IE 215 Solutions for Problems due Oct 8, 2008 (Chs 16 and 18) 16.1 A screen with 325 mesh count has wires with a diameter of 0.001377 in. Using Eq. (16.1), determine: (a) the maximum particle size that will pass through the wire mesh, and (b) the pro
22.6 A cylindrical work bar with 4.5 in diameter and 52 in length is chucked in an engine lathe and
supported at the opposite end using a live center. A 46.0 in portion of the length is to be turned to a diameter
of 4.25 in one pass at a speed of 450 ft/m
IE 215 Solutions for Problems due Sep 24, 2008 (Chs 24 & 10)
24.1 A machinability rating is to be determined for a new work material using the cutting speed for a 60 min
tool life as the basis of comparison. For the base material (B1112 steel), test data
NAME
rE 215
Hour Quiz
1
Fall2010
This exam is closed books, closed notes. You can use a formula sheet as specified in the syllabus. No lists
figures, tables, or sample problems are allowed. State any assumptions you make that are not given in
the problem
HW #9
34.1 A single crystal boule of silicon is grown by the Czochralski process to an average diameter of 320 mm
with length = 1500 mm. The seed and tang ends are removed, which reduces the length to 1150 mm. The
diameter is ground to 300 mm. A 90-mm-wid
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IE 215
Hour Quiz 1
Fall 2011
This exam is closed books, closed notes. Turn all cell phones off and put them away. You may use a
formula sheet as specified in the syllabus. No lists, figures, tables, or sample problems are allowed. State
any assumpt
IE 215 Quiz 2 Solutions October 2010
1. (10pts)What are some of the reasons why plastic shaping processes are important?
Answer. The reasons include (1) many of the processes are net shape processes; (2) in general, less
energy is employed than in metalwo
HW #8
32.2 A 3/8-24 UNF nut and bolt (3/8 in nominal diameter, 24 threads/in) are inserted through a hole in two
stacked steel plates. They are tightened so the plates are clamped together with a force of 1000 lb. The
torque coefficient is 0.20. (a) What
29.3 A welding heat source is capable of transferring 150 Btu/min to the surface of a metal part. The
heated area is approximately circular, and the heat intensity decreases with increasing radius as follows:
50% of the power is transferred within a circl
HW #3
23.2 Solve Problem 23.1 except that the tool life criterion is 0.50 mm of flank land wear rather than 0.75
mm.
23.1
Flank wear data were collected in a series of turning tests using a coated carbide tool on
hardened alloy steel at a feed of 0.30 mm/
22.3 A facing operation is performed on an engine lathe. The diameter of the cylindrical part is 6 in
and the length is 15 in. The spindle rotates at a speed of 180 rev/min. Depth of cut = 0.110 in, and
feed = 0.008 in/rev. Assume the cutting tool moves f
HW #4 Fall 11
10.1 A disk 40 cm in diameter and 5 cm thick is to be cast of pure aluminum in an open mold casting
operation. The melting temperature of aluminum = 660C, and the pouring temperature will be 800C.
Assume that the amount of aluminum heated wi
18.2 A metal has a flow curve with strength coefficient = 850 MPa and strain-hardening exponent =
0.30. A tensile specimen of the metal with gage length = 100 mm is stretched to a length = 157 mm.
Determine the flow stress at the new length and the averag
20.4 A blanking die is to be designed to blank the part outline shown in Figure P20.4. The material is 4 mm
thick stainless steel (half hard). Determine the dimensions of the blanking punch and the die opening.
Solution: From Table 20.1, Ac = 0.075. Thus,
HW #4
10.2 A sufficient amount of pure copper is to be heated for casting a large plate in an open mold. The plate
has dimensions: length = 20 in, width = 10 in, and thickness = 3 in. Compute the amount of heat that must
be added to the metal to heat it t
HW #3
23.6 Tool life tests in turning yield the following data: (1) when cutting speed is 100 m/min, tool life is 10
min; (2) when cutting speed is 75 m/min, tool life is 30 min. (a) Determine the n and C values in the Taylor
tool life equation. Based on
HW #1, IE 215 Fall 2012
21.3 In an orthogonal cutting operation, the 0.250 in wide tool has a rake angle of 5. The lathe is set so the
chip thickness before the cut is 0.010 in. After the cut, the deformed chip thickness is measured to be 0.027
in. Calcul
IE 215 Solutions for Problems due Oct 1, 2008 (Ch 13) 13.1 The diameter of an extruder barrel is 65 mm and its length = 1.75 m. The screw rotates at 55 rev/min. The screw channel depth = 5.0 mm, and the flight angle = 18. The head pressure at the die
IE 215 Solutions for Problems due Oct 17, 2008 (Ch 19) 19.15 A cylindrical workpart with D = 2.5 in and h = 2.5 in is upset forged in an open die to a height = 1.5 in. Coefficient of friction at the die-work interface = 0.10. The work material has a
IE 215 Solutions for Problems due Sep 10, 2008 (Chs 21, 22) 21.31 Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density = 2.9 g/cm3, and thermal diffusivity = 0.8 cm2/s. The following cutting conditions are used: cu
IE 215 Solutions for Problems due Sep 17, 2008 (Ch 23) 23.3 A series of turning tests were conducted using a cemented carbide tool, and flank wear data were collected. The feed was 0.010 in/rev and the depth was 0.125 in. At a speed of 350 ft/min, fl
IE 215 Solutions for Problems due Sep 3, 2008 (Ch 21) 21.6 The cutting force and thrust force have been measured in an orthogonal cutting operation to be 300 lb and 291 lb, respectively. The rake angle = 10, width of cut = 0.200 in, chip thickness be
21.1 In an orthogonal cutting operation, the tool has a rake angle = 15. The chip thickness before the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a) the shear plane angle and (b) the shear strain for the operation. So
22.1
A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an engine lathe. Cutting speed = 2.30 m/s, feed = 0.32 mm/rev, and depth of cut = 1.80 mm. Determine (a) cutting time, and (b) metal removal rate. Solution: (a) N = v/(D) =
MACHINING OPERATIONS AND MACHINE TOOLS
1. Turning and Related Operations 2. Drilling and Related Operations 3. Milling 4. Machining Centers and Turning Centers 5. Other Machining Operations 6. Machining Operations for Special Geometries 7. High Speed Mach
10.1. A disk 40 cm in diameter and 5 cm thick is to be cast of pure aluminum in an open mold casting operation. The melting temperature of aluminum = 660C, and the pouring temperature will be 800C. Assume that the amount of aluminum heated will be 5% more
I E 215 HOMEWORK CHAPTER 18
18.1. The strength coefficient = 550 MPa and strain-hardening exponent = 0.22 for a certain metal. During a forming operation, the final t rue strain that the metal experiences = 0.85. Determine the flow stress at this strain a
IE 215 HOMEWORK 7 Bulk Deformation Solutions 19.14. A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and the initial height is 40 mm. The height after forging is 25 mm. The coefficient of friction at the diework interf
Injection Molding
1. Compute the percentage volumetric contraction of a polyethylene molded part, based on the
value of shrinkage given in Table 13.1. Solution: S = 0.025 for polyethylene from Table 13.1. Volumetric contraction = 1.0 - (1 - .025)3 = 1.0 -