Course No.

: ET ZC235
Course Title : MANUFACTURING PROCESSES
Q 1.
(a) Toughness: It is defined as the ability of the material to absorb energy up to fracture
during the plastic deformation. Toughness of a metal offers the resistance to breaking
when force is applied. It is measured as area under the stress strain curve. Or in other
terms Toughness can be determined by integrating the stress-strain curve
(b) Stiffness is the rigidity of an object, the extent to which it resists deformation in
response to an applied force or in other words it is the tendency of a material to react
with a small deformation when the material is stressed. It is measured with Young's
Modulus, which is the angular coefficient, or slope, of the linear stress-strain curve.
This property depends directly on the bond type between the atoms. The stronger the
bond, the higher the modulus (or the stiffness).

Q 2.

Q 3.
• Air Aspiration: if pressure anywhere in the flow stream falls below the atmospheric
pressure then gases originating from mould will enter into the molten metal stream
producing porous casting. This is known as air aspiration
• To avoid air aspiration, sprue should be tapered and sharp corners should be avoided
(2 marks)
Applying Bernoulli' s equation at 2 and 3
p2 v22 p v2
  gh2  3  3  gh3
 2  2
p3  0, h3  0andv 2  v3 ( A2  A3 )
p 2   gh
it shows that the pressure at point 2 is below atmospheric
at least P2  0 which gives
A2 ht

A3 hc (Derivation 3 marks) 2+3=5 Mark
Q 4.
A properly designed casting, a properly prepared mould and correctly malted metal should
result in a defect free casting. However, if proper control is not exercised in the foundry-
sometimes it is too expensive - a variety of defects may result in a casting.
These defects may be the result of:
(a) Improper pattern design,
(b) Improper mould and core construction,
(c) Improper melting practice,
(d) Improper pouring practice and
(e) Because of molding and core making materials.
(f) Improper gating system
(g) Improper metal composition
(h) Inadequate melting temp and rate of pouring

Misrun: A casting that has solidified before completely filling mold cavity

Sand Blow: Balloon-shaped gas cavity caused by release of mold gases during pouring

Penetration: When fluidity of liquid metal is high, it may penetrate sand mold or core,
causing casting surface to consist of a mixture of sand grains and metal
 Mold shift: A step in cast product at parting line caused by sidewise relative
displacement of cope and drag

Shrinkage cavity: Depression in surface or internal void caused by solidification

shrinkage that restricts amount of molten metal available in last region to freeze

Q 5.
(a)
Cold working: CW is done below the recrystallization temp of the material.
I. Pros
i. better accuracy
ii. better surface finish
iii. strain hardening increases strength and hardness
iv. grain flow during deformation provides directional properties
v. no heating is needed
II. Cons
i. higher forces and power are required
ii. surface should be cleansed
iii. ductility and strain-hardening limits the extent of forming.
Hot working: HW is performed above the recrystallization temp of the material.
I. Pros
i. larger deformation possible lower forces and power
ii. isotropic properties resulted from process
iii. no work hardening
II. Cons.
i. Poor surface finish
ii. less corrosion resistance
(b)

(i ) min  [(ti  t f ) / R]1/2  [(5  4) /100]1/2  0.1

(ii)i  0.1

Q6
(a) Resistance to permanent indentation
• Good hardness generally means material is resistant to scratching and wear
• Most tooling used in manufacturing must be hard for scratch and wear resistance
Test: 1) Rockwell Hardness Test2) Brinell Hardness Test.
(b) Desirable properties for mold are:
i. Strength - to maintain shape and resist erosion
ii. Permeability - to allow hot air and gases to pass through voids in sand
iii. Thermal stability - to resist cracking on contact with molten metal
iv. Collapsibility - ability to give way and allow casting to shrink without
cracking the casting
v. Reusability - can sand from broken mold be reused to make other molds?
Q7. (a)
Under most cutting conditions, some of the cut material will attach to the cutting Point.
This is due to the high temperature along the tool- chip interface. This tends to cause the
cut to be deeper than the tip of the cutting tool and degrades surface finish. Also, periodically
the built up edge will break off and remove some of the cutting tool. Thus, tool life is
reduced. However, sticking in cutting edge can be sometimes improves the cutting tool life.
Can be avoided by
 Increasing speed
 Increasing rake angle
 Decreasing feed
 Use of lubricants to reduce temperature etc.
 BUE formation
(b) Solution:
(a) r = to/tc = 0.30/0.65 = 0.4615
φ = tan-1(0.4615 cos 15/(1 - 0.4615 sin 15)) = tan-1(0.5062) = 26.85°
(b) Shear strain γ = cot 26.85 + tan (26.85 - 15) = 1.975 + 0.210 = 2.185
(2+3 =5 marks)