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ENME 489G – Exam 1

Instructions:

1. The Exam consists of 30 multiple-choice questions. each question carries 1 point. 3 word problems,
total of 70 points.

2. Open notes, open homework, open book.

3. The total number of pages (include this page): 9.

4. If you are working on separate pieces of paper, please write down the question number clearly.

5. Submit electronically.

6. Good luck!

Time: 75 minutes + 5 minutes

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Section 1 (30 points). Multiple-choice questions. No points if more than one answer is circled per question.
No penalty for wrong answers. Some questions are much harder than other, allocate your time wisely.

1. Which of following is a material 4. Which of following is true for shell

removal process? molding processes?
a. Casting a. Good dimensional accuracy
b. Rolling
c. Machining b. Mold collapsibility minimizes cracks in
d. Forging casting
c. More expensive metal pattern, difficult
to justify for small quantities
d. All of above.
2. Which of following is NOT true for
Permanent mold processes?
a. Permanent mold processes could be more
economic in high production operations
b. More intricate geometries are possible 5. Which of following is a typical
with permanent mold processes chemical reaction in a Blast Furnace?
c. Part shapes in permanent mold processes a. Fe2O3+CO →2FeO +CO2
are limited by the need to open the mold
b. CO2+C→ 2CO
d. A permanent mold can be used to
produce many castings c. FeO +CO → Fe + CO2
d. All of above

3. In sand casting, if density of sand is

1000kg/m3, density of molten metal is
6. The upper half of a sand-casting
5000kg/m3, what is approximately the
mold is called __________.
buoyance force act on a sand core with
a. Cope
volume 1000 cm3?
b. Drag
a. 60 N
c. Residual
b. 50 N
d. Top
c. 40 N
d. 10 N

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7. In casting, a flask is which one of the 11. Sand molds (for sand castings) are
following? classified as
a. Beverage bottle for foundrymen a. Wet-sand, Dry-sand, or Hot-sand
b. Box which holds the cope and drag molds
c. Container for holding liquid metal b. Warm-sand, Cold-sand, or Hot-sand
d. Metal which extrudes between the mold molds
halves c. Dry-sand, Green-sand, or Skin-dried
molds
d. Green-sand, Brown-sand, or Black-
8. In foundry work, a runner is which of sand molds
the following?
a. Channel in the mold leading from the
down sprue to the main mold cavity
b. Foundryman who moves the molten 12. Turbulence during pouring of the
metal to the mold molten metal is undesirable for which of the
c. Vertical channel into which molten metal following reasons?
is poured into the mold a. It causes discoloration of the mold
d. Messenger within the factory surfaces.
b. It dissolves the binder used to hold
together the sand mold.
9. In a sand-casting mold, the V/A ratio c. It Increases the formation of metallic
of the riser should be oxides that can become entrapped during
a. equal to the V/A ratio of the casting solidification.
itself d. It increases total solidification time.
b. greater than the V/A ratio of the casting
itself
c. smaller than the V/A ratio of the
casting itself 13. __________ is a thin portion of metal
d. minimal compared to the casting. at the exterior of a casting that results from
molten metal being squeezed into the spaces
between the die halves of the mold at the
parting line, or into the clearances around the
10. Some other expendable casting cores and ejector pins.
processes include all of the following, except a. Cupola
a. Shell molding b. Flash
b. Expanded polystyrene casting processes c. Sprue
c. Investment molding d. Excess metal
d. Low-pressure casting

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14. Which of the following are bulk For question 19 and 20 refer to the stress-
deformation processes? strain curve below
a. Bending, drawing and shearing
b. Drilling, extrusion, and rolling
c. Rolling, forging, and extrusion
d. Extrusion, shearing and stamping

15. Which factor(s) below affect(s) the

fluidity of a molten metal during pouring
into a mold cavity?
a. Pouring temperature 18. Which stress strain curve best
b. Metal alloy composition represents a ductile material?
c. Heat transfer to the surroundings
d. All of above (a) (b) (c) (d)

16. Which die-casting machines usually

19. Which stress strain curve best
have a higher production rate and why
represents a perfect brittle material?
a. Cold-chamber because there is no need
to heat up the chamber
(a) (b) (c) (d)
b. Cold-chamber because material can
solidify faster
c. Hot-chamber because ladling usually
takes more time 20. Which of following is the cause of
d. Hot-chamber because molten metal can Pinholes during sand casting process?
be ladled into the chamber very fast a. Release of mold gases during pouring,
balloon shaped gas cavity
b. Release of gas during pouring, many small
gas cavities
17. Which of the following types of stress– c. Irregularity in the surface of the casting
strain relationship best describes the behavior of result from erosion of sand mold during
low carbon steel? pouring
a. Elastic and Perfectly Plastic d. None of above
b. Elastic and Strain Hardening
c. Perfectly Elastic
d. None of the above

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21. Which of following statements is not
correct about the core in sand casting:
a. Create internal feature for the casting
b. Source of molten metal to compensate
shrinkage.
25. Brass bushings are made by horizontal
true centrifugal casting. The bushings have
outside diameter = 50 cm, and inside diameter =
30 cm. Rotation at 600 rpm will give a G-factor
of approximately

c. Waste metal that is usually recycled a. 80

d. None of above b. 100
c. 120
22. The flow rate of liquid metal into the
downsprue of a mold = 0.8 L/sec. The height of d. 140
the sprue = 175 mm. What is the maximum area
can be used at the base of the sprue to prevent
discntinuity of the flow? 26. A cylinder is elongated to twice of its
original length, and then compressed back to its
a. 320 mm2
original length. What is the resultant true strain?
b. 430 mm2
a. 0
c. 620 mm2
b. 0.69
d. 750 mm2
c. 1.38

23. Which of the following metal is typically d. 2

used in die casting:
a. Iron 27. Which of the following is usually the
b. Aluminum percentage of carbon for low carbon steel?

c. Titanium a. Up to 0.2%

d. None of above b. 0.2-0.5%

c. 0.5-1.2%

24. In sand casting, if density of sand is d. 1.2-2.1%

2000 kg/m3, density of molten metal is
6000 kg/m3, what is approximately the buoyance
28. The maximum possible draft in a rolling
force act on a sand core with volume 1000 cm3?
operation does NOT depend on which of the
a. 80 N following parameters
b. 60 N a. Roll width
c. 40 N b. Roll diameter
d. 20 N c. Motor power
d. coefficient of friction between roll and work

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29. To make 1 ton of pig iron in a Blast 30. Diameter of a roller = 600 mm, in order to
Furnace, it will take approximately: achieve maximum possible draft of 12 mm in one
pass, the minimum coefficient of friction between
a. 2 tons of iron ore, 1 ton of water, 0.5 tone of
rolls and work need to be
limestone, and 0.5 ton of gases.
a. 0.25
b. 2 tons of iron ore, 1 ton of coal, 1 tone of
limestone, and 0.5 ton of gases. b. 0.20
c. 1 tons of iron ore, 1 ton of coke, 0.5 tone of c. 0.15
water, and 0.5 ton of gases.
d. 0.10
d. 2 tons of iron ore, 1 tone of coke, 0.5 tone of
limestone, and 3.5 tons of gases.

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Section 2. Words problems. Please write clearly and show all steps for partial credits. If you use a formula,
please copy the formula down first before plug in any numbers (70 points).

Problem 1. (20 points) When casting low carbon steel under certain mold conditions, the mold
constant in Chvorinov's rule = 2.0 min/cm2. Assume the exponential constant in Chvorinov's
equation n = 2.

(a) Determine how long solidification will take for a rectangular casting whose length = 30 cm,
width = 15 cm, and thickness = 20 mm. (8 points)
(b) A cylindrical shape raiser with height = radius is used. What is minimum volume for this riser?
(8 points)
(c) If die casting is used instead to make above part, how the followings are going to be affected
(2 points)?
(1) Solidification time
(2) Surface roughness
(d) If the mold is heated up: (2 points)
(1) will the solidification time decrease or increase?
(2) how the grain size of the casting near the mold wall is going to be affected?

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Problem 2. (28 points) Aluminum has a true stress-strain curve given by σ = 180ε0.2 (MPa).
(a) What is its Ultimate tensile strength? (Remember that ultimate tensile strength is expressed as
engineering stress). (10 points)
(b) A cylindrical piece of this aluminum is loaded in a tensile test to a true strain of 0.1. Unloaded
and then reloaded, what would be its true yield strength upon reloading? (4 points)
(c) If the above piece of aluminum is loaded to a true strain of 0.25 in
this tension test, what will be the cross-section area at uniform and the
neck? You may assume the initial cross-sectional area to be Ao. (6
points).
(d) Plot the engineering strain stress curve and true string stress curve on the same graph. Mark
clearly the 1. elastic region, 2. plastic region, 3. necking and 4 fracture points on each curve.
(8 points)

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Problem 3. (22 points) A low-carbon steel plate is 300 mm wide and 25 mm thick. It is reduced in
one pass by cold roll in a two-high rolling mill to a thickness of 20 mm. Roll radius = 600 mm, and
material is fed into the rolling mill at 1 m/s. Forward slip is 0.087. The coefficient of friction is 0.5;
The roll force is measured to be 4.5 M Newton. The motor has a maximum power of 250 kW.
Determine:

(a) The roller speed Vr (4 points)

(b) Thickness of the slab when the roll pressure is the maximum. (4 points)

(c) Minimum power required to perform the operation. (10 points)

(d) If the plate needs to be reduced to 15 mm, can it still be rolled in one pass on this mill with same
speed? State your reason(s). (4 points)

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