206 Quiz Major Final AKS

King Fahd University of Petroleum & Minerals
Mechanical Engineering Department

ME 206 : Manufacturing Processes I
Fall Semester 2003-2004 (031)
Quiz # 1 Name

Dr. Anwar K. Sheikh Student #

Wednesday: 08 October 2003 Section: ME
206.04
Time Allowed: 20
minutes
Problem # 1
A cylindrical riser is to be designed for a sand casting
mold. The height over diameter ratio of the cylinder
(H/D)=2. The casting has a dimension of 3 in 4 in 5
in. It is desired that the solidification time of the riser
should be 25% greater than the solidification time of the
casting. The mold constant C=15 min/in
2
. Determine the
following:
a) Volume of casting = in
3
b) Surface area of the casting = in
2
c) Time to solidification of casting = min
d) Time to solidification of riser= min
ME 206 Quiz # 1 (031) Dr. Sheikh 2
e) Volume of riser = in
3
f) Surface area of riser = in
2
g) Diameter of the riser D = in
Height of riser H = in
Problem # 2
For the following statements check the correct answer by
putting [ ] in the appropriate boxes:
a) Martensite is formed by quenching austenite. The
lattice structure produced is
[ ] BCC (Body Centered Cubic) [ ] HC
P
( H
e x
a g
on
a l
C l
o s
ed
Pa
ck
)
[ ] FCC (Face Centered Cubic) [ ] BC
T
( B
od
y
Ce
n t
e r
ed
T e
t r
a g
on
al)
b) A channel distributing melt (molten metal) to several
locations of the same mold cavity or several mold
cavities is known as
[ ] sprue [ ] pouring
basin
[ ] riser [ ] runner
Problem # 3
Check [ ] whether the following statements are TRUE or
FALSE:
TRUE FALS
E
a In killed steel oxygen has been removed [ [
b
)
Investment casting is an expendable
mold and expendable pattern casting.
[
]
[
]
c
)
In solid solutions solute is the minor
component that is added to the solvent.
[
]
[
]
d Shape of the graphite in cast iron [ [
e Chills are used to produce equiaxed [ [
f) Gray cast iron is brittle because of the
presence of large amount of cementite
[
]
[
]
g
)
In good mold design one tries to keep
the Reynold Number >20,000.
[
]
[
]
h
)
Steels are more easier to cast than cast
iron.
[
]
[
]
ME 206/SE 322 : Manufacturing Processes I
1
st
Major Exam Name


Thursday: 16 October 2003 T i m e
Allowed: 1
h r . 3 0
minutes
Closed Books/Closed Notes
Proble Marks Grade
1 4
2 4
3 3
4 2
5 2
TOTAL 15
ME 206 1
st
Major Exam (031) Dr. Sheikh 2
This exam contains NINE ( 9 ) pages including the Cover
Page.
ME 206 1
st
Problem # 1 [TOTAL: 4 Points]
a) Cast iron is poured into a sand mold at 1600C.
The metal level in the pouring basin is 200 mm above
the metal level in the mold, and the runner is
circular, with a 12.5 mm diameter. What is the
velocity and rate of the flow of the metal into the
mold? Is the flow turbulent or laminar?
[ =7.1610
3
kg/m
3
, =6.1010
-3
kg/s-m, and g=9.81
m/sec
2
]
b) How long would it take for the sprue in Problem 1-a
to feed a casting with a square cross-section of 200
mm per side and a height of 100 mm? Assume that
ME 206 1
st
the sprue is frictionless.
ME 206 1
st
Figure 1
A top riser of a cylindrical shape
of height (H) equal to twice its
diameter (D) is to be designed for
a rectangular block of cast iron
(Figure 1 shows the casting and
the riser). The casting is
performed in a mold for which
the constant of Chvirnovs rule
=2.5 s/mm
2
.
a) Calculate the solidification
time of the casting. Ignore
the metal in gating system
and sprue (not shown in the
figure.
b) Determine the height (H) and diameter (D) of the top
riser such that its solidification time become 1.25
times that of casting.
ME 206 1
st
Figure 2
Figure 3
Estimate the clamping force to be applied
on a die used in a die casting machine in
which four disk-type parts are produced
simultaneously in a single multi-cavity die
with one shot of metal. Ech disk has an
outer diameter of 100 mm and inner
diameter of 50 mm. The metal is injected
at a pressure of 50 MPa.
b) The disk shape casting (18 inches
diameter and 6 inches height)
shown in Figure 3, need to be
made by and casting process. The
parting line is at the middle of the
part height which is at 3 inches
from the base. Density of the
molten metal-100 lb/ft
3
. Calculate
the force of buoyancy (lb) trying to separate the two
halves of the mold. The height of the sprue is 10
inches from the parting line.
ME 206 1
st
Check [ ] the correct answer in each of the following
problems:
1) The part of the mold cavity which is needed to
provide internal cavities or holes in a casting is
known ass
[ ] cope [ ] riser
[ ] gate [ ] core
2) The ability of the molten metal to fill a mold cavity
easily is known as
[ ] permeability [ ] collapsi
bility
[ ] fluidity [ ] porosity
3) The Reynolds number is used to quantify the aspect
of molten metal in the mold cavity. The higher value
of Reynolds number (>20,000) will cause the formation
of
[ ] micro-porosity [ ] shrinka
g e
cavity
[ ] dross [ ] h o t
spot
4) In true centrifugal casting process, the inner surface
of the casting part remains hollow cylindrical because
the molten metal is uniformly distributed by
[ ] inertia force [ ] centrif
u g a l
force
[ ] centripetal force [ ] applied
ME 206 1
st
Figure 4
pressur
e
duri ng
pouring
5) The cores of the dendrites which solidify first, in
comparison to the outer layer of the dendrites, have
[ ] higher concentration of the alloying element
[ ] lower concentration of the alloying element
[ ] same concentration of the alloying element
[ ] None of the above statement is valid
6) Figure 4 shows a typical grain
structure of the solidified
[ ] pure metallic material
[ ] composite material
[ ] alloy of eutectic composition
[ ] metallic solid solution
ME 206 1
st
cont ... Problem # 4
7) A misrun is which one of the following defects in
casting?
[ ] Globules of metal becoming entrapped in the
casting
[ ] Metal solidifies before filling the cavity
[ ] Micro-porosity
[ ] Metal is not properly poured into the
downsprue
8) Strength-to-weight ratio of all die cast parts
[ ] increases with increasing wall thickness
[ ] increases with decreasing wall thickness
[ ] is not influenced by wall thickness
[ ] is much lesser than the strength-to-weight
ratio of sand casted parts
ME 206 1
st
Check [ ] the correct answer in each of the following
problems:
1) Which of the following consideration is important for
a riser?
[ ] Solidifies sooner than the casting
[ ] shape should be prismatic (i.e., rectangular
base and required height)
[ ] (A/V)
riser
<(A/V)
casting
[ ] Should never be open to the atmospheric
pressure
2) The casting process used in making pipes of large
diameter, such as used in electric poles, is known as
[ ] investment casting [ ] s h
ell
c a
sti
ng
[ ] centrifuge casting [ ] c e
n t
rif
ug
a l
c a
sti
ng
3) Preheating a permanent mold
[ ] increases the chilling effect [ ]
r
e
ME 206 1
st
d
u
c
e
s
t
h
e
s
o
l
i
d
i
f
i
c
a
t
i
o
n
t
e
m
p
e
r
ME 206 1
st
a
t
u
r
e
[ ] increases the productivity [ ] increa
s e s
t h e
fluidity
of the
l i qui d
matter
4) The ultimate tensile strength (TS) of grey, nodular, and
malleable cast irons (all ferritic) are in the following
order:
[ ] (TS)
grey
>(TS)
malleable
>(TS)
nodular
[ ]
(TS)
grey
>(TS)
nodular
>(TS)
malleable
[ ] (TS)
malleable
>(TS)
grey
>(TS)
nodular
[ ]
(TS)
nodular
>(TS)
malleable
>(TS)
grey
5) Killed steel characterizes the following while solidifying the
ingot:
[ ] no dissolved oxygen has been removed
[ ] oxygen has been removed only partially
[ ] oxygen has been removed fully
[ ] it has nothing to do with oxygen, it indicate
that all impurities and inclusions have been
removed
6) The following material is not suitable for pattern making:
[ ] wood [ ] metals
[ ] wax [ ] ceramics
ME 206 1
st
7) Chills are used in casting process to
[ ] minimize the inclusions [ ] develop
a stronger structure
[ ] reduce shrinkage porosity [ ] produce
equiaxed grains
8) Small metallic toys, such as model cars, which are made
of Zn, Mg and/or Aluminum are produced by
[ ] sand casting [ ] investment
casting
[ ] centrifugal casting [ ] d i e
casting
ME 206 1
st
FORMULAS SHEET
Quiz # 2 Name


Wednesday: 06 November 2003 Section: ME
206.04
Time Allowed: 15
minutes
Problem # 1
True stress ( ) and true strain ( ) relationship for a
material is MPa. Determine the:
a) true strain at necking,
b) true stress at necking.
Problem # 2
A 200 lb force is applied to a 0.1 inch diameter
copper wire having a yield stress of 22,000 psi, and a
tensile strength of 41,000 psi. Determine:
a) whether the wire will plastically deform, and
b) whether the wire will experience necking.
Problem # 3
For the following statement select the correct statement by
1) For a tension test of a material, the strain at
fracture is a measure of its
[ ] elasticity [ ] resilien
ce
[ ] uniform elongation [ ] du
cti
l i t
y
2) If a cylindrical specimen is subjected to a uniaxial
load in direction z. The resulting strains in x, y, and
z directions are
x
,
y
, and
z
, respectively. The
Poisson ratio v for this situation will be defined as
[ ] -
x
/
y
[ ]
x
/
z
[ ]
y
/
x
[ ] -
x
/
z
3) Idealized stress-strain curve shown in Figure 1
represents
[ ] rigid, perfectly plastic material
[ ] perfectly elastic material
[ ] non-linear strain hardening material
[ ] elastic, linearly strain hardening material
4) The true strain rate of a material is given by
[ ] [ ]
[ ] [ ]
5) The stress-strain behavior of a material is given by
K
n
. A cubic specimen (each side having a length (l
o
)
of this material is subjected to plastic deformation
and experiences a true strain
1
. The ideal work of
deformation is given by
[ ] [ ]
[ ] [ ]
6) From the flow stress
versus true strain diagram
on the left,, the mean
flow stress is calculated
as
[ ] 600
[ ] 1200
[ ] 300
[ ] 400
Quiz # 3 Name


Wednesday: 03 December 2003 Section: ME
206.04
Time Allowed: 20
minutes
Problem 1 (6 Points)
Consider upsetting of a steel disc of 1-in. diameter, and
1/2 in. high to a height of 1/4 in. Given the flow curve
=100,000
0.30
and the coefficient of friction is 0.04.
Assume the process is subjected to sliding friction and the
average pressure, p
av
, can be approximated by:
a) Find the radius of the deformed disc, R.
b) Find the strain of the operation.
ME 206 Quiz # 3 (031) Dr. Shiekh 2
c) Find
d) Determine the forging force in tons.
Figure 1
Figure 2
Figure 3
Problem # 2 (4 Points)
Check the correct answer by putting [ ] in the
appropriate boxes for the following problems:
a) If back tension,
b
, is applied in a rolling process
(with no front tension,
t
=0), then the neutral point
will shift to
[ ] r i ght of t he neut ral poi nt l ocat i on
corresponding to
b
=
f
=0
[ ] l e f t o f t he neut r a l po i nt l o c a t i o n
corresponding to
b
=
f
=0
[ ] entry point
[ ] exit point
b) Forward slip in rolling (Figure
1) is defined as
[ ]
[ ]
[ ]
[ ]
c) The press shown in Figure 2 is
[ ] knuckle joint press
[ ] crew press
[ ] hydraulic press
[ ] crank press
d) Figure 3 shows
[ ] a cogging process
[ ] an orbital forging
process
[ ] ring rolling process
[ ] roll forging process
Quiz # 3 Name


206.04
Time Allowed: 15
minutes
Problem
2
nd
Major Exam Name


Thursday: 18 December 2003 T i m e
Allowed: 1
h r . 4 5
minutes
Proble Marks Grade
1 5
2 5
3 5
4 5
5 5
6 5
TOTAL 30
ME 206/SE 322 2
nd
This exam contains FOURTEEN ( 14 ) pages including the
Cover Page and Formula Sheets
ME 206/SE 322 2
nd
A steel rod (initial length=2 inches, initial diameter=0.25
inches) is subjected to tensile loading. Assuming that the
material has a stress-strain curve of the form =60
0.3
ksi:
a) Determine the true stress at the onset of necking.
b) Determine the ultimate tensile strength of the
material.
c) If the specimen fractures at a true strain of 0.4,
calculate:
I) the percent elongation in length, and
ii) the percent reduction in area.
ME 206/SE 322 2
nd
Part 1
A 302 stainless steel ( =1300
0.3
MPa) cylinder of height
120 mm and diameter 70 mm at room temperature is
compressed to a height of 40 mm between large platens.
Mineral oil ( =0.1) is used as a lubricant between the
cylinder and platens. Calculate:
a) The diameter of the cylinder at the end of the forging
operation.
b) True strain at the end of the operation.
c) The average pressure on the workpiece.
d) The force required in kN.
ME 206/SE 322 2
nd
Part 2
To reduce the force needed for the required deformation
of 302 stainless steel cylinder in Part 1, it is decided to
hot upset at 1000C to the final height of 40 mm by a
platen moving at 20 mm/s. Graphite ( =0.2) is used as
the lubricant between the platen and workpiece. Calculate
the average pressure and forging force needed. At 1000C,
the material stress ( ) and strain rate behavior is MPa.
ME 206/SE 322 2
nd
A 2-inch wide metal strip is cold rolled from a thickness
of 0.125 inch to 0.1 inch. The material has the strain
hardening properties of K=30,000 psi and n=0.2. The roll
radius is 10 inch and the roll speed is 120 rpm. If
coefficient of friction =0.2, estimate the horsepower
required for this operation. Answer your question in the
following order:
a) Length of arc of contact.
b) True strain of the operation.
c) Average flow stress, corresponding to true strain in
part (b).
d) Average force, in lbs.
ME 206/SE 322 2
nd
e) Power (horsepower) needed for both rollers.
ME 206/SE 322 2
nd
Figure 1
A cylindrical copper billet of
6 inch diameter and 10
inch long is extruded at
1500F at the speed of 10
in/s. Square dies are used
and a poor lubrication
conditions prevail. The final
shape of the product is
given in Figure 1. At
1500F, assume:
C = 20,000 psi, and
m = 0.06.
Determine:
a) Extrusion ratio.
b) Average true strain rate.
ME 206/SE 322 2
nd
c) Flow stress at 1500F.
d) The pressure needed to complete the extrusion
process.
e) The force required in the process.
ME 206/SE 322 2
nd
Figure 2
a) A metal is plastically deformed in a uniaxial tensile
test, and the strain in the loading direction is
1
=0.24.
If the specimen has not yet reached to the necking
point (the volume remains constant) and
2
=-0.12,
then
3
=
[ ] +0.12 [ ] +0.36
[ ] 0.24 [ ] 0.12
b) A thin-walled spherical shell of thickness , and
radius R of a perfectly plastic material with a yield
strength Y is subjected to an internal pressure p.
Using the maximum shear stress theory the pressure,
p, required to yield this shell is
[ ] 2Y /r [ ] 2Yr/
[ ] Y /2r [ ] 1 . 1 5
Y /2r
c) The state of stress
{
1
/2,
2
=0, (
3
=-

1
/2)} which is just
sufficient to start
the yield according
to maximum shear
stress theory is
located in the
figure (Figure 2)
by the
[ ] Point D
[ ] Point C
[ ] Point B
ME 206/SE 322 2
nd
[ ] Point A
d) If a metal obeys =K
n
, then the mean flow stress,
corresponding to strain, , is given by
[ ] [ ]
[ ] [ ]
ME 206/SE 322 2
nd
Figure 3
e) The relationship between cold work, CW (expressed as
a fraction) and true strain, , is given by
[ ] [ ]
[ ] [ ]
where cold work, CW=(A
o
-A)/A
o
. A
o
=original area of
cross-section, and A is the instant area of cross-
section of the workpiece.
f) An elastic, and linearly strain
hardened material has a true stress
and true strain curve as sketched
in Figure 3. For this material the
average flow stress corresponding to
a true stress
1
is
[ ] Y + 0.5 m
1
[ ] Y
[ ] 1.15 Y
[ ] Y + m
1
g) The Poisson ratio at the yield point is
[ ] 0.5 [ ] 0.25
[ ] 1.0 [ ] 0.3
h) As %cold work increases
[ ] yield strength increases, tensile strength
increases, but %elongation decreases
[ ] yield strength decreases, tensile strength
decreases, but %elongation increases
increases, and %elongation increases
remains same, but %elongation decreases
ME 206/SE 322 2
nd
Figure 4
i) The grain size depend on
prior cold work and
annealing temperature. The
curve which relates grain
size (d) to cold work (%CW)
at different annealing
temperatures (T
1
, T
2
, T
3
) are
shown in Figure 4. Check
the correct answer:
[ ] T
3
>T
2
>T
1
[ ] T
1
>T
2
>T
3
[ ] T
1
<T
3
<T
2
[ ] T
3
>T
1
>T
2
ME 206/SE 322 2
nd
j) For a fixed time of annealing, recrystallization
temperature is influenced by prior cold work, in the
following manner:
[ ] as the prior col d work increases the
recrystallization temperature decreases
[ ] as the prior cold work increases the
recrystallization temperature also increases
[ ] as t he pri or col d work i ncreases t he
recrystallization temperature remain unaffected
recrystallization temperature becomes <0.5 T
m
ME 206/SE 322 2
nd
For the following statement check the correct answer by
a) Camber is a result of
[ ] deflection of rollers [ ] s p
r e
ad
i n
g
o f
r o
lle
d
p r
od
uc
t
[ ] excessive friction [ ] n o n
uni f or
m
pressur
e
b) In an impression die forging of a simple shape (with
no flash), the projected cross-sectional area is 10 in
2
.
The flow stress of the material of the workpiece is
50,000 psi. The force necessary to make this part is:
[Check the closest answer.]
[ ] 2,000,000 lbs [ ] 5,000,0
00 lbs
[ ] 4,000,000 lbs [ ] 1,000,0
ME 206/SE 322 2
nd
Figure 5
00 lbs
c) Flash produced in impression die forging
[ ] help to fill the die cavities [ ]
r e
du
c e
s
fri
cti
on
[ ] reduces the forging load [ ] c a
us
e s
i n
c o
m
p l
e t
e
f o
r g
i n
g
d) The forging process shown in Figure
5 is named
[ ] hubbing
[ ] fullering
[ ] edging
[ ] cogging
e) Barreling during the open die forging can be
minimized by
ME 206/SE 322 2
nd
[ ] applying an effective coolant and increasing
the strain rate
[ ] appl yi ng an effecti ve l ubri cati on and
increasing the working temperature
[ ] appl yi ng an ef f ect i ve l ubri cant and
decreasing the working temperature
ultrasonically vibrating the platens
f) After forging, minimum finishing is required in
[ ] conventional-type forging [ ] b l
o c
ke
r-
t y
pe
f o
r g
i n
g
[ ] flashless forging [ ] impres
s i o n
d i e
forging
ME 206/SE 322 2
nd
g) In rolling, neutral point is the point, where
[ ] pressure is minimum
[ ] friction is maximum
[ ] workpiece velocity is greater than roll
velocity
[ ] workpiece velocity=roll velocity
h) For good quality and high productivity, threaded bolt
from bar stocks may be produced by
[ ] turning on a lathe
[ ] thread rolling
[ ] casting
[ ] extrusion
i) A 10-in.-wide strip 1.0 in. thick is fed through a
rolling mill with two powered rolls each of 10-in.
radius. The strip thickness is to be reduced to 0.8
in. in one pass. The coefficient of friction between
the roll and the work is assumed to be 0.12. It is
needed to decide whether this operation is possible or
not. Based on the given information it can be
concluded that the rolling operation
[ ] is possible
[ ] is not possible
[ ] needs extra information on average roll
pressure, p
av
, to decide the feasibility
[ ] the flow stress Y
f
is needed to decide the
feasibility of the operation
j) If a sheet is rolled in plain strain from h
0
=1 in. to
h
f
=0.8 in. the spread is
[ ] 0.2 in. [ ] 1.2 in.
ME 206/SE 322 2
nd
[ ] 0 in. [ ] ln(1/0.
8)
ME 206/SE 322 2
nd
ME 206/SE 322 2
nd
2
nd
Major Exam (Makeup) Name


Thursday: 18 December 2003 T i m e
Allowed: 1
h r . 4 0
minutes
Proble Marks Grade
1
2
3
4
5
6
TOTAL
ME 206/SE 322 2
nd
This exam contains TWELVE ( 12 ) pages including the
Cover Page.
ME 206/SE 322 2
nd
Figure 1
Problem # 1 [TOTAL: .. Points]
A stainless steel cube with an edge
length 2-in made of a material with
K=185,000 psi and n=0.45 is placed
in the center of a rigid die with a
groove (or slot) that is 3 in wide
(see Figure 1). It is being
compressed without friction.
a) Calculate the true strain at which the workpiece
touches the die walls.
b) Calculate the work done up to the deformation,
corresponding to the condition expreed in part (a).
c) If the compression process of part (a) is further
continued until the height of the workpiece is reduced
to 0.4 in then calculate the true compressive force
needed at the end of the compression Process. Give
your answer using:
i) maximum shear stress theory
ii) distortion energy theory.
ME 206/SE 322 2
nd
A medium carbon steel cylindrical billet of 125 mm
diameter and 100 mm height is upset (open die forged) at
900C to a disk of final height equal to 25 mm. A
graphite lubricant reduces friction to =0.2. A press with
10 m/sec speed is used to make this part. At 900C, and
at the strain rate corresponding to this process, the
medium carbon steel has following values for the
parameters of flow curve: C=160 MPa, and m=0.1.
a) Determine the final diameter of the disk.
b) Calculate the flow stress at the end of the stroke.
ME 206/SE 322 2
nd
c) Calculate the average die pressure (MPa) required to
forge the part.
d) Calculate the average force (MN) required to forge the
part, also express your answer in terms of tonf.
e) If graphite lubricant is not used, then the conditions
of sticking friction will occur. Under these sticking
friction condition, what will be the maximum die
pressure at the end of the stroke?
ME 206/SE 322 2
nd
A 300 mm wide aluminum strip (K=200 MPa, n=0.2) is
rolled from a thickness of 25 mm using a mill equipped
with 250 mm radius working rolls, using a lubricant that
gives a coefficient of friction =0.2. It is proposed that a
reduction in thickness of 25% be taken in the first pass.
a) Check whether the proposed reduction of 25% is
possible or not. [If yes, directly proceed to part (b).
If no, then suggest the maximum allowable reduction
and proceed to part (b).]
b) Calculate the pressure at entry, exit, and neutral
points:
Pressure at entry =
Pressure at exit =
ME 206/SE 322 2
nd
Pressure at neutral point =
ME 206/SE 322 2
nd
c) Calculate the average roll force required for both rolls
to do this process.
d) Calculate the power (in kW) required for this
operation. N=100 rpm.
e) Calculate the pressure at entry, exit, and neutral
points if a back tension=20 MPa is also applied.
Pressure at entry =
Pressure at exit =
ME 206/SE 322 2
nd
Pressure at neutral point =
ME 206/SE 322 2
nd
1100-O aluminum (K=26,000 psi and n=0.2) is direct
extruded from a diameter of 6 in to 2 in. The redundant
work is 40% of the ideal work of deformation and the
friction work is 25% of the total work of deformation.
Determine:
a) Extrusion ratio, R
b) True strain extruded,
c) The average flow stress is
d) The ideal extrusion pressure is
e) The ideal extrusion force is
f) Total force, F
total
ME 206/SE 322 2
nd
Figure 2
a) A metal is plastically deformed in a uniaxial tensile
test, and the strain in the loading direction is
1
=0.24.
If the specimen has not yet reached to the necking
point (the volume remains constant) and
2
=-0.12,
then
3
=
[ ] +0.12 [ ] +0.36
[ ] 0.24 [ ] 0.12
b) A thin-walled spherical shell of thickness , and
radius R of a perfectly plastic material with a yield
strength Y is subjected to an internal pressure p.
Using the maximum shear stress theory the pressure,
p, required to yield this hell is
[ ] 2Y /r [ ] 2Yr/
[ ] Y /2r [ ] 1 . 1 5
Y /2r
c) The state of stress {
1
/2,
2
=0,
(
3
=-
1
/2)} which is just
sufficient to start the yield
according to maximum shear
stress theory is located in the
figure (Figure 2) by the
[ ] Point D
[ ] Point C
[ ] Point B
[ ] Point A
d) If a metal obeys
f
=K
n
, then the mean flow stress,
corresponding to strain, , is given by
[ ] [ ]
ME 206/SE 322 2
nd
[ ] [ ]
e) The relationship between cold work, CW (expressed as
a fraction) and true strain, , is given by
[ ] [ ]
[ ] [ ]
where codl work, CW=(A
o
-A)/A
o
. A
o
=original area of
cross-section, and A is the instant area of cross-
section of the workpiece.
ME 206/SE 322 2
nd
Figure 3
Figure 4
cont ... Problem 5
f) An elastic, and linearly strain
hardened material has a true stress
and true strain curve as sketched
in Figure 3. For this material the
average flow stress corresponding to
a true stress
1
is
[ ] Y + 0.5 m
1
[ ] Y
[ ] 1.15 Y
[ ] Y + m
1
g) The Poisson ratio at the yield point is
[ ] 0.5 [ ] 0.25
[ ] 1.0 [ ] 0.3
h) As %cold work increases
increases, but %elongation decreases
[ ] yield strength decreases, tensile strength
decreases, but %elongation increases
increases, and %elongation increases
remains same, but %elongation
decreases
I) The grain size depend on prior
cold work and annealing
temperature. The curve which
relates grain size (d) to cold
work (%CW) at different annealing
temperatures (T
1
, T
2
, T
3
) are
ME 206/SE 322 2
nd
shown in Figure 4. Check the correct answer:
[ ] T
3
>T
2
>T
1
[ ] T
1
>T
2
>T
3
[ ] T
1
<T
3
<T
2
[ ] T
3
>T
1
>T
2
j) For a fixed time of annealing, recrystallization
temperature is influenced by prior cold work, in the
following manner:
[ ] as the prior col d work i ncreases the
recrystallization temperature decreases
[ ] as the pri or cold work increases the
recrystallization temperature also increases
recrystallization temperature remain unaffected
recrystallization temperature becomes <0.5 T
m
ME 206/SE 322 2
nd
For the following statement check the correct answer by
a) Camber is a result of
[ ] deflection of rollers [ ] s p
r e
ad
i n
g
o f
r o
lle
d
p r
od
uc
t
[ ] excessive friction [ ] n o n
uni f or
m
pressur
e
b) In an impression die forging of a simple shape (with
no flash), the projected cross-sectional area is 10 in
2
.
The flow stress of the material of the workpiece is
56,000 psi. The force necessary to make this part is:
[Check the closest answer.]
[ ] 2,000,000 lbs [ ] 5,000,0
00 lbs
[ ] 4,000,000 lbs [ ] 1,000,0
ME 206/SE 322 2
nd
Figure 5
00 lbs
c) Flash produced in impression die forging
[ ] help to fill the die cavities [ ]
r e
du
c e
s
fri
cti
on
[ ] reduces the forging load [ ] c a
us
e s
i n
c o
m
p l
e t
e
f o
r g
i n
g
d) The forging process shown in Figure
5 is named
[ ] hubbing
[ ] fullering
[ ] edging
[ ] cogging
e) Barreling during the open die forging can be
minimized by
ME 206/SE 322 2
nd
[ ] applying an effective coolant and increasing
the strain rate
[ ] appl yi ng an effecti ve l ubri cati on and
increasing the working temperature
decreasing the working temperature
ultrasonically vibrating the platens
f) After forging, minimum finishing is required in
[ ] conventional-type forging [ ] b l
o c
ke
r-
t y
pe
f o
r g
i n
g
[ ] flashless forging [ ] impres
s i o n
d i e
forging
ME 206/SE 322 2
nd
Figure 6
Figure 7
g) In a plane strain forging with
sticking friction (see Figure 6), the
average pressure is given by
[ ]
[ ]
[ ]
[ ]
h) In a rolling operation as the friction coefficient =0
[ ] neutral point moves towards entry direction
[ ] neutral point does not change its position
[ ] rolling can be done at very low force
[ ] rolling cannot be done
I) In rolling, neutral point is the point, where
[ ] pressure is minimum
[ ] friction is maximum
[ ] workpiece velocity is
greater than roll
velocity
[ ] w o r k p i e c e
velocity=roll velocity
j) Pressure distribution in the
roll gap as a function of the
coefficient of friction is shown
in Figure 7. Which of the
following statement is a true
statement?
[ ]
1
=
2
=
3
=
4
[ ]
1
<
2
<
3
<
4
ME 206/SE 322 2
nd
[ ]
1
>
2
>
3
>
4
[ ] None of the above are true
k) For good quality and high productivity, threaded bolt
from bar stocks may be produced by
[ ] turning on a lathe
[ ] thread rolling
[ ] casting
[ ] extrusion
ME 206/SE 322 2
nd
Figure 8
l) A 10-in.-wide strip 1.0 in. thick is fed through a
rolling mill with two powered rolls each of 10-in.
radius. The strip thickness is to be reduced to 0.8
in. in one pass. The coefficient of friction between
the roll and the work is assumed to be 0.12. It is
needed to decide whether this operation is possible or
not. Based on the given information it can be
concluded that the rolling operation is
[ ] possible
[ ] not possible
[ ] extra information on average roll pressure,
p
av
, is needed to decide
[ ] the flow stress Y
f
is needed to decide
m) If a sheet is rolled in plain strain from h
0
=1 in. to
h
f
=0.8 in. the spread is
[ ] 0.2 in. [ ] 1.2 in.
[ ] 0 in. [ ] ln(1/0.
8)
n) The rolling defect shown in Figure 8 is
named
[ ] wavy edges
[ ] edge cracks
[ ] zipper cracks
[ ] spreading
o) The coefficient of friction during a rolling operation is
=0.05. The maximum value of the angle of
acceptance,
max
, for this process is
[ ] 0.05 [ ] 2.86
[ ] 87.13 [ ] 8.72
ME 206/SE 322 2
nd
p) The purpose of providing front and back tension in
flat rolling process is to
[ ] reduce the friction [ ] i n
c r
e a
s e
t h
e
r e
du
nd
an
t
wo
rk
[ ] increase the roll pressure [ ] r e
du
c e
t h
e
r o
l l
p r
e s
s u
re
q) Aluminum foil is produced by
[ ] shape rolling [ ] r i n g
rolling
[ ] pack rolling [ ] temper
rolling
Figure 1
Quiz # 3 (Makeup) Name


206.04
Time Allowed: 20
minutes
Problem
A stainless steel cube with an edge
length 2-in made of a material with
K=185,000 psi and n=0.45 is placed
in the center of a rigid die with a
groove (or slot) that is 3 in wide
(see Figure 1). It is being
compressed without friction.
a) Calculate the true strain at which the workpiece
touches the die walls.
b) Calculate the work done up to the deformation,
ME 206/SE 322 2
nd
corresponding to the condition expreed in part (a).
c) If the compression process of part (a) is further
continued until the height of the workpiece is reduced
to 0.4 in then calculate the true compressive force
needed at the end of the compression Process. Give
your answer using:
i) maximum shear stress theory
ii) distortion energy theory.
Name

FINAL EXAM
Student #

Dr. Anwar K. Sheikh
Section: ME 206.04/SE
322.04
Sunday: 18 January 2004
Time Allowed: TWO
hours
Proble Marks Grade
1 5
2 4
3 4
4 5
5 4
6 4
7 4
ME 206/SE 322 Final Exam (031) Dr. Sheikh 2
TOTAL 30
This exam contains TWELVE ( 12 ) pages including the
Cover Page.
An orthogonal cutting operation is being carried out
under the following conditions: t
o
=0.1 mm, t
c
=0.2 mm,
width of cut=5 mm, V=2 m/s, rake angle=10, F
c
=500 N,
and F
t
=200 N.
Calculate the percentage of the total energy that is
required for cutting along the shear plane.
A 12 mm diameter high-speed standard drill is machining
a steel (specific cutting energy is u
t
=2.46 W-s/mm
3
). The
length of the hole drilled is 75 mm. The cutting speed
is set at 0.2 m/sec, and the axial velocity of the drill is
50 mm/min. Determine:
a) Machining time, in seconds.
b) Metal removal rate (MRR), in mm
3
/second.
c) Power needed, in watt.
d) The torque on the drill (Nm) during the drilling
process.
A 2 mm titanium sheet is bent to a radius of 20 mm.
The metal has yield strength of 600 MPa and E=100 GPa.
a) Calculate the actual radius of the part after it is
bent.
b) If 20 mm is the minimum radius the sheet can be
bent without crack, estimate the theoretical percent
reduction of area of this metal in a tension test.
A round of 70-30 brass (K=900 MPa, and n=0.5) is being
drawn from a diameter of 10 mm to one of 8 mm at a
speed of 0.5 m/s. Assume that the frictional and
redundant work together constitute 40% of the ideal work
of deformation.
a) Calculate the power required in this operation.
b) Calculate the pressure at the die exit.
c) Estimate the maximum reduction in cross-sectional
area per pass that is possible in this operation.
Additional Sheet for Problem # 4
Check the correct answers for the following statements by
a) A tool has a temperature T, velocity V and feed f,
relationship expressed as
T V
0.5
f
0.375
.
The tool seems to be made of
[ ] carbide [ ] ceramic
[ ] high speed steel [ ] diamon
d
b) Gross chipping of the tool is called
[ ] crater wear [ ] f l a n k
wear
[ ] nose wear [ ] catastr
o p h i c
failure
c) The figures shows a
tool life T and
cutting velocity V
r e l a t i o n - s h i p ,
e x p r e s s e d b y
Taylors Tool Life
relationship VT
n
=C,
where
[ ]
[ ]
[ ]
[ ]
d) Generalized Taylors Tool Life relationship is given by:
In general
[ ] > > [ ] >
>
[ ] > > [ ] >
>
e) The allowable average wear (V
B
) for high speed steel
reamers is
[ ] 1.5 mm [ ] 0.4 mm
[ ] 0.3 mm [ ] 0.15 mm
f) In orthogonal machining chip velocity is
[ ] equal to cutting velocity [ ] s
m
all
e r
t h
an
t h
e
cu
tti
ng
v e
l o
cit
y
[ ] independent of cutting velocity [ ] g r
e a
t e
r
t h
an
t h
e
cu
tti
ng
v e
l o
cit
y
g) Cost of ceramic tools is
[ ] less than carbide tools [ ] great
e r
t h a n
cubic
boron
nitrid
e
tools
[ ] more than carbide tools [ ] l e s s
t ha n
high-
speed
steel
tools
h) Complex tools, such as slab milling cutters and
broaches, are primarily made of
[ ] carbides [ ] ceramics
[ ] coated carbides [ ] h i g h -
s p e e d
steel
Check the correct answers for the following statements by
1) The Taylor tool life equation constants are n=0.25,
C=400 fpm. When the cutting speed V
1
is reduced to
V
2
=0.5 V
1
, the ratio of the new tool life T
2
to the tool
T
1
is
[ ] [ ]
[ ] [ ]
b) For cast iron and non-ferrous metals for roughing
cut, the following grade of tungsten carbide tools is
the best
[ ] C5 [ ] C6
[ ] C3 [ ] C1
c) In machining, tool materials loose hardness due to
[ ] negative rake angle [ ] bu
i l
t-
up
ed
g e
on
t o
o l
f a
ce
[ ] formation of oxide layer [ ] h i
gh
t e
m
pe
r a
t u
r e
i n
cu
tti
ng
d) Tungsten carbide tools are often selected for
automated machining because of their
[ ] high fracture toughness [ ] h i
gh
m
od
u l
us
o f
e l
a s
tic
ity
[ ] low fracture toughness [ ] h i
gh
ho
t
ha
r d
ne
ss
e) Holes made by drilling process are often finished by
[ ] grinding [ ] shaping
[ ] milling [ ] reaming
f) Most of heat generated in machining is carried away
by
[ ] cutting tool [ ] finishe
d part
[ ] machine tool [ ] chip
g) Chip breakers provides obstruction to the chip flow
creating a substantial change in curvature of the chip.
This causes a continuous chip to break because it
becomes
[ ] softer [ ] weaker
[ ] more ductile [ ] harder
a n d
stronge
r
h) In flat rolling process, tension can be applied either
at entry (back tension) or at the exit of the strip
(front tension). The purpose of the tension is to
[ ] reduce the friction [ ] r e
du
c e
t h
e
r e
du
nd
an
t
wo
rk
[ ] reduce the roll pressure [ ] i n
c r
e a
s e
t h
e
r o
l l
p r
e s
s u
re
Check the correct answer for the following statements by
1) In rod or wire process the die pressure, p
[ ] is maximum at the die entry [ ] r e
m
a i
n
s a
m
e
a l
on
g
t h
e
d i
e
c o
n t
a c
t
l e
ng
th
[ ] is maximum at the die exit [ ]
i s
m
ax
im
u
m
a t
t h
e
d i
e
c e
n t
er
2) Which one of the following process uses non-
consumable electrodes?
[ ] SAW [ ] SMAW
[ ] TIG welding [ ] M I G
welding
3) Which joining process is most frequently used in car
body manufacturing and assembly process?
[ ] Seam welding [ ] H i
gh
f r
e q
ue
nc
y
bu
t t
we
ldi
ng
[ ] Flash welding [ ] Sp
o t
we
ldi
ng
4) The welding process which uses acetylene fuel is
known as
[ ] resistance welding [ ] ox
y a
c e
tyl
en
e
we
ldi
ng
[ ] oxypropane welding [ ] t h
e r
mi
t
we
ldi
ng
5) The heat generated in resistance welding in Joules is
given by
[ ] I
2
R t [ ] I
2
R/t
[ ] IR
2
t [ ] It/R
2
where I is current in amperes, R is resistance in
ohms and t is the time of current flow.
6) The most desirable sheet metal will have
[ ] high n value but low m value [ ] l o
w
n
v a
l u
e
an
d
l o
w
m
v a
l u
e
[ ] low n value but low m value [ ]
h i
gh
n
v a
l u
e
an
d
h i
gh
m
v a
l u
e
7) In open punching operation (Process 1) a hole of
diameter d is punched in a sheet metal of thickness
t. In another punching operation (Process 2) a hole
of diameter 2d is punched in the same sheet. The
ratio of punching force P
2
/P
1
is given by
[ ] 2 [ ]
[ ] [ ] 4
8) The maximum reduction in area per pass in drawing
round bars of perfectly plastic material (while
neglecting friction and redundant work) is
[ ] 58% [ ] 63%
[ ] 45% [ ] 85%
FORMULA SHEET # 1
Extrusion
Extrusion ratio,
Extrusion pressure, ideal, p = Y ln R
Extrusion pressure, with friction,

Rod and Wire drawing
Drawing stress, ideal,
Drawing stress, with friction,
Die pressure,
Summary of Equations
Maximum punch force in shearing,
Strain in bending,
Minimum
Springback,
Maximum bending force,
where the factor k ranges from about 1.2 to 1.33
for a V die. The k values for wiping and U dies
are 0.25 and 2 times, respectively, that for k for
V dies.
FORMULA SHEET # 2
Metal Cutting Machining
Cutting ratio,
Shear strain,
Velocity relationships:
Friction force,
Normal force,
Coefficient of friction,
Thrust force,
Shear angle relationships,

Tool cutting power = F
c
V
Specific energy,
Frictional specific energy,
Shear specific energy,
Mean temperature,

Tool life,
Material removal rate, MRR, in turning =
in drilling =
Quiz # 4 Name


322.04
Time Allowed: ..
minutes
Problem
A metal is used in wire drawing. The material has the
strain hardening properties of K=30,000 psi, and n=0.5.
Assume the friction and redundant work comprise a total
of 30% of the ideal work of deformation. Estimate the
maximum reduction in cross-sectional area per pass that
is possible during this operation.
Quiz # 5 Name


322.04
Time Allowed: ..
minutes
Problem
In an orthogonal cutting process the cutting velocity,
V=500 ft/min, =6, and the width of cut is w=0.40 in.
The undeformed chip thickness is 0.008 in. The thickness
of the chip is 0.013 in. If a toolpost dynamometer gives
cutting and thrust forces of F
c
=250 lb, and F
t
=100 lb,
determine the percentage of the total energy that goes
into overcoming friction at the tool-chip interface and the
percentage that is required for cutting along the shear
plane.
Homework Assignment Date Assigned: Wed: 31 Dec 2003
Date Due: Wed: 07 Jan 2004
Problem # 1
a) It is recommended to turn a 2-inch diameter
steel bar at a cutting speed of 200 ft/min u sing
a cemented carbide-cutting tool. What is the
lathe rpm setting? If the diameter of the bar is
3 inches, what would be the rpm setting using
the same cutting speed?
b) A turning operation is made with a rake
angle of 10, a feed of 0.010 in/rev, and a depth
of cut=0.100 in. The shear strength of the work
material is known to be 50,000 lb/in
2
, and the
chip thickness ratio is measured after the cut to
be 0.40. Determine the cutting force and the
feed force. Use the orthogonal cutting model ass
an approximation of the turning process.
Problem # 2
a) Determine the shear plane angle in orthogonal
machining with a 6 positive rake angle for hot
rolled AISI 1040 steel. (Use Lee & Schaffers
Theory.) The coefficient of friction, =0.5.
b) A cemented carbide tool has the following
relationship:
If there is a decrease of 50 percent in cutting speed
then estimate the %change in tool life.
c) Average value for the specific energy in
machining stainless steel is obtained as 1.5
hp.min/in
3
. If a piece of stainless steel rod 6
inch long is machined from 0.5 inch diameter to
ME 206/SE 322 Homework (031) Dr. Sheikh 2
0.450 inch diameter on a lathe in one pass, then
calculate the work done in machining.
Problem # 3
In an orthogonal cutting process, the undeformed chip
thickness is 0.30 inch, and the rake angle is 10. The
chi thickness was found to be 0.035 inch. Estimate
the shear force, if the yield shear strength of the
workpiece is 35,000 psi. The width of cut is 0.1 inch.
Problem # 4
The tool life curve for a certain carbide tool is shown
below:
a) Find the tool life equation.
b) Using the equation in (a), determine the rpm
setting of a lathe when cutting a steel bar 4
inch in diameter, and mut achieve a tool life of
60 minutes.
Problem # 4
In an orthogonal turning operation on a mild steel
bar, it is required to reduce the diameter from 38
mm to 30 mm in one pass using a 6 kW lathe
machine. The following information is available:
Operation is at half power,
lathe machine efficiency is 75%,
rotational speed of the workpiece is 10
rev/sec,
the rake angle of the cutting tool is 15,
specific cutting energy of the workpiece is
2.25 GJ/m
3
(=2.25 W-s/mm
3
),
average chip thickness is 0.4 mm, and
feed (thrust) force is 800 N.

206 Quiz Major Final AKS

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King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

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