1.

Please name each part of casting tools as shown in Figure 1.1 below.

Round casting: Surface area = 2rl + 2 r2 = 0.377 m3 Volume = 2r2 h = 0.031 m3 Elliptical casting: Let major diameter = a, and minor diameter = b, where a = 2 b. Therefore a b = r2 2 b2 = r2 Thus b = 0.071 m and a = 0.14 m The surface area Aellipse = 2ab + 2h Volume = 0.031 m2 + = 0.566 m2

Figure 1.1 Sand Casting tools A. B. C. D. E. F. G. H. 2. Pouring Cap Side Riser Top Riser Casting Gate Runner Well Sprue Solidification time = C =C =C 4. = 2.17

Explain about operation process of sand casting. Placing a pattern in sand to make an imprint. Incorporating a gating system Removing the pattern and filling the mold cavity with molten metal. Allowing the metal to cool until it solidifies. Breaking away the sand mold Removing the casting & Finishing surface A round casting is 0.2 m (7.9 in.) in diameter and 0.5 m (19.7 in.) in length. Another casting of the same metal is elliptical in cross-section, with a major to minor axis ratio of 2, and has the same length and cross-sectional area as the round casting. Both pieces are cast under the same conditions. What is the difference in the solidification times of the two castings? Known: same length and cross sectional area same casting condition

A 100-mm (4-in.) thick square plate and a right circular cylinder with a radius of 100 mm (4 in.) and a height of 50 mm (2 in.) each have the same volume. If each is to be cast using a cylindrical riser, will each part require the same size riser to ensure proper feeding? A casting that solidify rapidly, would most likely require a smaller riser. Cylindrical part: Volume V = r2 h = 100.5 in2 Surface Area A = 2 r l + 2 r2 = 150.8 in2 Tcylinder = C(100.5 / 150.8)2 = 0.444 C Square plate: Volume

3.

V = 100.5 in3 V = L2 h = L2 (4) Therefore L = 5.0 in Surface area A = 2 L2 + 4 L h = 130. in2 Tplate = C(100.5 / 130.)2 = 0.59 C Since Tcylindrical < Tplate, the cylindrical casting will take less time to solidify, and thus require smaller riser

5.

A sprue is 10 in. long and has a diameter of 5 in. at the top, where the metal is poured. If a desire flow rate of 40 in3/sec is to be achieved, what should be the diameter of the bottom of the sprue? Top area: Diameter Area, A1 Flow rate, Q Therefore, v1

7.

= 5 in. = (d2) / 4 = 19.6 in2 = 40 in3/sec = v1 A1 = Q / A1 = 2.04 in2

What are the benefits and drawbacks to heating the mold in investment casting before pouring in the molten metal? The benefit of heating the mold: Greater fluidity for detailed parts. Slower cooling. The drawback of heating the mold: The binder may not be able to withstand the higher temperature. The metal may be less viscid and become turbulent Pure aluminum is poured into sand mold. The metal level in the pouring basin is 8 in. above the metal level in the mold, and the runner is circular with 0.5 in. diameter. What is the velocity and the rate of flow of the metal into the mold? Using Bernoullis theorem (assume no frictional losses and pressure change is negligible) + + 2 = + + 2

8.

Using Bernoullis theorem (assume no frictional losses and pressure change is negligible) + Therefore, v2= 2 + 2 = + + + 2

= 2 32.2 =87.9 in/s

12

10

+ 2.04 /

Therefore,

v2= 2

h1=h2+

6.

Chocolate is available in hollow shapes. What process is used to make these candies? Use slush casting. The molten chocolate is poured into the mold. After a desired thickness of solidified skin is obtained, the mold is inverted and the remaining molten chocolate it poured out. The mold halves are then opened and the casting is removed. 9.

= 2 32.2 =7.86 in/s

/ 12

The runner is circular with 0.5 in. diameter. Thus, the flow rate Q = v A = v (d2/4) = 15.4 in3/s Pattern is used to mold the sand mixture into the shape of the casting. The design of pattern is very critical which need to consider the metal shrinkage and ease of removal part from the sand mold. Explain THREE (3) types of pattern. One-piece pattern (loose or solid patterns) Generally used for simpler shapes and low quantity productions. Generally made from wood. Easiest to fabricate but difficult to make mold.

Split patterns Involved two pieces of patterns each part forms a portion of the cavity for the casting Suitable for complicated shapes of products. Match-plate patterns Two-piece patterns are constructed by securing each half of one or more split patterns to the opposite sides of a single plate. For this particular case, the gating system can be mounted on the drag side of the pattern.

10. To produce engine blocks using sand casting process, what are the important considerations in casting operations? Flow of the molten metal into the mold cavity. Solidification and cooling of the metal in the mold Influence of the type of mold material.

11. Explain why the difference between engineering strain and true strain becomes larger as strain increases. This due to the definitions of engineering strain and true strain are different. The true strain based on the actual or instantaneous area. As deformation progresses the actual area decreases, the true strain in tension increases more rapidly than the engineering strain, and it is higher.

12. Which hardness tests and scales would you use for very thin strips of metal, such as aluminum foil? Why? A hardness test that produces small indentations would have to be used. Also, since aluminum foil is relatively soft, a very light load would be required. Two scales that satisfy these requirements are the Knoop microhardness (HK) and the Vickers hardness (HV) at very light loads.

13. If you pull and break a tension-test specimen rapidly, where would the temperature be highest, and why? Since temperature rise is due to work input, the temperature will be highest in the necked region because that is where the strain is highest and hence the energy dissipated per unit volume in plastic deformation is highest

14. Joining is the process to assembly of two or more parts so that they can function reliably. For example it will be ease maintenance or replacement purposes and impossible to manufacture as a single product. (a) Describe TWO (2) methods of Plasma Arc Welding. Transferred-arc method Workpiece being welded is part of the electrical cuircuit. The arc transfers from the electrode to the workpiece. Nontransferred-arc method The arc occurs between the electrode and the nozzle. The heat is carried to the workpiece by the plasma gas. (b) Explain the basic soldering technique Assemble proper tools Mount component by bending lead out slightly Heat iron, clean tip with damp sponge Apply heat, apply solder Remove solder, remove iron Inspect solder, cut lead Explain the advantages and disadvantages of adhesive bonding. It provides a bond at the interface either for structural strength or for non structural applications such as sealing, insulation, the prevention of electrochemical corrosion between dissimilar metals, and the reduction of vibration and of noise. It distributes the load at an interface and thereby eliminates localized stresses that usually result from joining the components with mechanical fasteners, such as bolts and screws. The external appearance of the bonded components is unaffacted. Very thin and fragile components can be bonded without significant increase in their weight. Porous materials and materials of very different properties and sizes can be joined. Because it usually carried out at a temperature between room temperature and about 2000C, therefore there is no significant distortion of the components or change in their original properties.

15. Lubricant and coolant are used during machining process such as milling and turning process. Differentiate between the coolants and lubricants functions in machining process.Cutting tool are used to cut away material to leave the desired part shape. One of the tool wear in machining are caused by gradual wear failure which due to wear at the cutting edges. Explain any THREE (3) types of reason for gradual wear failure. Abrasion hard particles in work material gouging and removing small portion of the tool (flank and rake) Adhesion at high T and P, adhesion/welding occurs between chip and rake face. The chip broken chip carry some particle from the tool. Diffusion atoms exchange at the tool-chip boundary-some atoms responsible for hardness was depleted- prone to abrasion and adhesion. (crate wear) Chemical reaction oxidation at the rake face due to high T and machining speed. The sheared away oxidized layer will exposed new layer. Plastic deformation at the cutting edge-vulnerable to abrasion (flank wear) 16. Explain why the difference between engineering strain and true strain becomes larger as strain increases. 17. Which hardness tests and scales would you use for very thin strips of metal, such as aluminum foil? Why? 18. List the factors that you would consider in selecting a hardness test and in then interpreting the results from this test. Hardness tests mainly have three differences: Type of indentor, applied load, method of indentation measurement, i.e., depth or surface area of indentation, or rebound of indentor. The hardness test selected would depend on: the estimated hardness of the workpiece its size and thickness. The scleroscope, which is portable, is capable of measuring the hardness of large pieces that cannot be used for measurement by other techniques. The Brinell hardness test leaves a fairly large indentation which provides a good measure of average hardness

(c)

The Knoop test leaves a small indentation that allows for determination of the hardness of the phases in a two-phase alloy The small phase alloy. indentation of the Knoop test also allows it to be useful in measuring the hardness of very thin layers or plated layers on parts. Note that the depth of indentation should be small relative to part thickness, and that any change on the bottom surface appearance of the part makes the test results invalid. 19. If you pull and break a tension-test specimen rapidly, where would the test temperature be highest, and why? 20. Will the disk test be applicable to a ductile material? No, Because: With a ductile material, a point load on a disk results in the circular disk aterial, being flattened at the platens This causes a rather elliptical shape. The flattening converts the point load to a distributed load, completely changing the stress state in the piece. 21. What hardness test is suitable for determining the hardness of a thin ceramic coating? For a thin ceramic coating, the purpose is to measure the hardness of the coating, not the substrate. Most ceramics have limited ductility, so that a Knoop or Vickers measurement can take place.

22. There are a few products that have been produce as shown in Figure 3.1 below. Explain your observation on how the products were produced.

Figure 3.1 Manufactured product The plastics normally used in this process are; polythene, PVC and polypropylene. The plastic is fed in granular form into a 'hopper' that stores it. A large thread is turned by a motor which feeds the granules through a heated section. ection In this heated section the granules melt and become a liquid and the liquid is fed into a mould. Air is forced into the mould which forces the plastic to the sides, giving the shape of the bottle. The mould is then cooled and is removed.

23. Shearing process generally starts with the formation of cracks on both top rts and bottom edges of the work piece (at points A, B, C and D) as shown in Figure 3.2. These cracks eventually meet each other and complete . separation will occur. Describe TWO (2) main observations of this event.

Figure 3.2 Schematic diagram of shearing process

The major processing parameters in shearing are The shape of the punch and die. The speed of punching process. The edge quality can be improved with increasing punch speed Lubrication. (to ensure that the metal will slide between punch and die during the operation) The clearance is a major factor in determining the shape and the quality of the sheared edge. The clearance, c, between the punch and the die are needed to be considered. As the clearance increase, the zone of deformation become larger, and the sheared edge become rougher. 24. Wear land on cutting tools are indicator for the tool life. When should cutting tools need to be replaced or sharpened? the surface finish of the machined w/piece begins to deteriorate. cutting forces increase significantly. temperature rises significantly 25. Let n = 0.5 and C = 400 in the Taylor equation for tool wear. What is the percent increase in tool life if the cutting speed is reduced by: i. 20%, ii. 40%. The Taylor equation for tool wear is: V Tn = C For n = 0.5 and C = 400: = 400 a) If the cutting speed is reduced by 20%: V2 = 0.8 V1 = =
.

mechanical efficiency of 80%. The spindle speed is 400 rpm. What is the maximum feed that can be used before the lathe begins to stall? The lathe is equipped with a 10-hp electric motor with 80% mechanical efficiency. Therefore, the power which is available for cutting is 8 hp. The specific power required for titanium alloys is 1.5 hp.min./in3. Therefore, the MRR = = Notice that MRR = Dave d f N Therefore, the maximum feed rate = =
. . /

= 5.33

5.33 = 0.021 3.950 0.05 400

27. A 0.5-in. diameter drill is used on a drill press operating at 200 rpm. If the feed rate is 0.005 in./rev., what is the MRR? What is the MRR if the drill diameter is tripled? For drilling, the MRR = =
.

0.005 200 = 0.224

/min

If the drill diameter is tripled: 3 0.5 0.005 200 = 0.224 = 4

9 = 2.016

= 1.56

Thus, the tool life is enhanced by 56%. b) If the cutting speed is reduced by 40%: V2 = 0.6 V1 =
.

= 2.78

Thus, the tool life is enhanced by 178%. 26. A high strength titanium bar 4-in. in diameter is being turned at a depth of cut d = 0.050 in. The lathe is equipped with a 10-hp electric motor and has a

28. A 4-1n. Diameter gray cast iron cylindrical part is to be turned on a lathe at 600 rpm, with a depth of cut of 0.25 in. and a feed of 0.02 in./rev. What should be the minimum horsepower of the lathe? The MRR is given by MRR = Dave d f N = 3.875 0.25 0.02 / 600 3 = 3.65 in /min The specific power required for gray cast iron is 2.0 hp.min./in3. Therefore, the horse power needed is HP = MRR . HPs = (36.5) (2.0) = 73 hp

Eddy-current inspection. Thermal inspection

31. An alloy which has melting point of 1100C is to be machined in an Electrical Discharge Machine (EDM) operation. If discharge current is 25 amp, what is the expected metal removal rate.

R MR =

KI 1 T m . 23

29. A 300-mm part is to be faced starting at the outside. Determine the machining time and the speed if the following data are as shown in Table 4.1: Table 4.1 Spindle rotational speed 10 revolutions per second Depth of cut 4 mm Feed 0.10 mm per revolution (Assume allowance = 0) D = 300 mm N = 10 rev/sec. = 600 rev/min. d = 4 mm F = 0.10 mm/rev =
.

where RMR- metal removal rate(mm3/min), K- constant of proportionality whose value = 664 Tm melting temperature of work metal, C. 664( 25) RMR = = 3.01 mm3 / s 11001.23 32. An Electrochemical Machining (ECM) operation is to be used to cut a hole into a plate of aluminium that is 12 mm thick. The hole has a rectangular cross section, 10 mm by 30 mm. The ECM operation will be accomplished at a current = 1200 amps. Efficiency is expected to be 95%. (Specific Removal Rate C for Al = 3.44 x 10-2 mm3/A, frontal area of the electrode A = 10 x 30 = 300 mm2), determine: i. Feed rate. ii. Time required to cut through the plate. From the table, specific removal rate C for Al =3.44x10-2 mm3/A.s. The frontal area of the elctrode A=10x30=300mm2. (a) At a current level of 1200 amps, feed rate is At an efficiency of 95%, the actual feed rate is
1200 f r = 0.00344mm3 / A.s ( A / mm 2 ) = 0.1376mm / s 300

= 9.420mm/sec = 9.42m/sec

= 150 300

10

f r = 0.1376mm / s(0.95) = 0.1307mm / s

30. Nowadays, Non Destructive Test (NDT) used of computer graphics and other enhancement techniques have reduce significantly the human error in term generally require operator skill especially which involve with interpreting the accuracy of the test results. Please list down the basics principles of major non-destructive testing techniques. Liquid penetrates. Magnetic-particle inspection. Ultrasonic inspection. Acoustic methods. Radiography technique. (b) Time to machine through the 12mm plate is

tm =

12 = 91.8s = 1.53 min ute 0.1307

33. A paper clip is made of wire 1.2 mm in diameter. If the original material from which the wire is made is a rod 18 mm in diameter, calculate the longitudinal engineering and true strains that the wire has undergone during processing.

Engineering Strain = = 1 = 1 = 224 True strain = = = 18 1.2 = 4

35. Agile manufacturing is an implementation of the principles of lean production on a broad scale. The term is applied to an organization that has created the processes, tools, and training to enable it to response quickly (flexible) to customer needs and market changes while still controlling costs and quality i. List THREE (3) components of flexibility that influences agile manufacturing. people, equipment, computer hardware and software, communication ii. Explain the term of lean production with TWO (2) appropriate examples. A systematic approach to identifying and eliminating waste in manufacturing process through continuous improvement by following the product at the demand of the customer Explain THREE (3) benefits of the lean manufacturing application in industries. Overhead operating costs reduces Sales per employee increases. Profits increased. Lead time reduces Process queues cut

= 5.41 iii.

34. You are given the K and n values of two different metals. Is this information sufficient to determine which metal is tougher? If not, what additional information do you need? The true stress and strain curve can be represented by: = K n where, K = the strength coefficient n = the strain-hardening (work hardening exponent). The values for K and n for several metals can be found in Table 2.3 The values of K and n may give a good estimate of toughness. In addition, the true fracture stress and true strain at fracture are also required for accurate calculation of the toughness of the metal

36. Just-In-Time (JIT) and Kanban are other useful manufacturing approaches in nowadays industrial practices. i. Explain the JIT application. Raw materials, parts & components are delivered to the manufacturer just in time to be used ii. Describe TWO (2) benefits of JIT. Low inventory carrying cost Fast detection of defects in the production or the delivery of supplies and, hence, low scrap loss Reduced inspection and reworking of parts High quality products made at low cost iii. Explain the Kanban system. It is a system of notification from one process to the other in a manufacturing system. List TWO (2) benefits of Kanban practices. Production card: authorizes the production of one container or cart of identical, specified parts at a workstation. Conveyance/move card: authorizes the transfer of one container or cart of parts from that particular w/station to the w/station where the parts will be used.

iv.