SEPTEMBER 2016 ASSIGNMENT

SECTION A (Total: 100 marks)

INSTRUCTION: Answer ONLY FIVE questions.

1. i. Distinguish some of the general properties that distinguish metals from

ceramics and polymers?
ii. Define the two major groups of metals? Define them.
iii. Identify some of the properties for which aluminum is noted?
iv. The superalloys divide into three basic groups, according to the base metal
used in the alloy. Name the three groups.
v. What is so special about the superalloys? What distinguishes them from
other alloys?

2. i. Identify some of the important advantages of shape-casting processes.

ii. What are some of the limitations and disadvantages of casting?
iii. What is the difference between an open mold and a closed mold?
iv. Name the two basic mold types that distinguish casting processes.
v. What is meant by the term superheat?

3. i. Name some of the reasons for the commercial importance of powder

metallurgy technology
ii. What are some of the disadvantages of PM methods?
iii. In the screening of powders for sizing, what is meant by the term mesh
count?
iv. What is the difference between open pores and closed pores in a metallic
powders?

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Document No : UniKL MFI_SD_AC41 (b)
Revision No: 03
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 SEPTEMBER 2016 ASSIGNMENT

4. i. What are the differences between bulk deformation processes and sheet
metal processes?
ii. Extrusion is a fundamental shaping process. Describe it.
iii. Why is the term pressworking often used for sheet metal processes?
iv. What is the difference between deep drawing and bar drawing?
v. Indicate some of the advantages of cold working relative to warm and hot
working.

5. i. What are the differences between rotational parts and prismatic parts in
machining?
ii. Distinguish between generating and forming when machining work part
geometries.
iii. Give two examples of machining operations in which generating and forming
are combined to create work part geometry.
iv. Describe the turning process.
v. What is the difference between threading and tapping?

6 i. Why are the nontraditional material removal processes important?

ii. There are four categories of nontraditional machining processes, based on
principal energy form. Name the four categories.
iii. How does the ultrasonic machining process work?
iv. Describe the water jet cutting process.
v. What is the difference between water jet cutting, abrasive water jet cutting,
and abrasive jet cutting?

7. With reference to the physical and mechanical properties of metals and polymers,
compare and contrast the
(a) Manufacturing processes used to form these materials into shaped products.
(b) Give examples, which include comparisons for casting / moulding, extrusion and
sheet forming processes.

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Document No : UniKL MFI_SD_AC41 (b)
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8. Many machine parts are by routes that begin with metal powder.

(a) Briefly state the main benefits of making components in such a way.
(b) Identify the steps involved in the process of shaping metal powder by uniaxial die
compaction.
(c) Illustrate the pressure distribution in a powder compact subjected single-action,
uniaxial die compaction.
(d) Write an expression for the variation in pressure through the height of a compact
pressed in the above manner.
(e) Using this expression, and assuming the coefficient of friction at the die wall is 0.1and
the inter-particles friction factor is 2, determine what fraction of the applied pressure
is transmitted to the base of compact with an aspect ratio of 2.
(f) How does this pressure distribution relate to the compact density?
(g) Why is a uniform compact density desirable and what measures can be taken to
improve the degree of uniformity achieved during uniaxial powder compaction?

9. Many manufacturing processes are based on plastic deformation of the material

being shaped.

(a) Explain why such manufacturing techniques are much more widely used for forming
metals than they are for ceramics and polymers.
(b) Clearly define what is meant by
i. Hot-working and
ii. Cold working of metals.
iii. Using this definition, clearly why tungsten can be cold worked at 9000C and lead hot
worked at room temperature.

(c) Illustrate, with the aid of a stress-strain curve, the phenomenon of work hardening.
How, therefore, is the strength of a metal altered by extensive cold working and how
may the original yield strength and ductility of an extensively cold rolled material be
restored?

(d) Identify the main advantages and disadvantages of both hot and cold rolling.

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(e) Suggest a series of manufacturing steps by which a molten Aluminium alloy could be
turned into thin roll.

10a) Describe the product geometries (including design considerations) and the types of
production volumes for which injection moulding of polymers and the pressure die
casting of molten metals are suitable.

(b) Sketch, for both a cast metal and injection moulded (semi-crystalline) polymer parts,
how the microstructure varies from the outside to the centre line. Comment on how
the microstructure would change if the dies were heated to a higher temperature
before processing.

(c) What measures can be implemented to minimize the variation in microstructure

i. Cast and
ii. Moulded parts?

(d) Explain why shrinkage occurs in moulded and cast products.

11a) Define the difference between fusion and solid state welding processes.
(b) Give examples (with sketches) of four (4) ways in which heat may be supplied in
fusion welding processes. Give the main advantages and limitations for each of
these methods.

(c) Detail the main methods used to join ceramics and polymers. Give clear reasoning as
to why many of the methods available for joining metals are not appropriate for
ceramics and polymers.

12a) Derive an expression for the mean pressure during direct extrusion of a metal. You
may assume ideal deformation conditions.
(b) Briefly describe what effect, if any, the following factors have on the extrusion load;

i. Billet temperature,
ii. Ram speed,
iii. Diameter of the extruded product,
iv. Surface area of the extruded product.

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(c) Sketch the real load-displacement plot for direct extrusion. Mark the 3 critical regions
and explain the processes taking place which give rise to the characteristic load-
displacement behavior in each of these regions.

(d) What might happen if frictional heating of the billet becomes severe?

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Document No : UniKL MFI_SD_AC41 (b)
Revision No: 03
Effective Date: 01 March 2016