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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Quantitative problems (12 points each). Solve the problem in the space provided below.

Problem 1
Consider the tin-lead phase
diagram. Make phase
analyses of an alloy of 40
wt % tin–60 wt % lead at
the temperatures: (a)
slightly below 183°C, and
95%
(b) around 100°C.
In the phase analyses,
include: (i) the phases
present, (ii) the chemical
compositions of the phases,
and (iii) the wt % of each
phase.
Solution:

Spring 2017 1
MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 2
Consider the Iron-Carbon phase diagram.
(a) Consider a hypoeutectoid steel. If the
weight percentage of its proeutectoid ferrite is
30%, what is the carbon content of the steel?
(b) What is the weight percentage of its o
727 C
o
eutectoid ferrite at slightly below 727 C?
0.77
(c) On a continuous cooling diagram, draw
the time-temperature cooling path that would
create a microstructure of both pearlite and
martensite in this material.

Solution:

Spring 2017 2
MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 3
An austenitized 60 mm diameter steel bar is quenched in agitated water.
(a) If it is 4140 steel, predict the Rockwell C hardness at the center of the bar using the following
diagrams.
(b) If the steel is unknown but the Rockwll C hardness at ¾ R from the center is known to be
approximately 44 RC, determine the type of steel.

Fig.1 Fig. 2

Solution:

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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 4
(a) Pure aluminum is poured into a sand mold. The metal level in the pouring basin is 6 in. above
the metal level in the runner, and the horizontal runner is circular with a 0.4-in. diameter.
What are the velocity and rate of the flow of the metal into the mold? Is the flow turbulent or
laminar? Assume the pressure does not change appreciably and there is no friction in the
sprue. Pure aluminum has a density of 0.098 lb/in3 and a viscosity of around 8.42 ×
10−5 lb/(in ∙ s) around 700°C.
(b) For the sprue described above, what runner diameter is needed to ensure a Reynolds number
of 2000? How long will a 20 in3 casting take to fill with such a runner?
Solution:

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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 5
An aluminum plate of thickness ℎ𝑜 = 12 mm is
rolled to a final thickness ℎ𝑓 = 7 mm. The roll
radius R is 100 mm and the rolling speed is 150
rpm.

(a) Calculate roll gap L and friction coefficient .

(b) Calculate the true strain 𝜀 and strain rate 𝜀̇.

(c) If the rolling is carried out at 200°C and


800°C, respectively (see the diagram),
determine the % increase in tensile strength
at this strain rate compared with that at very
slow strain rate (𝜀̇ = 10−6 𝑠 −1 ). Why the
increase in more significant at the higher
temperature?

Solution:

Spring 2017 5
MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 6
In an orthogonal cutting operation, depth of cut to = 0.3 mm, chip thickness tc = 0.45 mm, cutting
speed V = 2.5 m/s, and tool rake angle 𝛼 = 12o. The cutting force Fc is measured as 400 N and
thrust force Ft as 150 N.

(a) Calculate the chip velocity Vc and frication force F acting on the tool rake face.

(b) Calculate the shear angle 𝜙 and shear velocity Vs.

Solution:

Spring 2017 6
MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 7
(a) A laser is used in a fusion cutting process of a steel plate. The laser outputs a power of
1,500W and the beam is focused to a diameter of 0.25mm. If the achieved cutting velocity is
200 mm/s, determine the plate thickness.

(b) If the same laser is applied to a percussion drilling process of the steel plate to achieve the
same penetrating velocity as the cutting velocity above, how much laser power is required?

For steel,  = 7,870 kg/m3, Lf =275 kJ/kg, Lv =6,362 kJ/kg, Cp = 460 J/kgC, Tm = 1,536C, Tv =
3,000C. Assume To = 20C and 𝜂 = 0.2

Solution:

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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Problem 8
(a) If the molecular weight of polyacrylonitrile (see figure to the right) is
280,000 g/mol, what is its degree of polymerization?

(b) In a vinyl chloride-vinyl acetate copolymer, if the mole fraction of


vinyl chloride is 25%, determine weight % of polyvinyl chloride.

Note: The atomic weight of H is 1, of C is 12, of Cl is 35.5, of N is 14, and of O is 16.

Solution:

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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

Qualitative questions (3 points each). Enter your answer within the space provided below.

1) Why is the solid solubility of carbon in ferrite exceedingly low?

2) Why the annealing temperature range is quite wide (from about 550 to 700°C) in the Process
Annealing of low carbon steel?

3) In continues-cooling transformation (CCT) diagrams, why are the c-shaped curves moved
rightward and the lower half of the c-shaped curves removed?

4) How do reduce porosity caused by increased gas solubility at elevated temperature in sand
casting process? How to reduce porosity caused by material shrinkage in sand casting
process?

5) Cold rolling of metallic plates could result in tensile or compressive residual stress along the
plate surfaces. Which one is more desirable? Why?

6) Define the normal anisotropy, R. Why is it desirable to have a large R value in sheet metal
deep drawing?

7) Why cannot the blank holding force be too large or too small in stamping?

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MECE E3610 Materials and Processes in Manufacturing Final Exam Name: _________________________

8) Briefly describe adhesive wear.

9) It is common to coat cutting tools with multiple layers of different materials. Name two
reasons for doing so.

10) Under what circumstances should up-milling be used during slab milling operations?

11) Briefly describe how material is removed in wire electrical discharge machining (wire EDM).

12) Why is a polymer with higher degree of polymerization stronger?

13) Is a polymer with higher degree of crystallinity stronger? Why?

14) Define parison in blow molding of polymer.

15) List two properties of laser which make higher intensity possible.

16) Why do the plated materials tend to preferentially attach to corners and protrusions of plated
parts in electroplating process?

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