odio non ligula. Maecenas hendrerit sagittis rhoncus. Aenean rhoncus consequat temper. Vivamus eu elit in mi fringilla porttitor vel consequat magna. Fusce velit dolor, pellentesque vel vestibulum ut, convallis ac augue. In Vitae neque a nunc accumsan faucibus. Fusce blandit euismod magna sit amet hendrerit. Pellentesque id consectetur quam. Aenean nibh quam, lobortis non congue eget, scelerisque ut mi. Maecenas at enim metus. Praesent commodo faucibus nisl a aliquam. Mauris scelerisque nulla et ipsum malesuada aliquam. Donec at pretium magna. Phasellus auctor pu1vinar placerat. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Vivamus egestas tempus sem quis adipiscing. Mauris accumsan aliquam ullamcorper. Fusce id mattis elit. Praesent magna mi, placerat ut sagittis a, luctus sit amet est. Duis facilisis consectetur nunc sit amet tristique. Integer quis pretium felis."Sed aliquet convallis porta. Donec et rutrum libero. Suspendisse nisl massa, tincidunt faucibus lacinia ut, pretium vel ligula. Donec tristique ultrices aliquet. Suspendisse scelerisque mi eu magna porta dictum. Nunc quam urna, imperdiet vel aliquet ac, faucibus nec nisl. Suspendisse potenti. V ~ 0] *** A lathe operation is turning a 1” diameter shaft at 500 SFM with a feed of 0.020 in/rev and width of cut of 0.3 in. -— What should the approximate spindle speed (rpm) be? 975 1150.300 3800 4600 6000 7200 —— What is the metal removal rate (in3/min)? 12 18 24 0042 48 60 66 72 * Which nontraditional process is NOT additive? @FDM LOM SL SLS * What is a typical contemporary water-j et pressure (psi) for cutting thick steel plate? 5 50 500 5000 50,000 * Which of the followin is NOT a type of “code” used in NC machine tools? G M * Chatter during metal—cutting is an example of what kind of vibration? free forced * In the Rosenthal solution to the partial differential equation for heat analysis of thick-plate welding, what direction has the greatest effect on temperature? 62H * Which resistance welding operation requires a sheet metal forming operation before welding? resistance projection welding resistance seam welding resistance spot welding ** In the modeling of self—regulation in GMAW, which variable represents - melting (burn-off) rate H L F X — wire feed rate @ H L R X * What regulation bans lead solder in some European countries for many applications ANSI ‘ BSI CE DIN NFPA * Which welding rod will cause the weld to penetrate better? 6013 7018 * Which of the following terms does NOT describe the same process as the other three terms? GTAW Heli—Arc TIG ' * Which of the following processes will produce the smallest HAZ GMAW GTAW SMAW * Which of the following is NOT used to move material in modern manufacturing plants? AGV AS/RS * A “pop” rivet requires access to how many sides of a joint? ' both sides *** Who pioneered the following technologies? — chatter analysis Boothroyd Gatt Gibreth _Opitz Taylor — design for assembly Boothroyd Gatt Gibreth Opitz Taylor Tlusty — high speed steel Boothroyd Gatt Gibreth Opitz Tlusty * The dividing line (°C) between soldering and brazing is at about 150 250 350 550 650 750 850 *** Consider the Taylor tool life equation VphqbrT = C - which exponent is usually largest? @qr — what are the usual units on T? milliseconds seconds hours — changing the spindle speed on a lathe will affect which variable? ®hb * The use rate for a typical NC lathe in the USA would be closest to $l/hr $lO/hr $lOO/hr $lOOO/hr * Which is the least important attribute of a cutting tool material chemical stability ‘ high modulus of elasticity high toughness high hot hardness high strength * Which of the following materials has the lowest thermal diffusivity .302 4140 * Which ceramic cutting tool material has the most popularity for cutting cast iron? A1203 SiC SiAlON TiC TiCN TiN * Which cutting tool Will wear the least when cutting composites that have very abrasive fibers? A1203 CBN WC WC-TiC—TaC * Which process is NOT used to produce seamless tubing? extrusion _ Mannessman resistance welding * The two steel plates are aligned with 9= 900 before welding. What is the true 9 after welding and cooling? e<90° e=9o° @ 6/ ** A wire is reduced from 5 mm diameter to 4 mm diameter by drawing ‘ — What is the strain? 0.22 0.4 .06 0.8 1.0 1.25 1.5 - If the material is non-strain hardening and has a yield strength of 200 MPa, what is the specific work? 110 130 150 160 180 200 E W:Z/é~("%@= 2/2255}; 2032/5 Zia/OE ’l" Kaz f) * A sheet of metal is being reduced from 15 mm to 11 mm thick by passing it between 200 mm diameter rollers. What is the minimum coefficient of friction necessary to insure that the sheets feed into the rollers? 0.04 005 0.06 01>. 0.2503. 0.5 1.0 M/otfiz - l4; _ l/s=/I _. LL 4/1— E 6 /OO A 26- gr *** The most common primary process used to produce each following items is -Al alloy gear case forging powder-metallurgy rolling sand-casting _ cast iron gear case die—casting forging powder-metallurgy rolling - WC tool insert die-casting forging (powder-metallurgy) rolling sand-casting ** Consider the operation conducted in a press shown below — what operation is it? @ drawing open die forging upsetting — what is the item labeled @ ? core parting skin slag *** Consider the Mohr’s circles (a: b, c, d, e, and f) shown below. Which one represents - the tension test 6) b c d e f — rolling with interstand tension a b G d .e f (not at neutral point) — HlPing a b c d f salve +44%: * “skelp” is used to produce castings cutting tools extrusion dies lathes @ ** When upsetting a two foot diameter cylindrical workpiece, the average pressure is 73,000 psi. - What is the force (T) needed? 57 66 115 130 230 260 .19,000 33,000 38,000 - As the cylinder is compressed further, the force will tend to go down _ remain about the same ._. a j: 2“ 6; 2L 2 I‘m: ’1; F—p/flr — ‘19 got —(73,0<>0 1,? ( 2 @[2560/9 2 /é,5©0 T * A soft piece of steel has a BHN of about 80. What is the ultimate tensile strength (ksi)? 30'50 60 7o 80- 90 100 a eds 2500 (BAA/25230 91:56 = [raga * The following three structures appear in a particular Jominy bar. Which structure is at the end where the water was sprayed? bainite pearlite * What kind of alloys are most likely to be precipitation hardened? brass bronze carbon steel * Which of the following heat treatments will result in the strongest 7075? * All other things (including yield strength) being the same, when bending these materials, which will have more springback? ‘ * Tg is important for: aluminum alloys stainless steels titanium oc-B alloys * In a roll cluster rolling mill, the smallest diameter roller should be: be far from the sheet being rolled it doesn’t matter ** A non-strain—hardening metal with yield strength Y is being reduced in diameter. Five possible curves (a, b, c, d, and e) of the pressure on the die are shown) — What IS the pressure if you are drawing? / / // a b C d® NA - What is the pressure if you are extruding? HW— / / / / a @ C d e —— // / / ** Three holes of 73 mm diameter are simultaneously being punched in a 4 mm thick sheet of steel. Assume the steel has a shear flow stress of 180 MPa and an ultimate tensile strength of360 MPa. L _:_ 33,773 ;é<0:\g Mm - What is the force (MN) required according to the industry standard method? 0.4 0.45 0.5 0.55 0.6 0.65‘ 0.75 0.8 0.85 0.9 — What is the force (MN) required according to Tlusty’s method? 0.4 045' 055 0.6 0.65 0.7 0.75 0.85 0.9 {220.7 @735”. /&7(360/@85:)(o.0040 (mass r»: [w A 1 {so @%©(0,[email protected]= @. 4?: * What plastic is used to form the vaporized pattern for large engine block castings? Bakelite Lexan nylon- Teflon * What type of machine tool would be used to stamp coins? forging hammer hydraulic press @ *** Using the Boothroyd method to simulate the temperature field in a machining chip, you calculate the temperature along the chip-tool interface. The plot below is that temperature for the cutting of three cases: 1. 7075 with _NQ heat transfer into the tool 2. 1045 with 119 heat transfer into the tool 3. 1045 with heat transfer into the tool - Which plot is 1045 with heat transfer into the tool? [email protected] - Increasing chip width (“b” in “bhv”) will have what effect on the plots below? raise all curves lower all curves raise some/lower some - The first column of elements in the simulation all have a value equal to u mean a ...
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