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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): 8.

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. Product lifecycle management (PLM) 5. Which of following is the cause of sand

can be divided into 4 phases, which phase blow during sand casting process?
manufacture process belongs to? a. Release of mold gases during pouring,
a. Conceive balloon shaped gas cavity
b. Release of gas during pouring, many small
b. Design gas cavities
c. Realise c. Irregularity in the surface of the casting
result from erosion of sand mold during
d. Service
pouring
d. None of above
2. Which of following is not a Deformation
process?
a. Casting
6. Which of the following types of stress–
b. Rolling
strain relationship best describes the behavior of
c. Extrusion brittle materials such as ceramics and cast iron?

d. forging a. Elastic and Perfectly Plastic

b. Elastic and Strain Hardening
c. Perfectly Elastic
3. Which of following is not a ferrous
metal? d. None of the above

a. Brass
b. Cast Iron
7. Which of following statements is not
c. Steel correct about the riser in sand casting:
d. None of above a. Create internal feature for the casting
b. Source of molten metal to compensate
shrinkage.
4. Die casting has which of following
advantages over sand casting? c. Waste metal that is usually recycled
d. None of above
a. Better surface finish
b. Cheaper in mass production
c. Better mechanical property
d. All of above

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8. The flow rate of liquid metal into the 12. Which of following is NOT true for
downsprue of a mold = 0.8 L/sec. The height of shell molding process?
the sprue = 175 mm. What is the maximum area
can be used at the base of the sprue to prevent a. Good dimensional accuracy
discntinuity of the flow? b. Mold collapsibility minimizes cracks in
a. 320 mm2 casting
b. 430 mm2 c. Part shapes are limited by the need to open
c. 620 mm 2 the mold
d. 750 mm2 d. More expensive metal pattern, difficult to
justify for small quantities

9. Which of the following metal is not

typically used in die casting:
13. A misrun is which one of the following
a. Iron
defects in casting:
b. Aluminum
a. Globules of metal becoming entrapped in the
c. Tin casting
d. None of above b. Metal solidifies before filling the cavity
c. Metal is not properly poured into the
10. Which of below is not an expendable downsprue
casting process: d. Metal runs to wrong directions
a. Shell molding
b. Low pressure casting
14. Which die-casting machines usually
c. Vacuum molding
have a lower production rate and why
d. Investment molding
a. Hot-chamber because heat up the chamber
usually takes more time
11. In sand casting, if density of sand is b. Hot-chamber because the hot molten metal
2000 kg/m3, density of molten metal is takes longer time to solidify
6000 kg/m3, what is approximately the buoyance
c. Cold-chamber because ladling usually takes
force act on a sand core with volume 2000 cm3?
more time
a. 80 N
d. Cold-chamber because heat up the material
b. 60 N takes more time
c. 40 N
d. 20 N

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15. Brass bushings are made by horizontal 19. The shear strength of a metal is
true centrifugal casting. The bushings have commonly determined in which one of the
outside diameter = 40 cm, and inside diameter = following tests?
30 cm. Rotation at 600 rpm will give a G-factor
a. Bending test
of approximately
b. Compression test
a. 80
c. Tensile test
b. 100
d. Torsion test
c. 120
d. 140
20. A cylinder is compressed to half of its
original length, and then elongated back to its
16. ______________ is a crack in the original length. What is the resultant true strain?
casting caused by a mold that does not yield to a. 0
the metal during the early stages of solidification
b. 0.69
shrinkage.
c. 1.38
a. cold shuts
d. 2
b. cold shots
c. hot tearing
21. Consider the engineering stress-strain
d. shrinkage cavity
curves for three materials labeled A, B, and C
below. Which material is the most ductile?
17. If a material is subjected to two a. A
incremental true strains namely ε1 and ε2, then
b. B
the total true strain is?
c. C
a. ε1 * ε2
d. Cannot be determined
b. ε1 - ε2
c. ε1 + ε2
d. ε1 / ε2
22. The formation of new strain-free grains
in a metal that has been heated to an elevated
18. As compared with conventional stress- temperature is called which one of the following:
strain curve, the true stress-strain curve is? a. Hot hardness
a. Above and right b. Recrystallization
b. Below and right c. Strain hardening
c. Above and left d. Strain softening
d. Below and left

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23. Which of following is NOT a typical 27. Rockwell test utilizes ___________ to
chemical reaction in a Blast Furnace? measure of hardness.
a. Fe2O3+CO →2FeO +CO2 a. Load
b. CaO + H2O = Ca(OH)2 b. Depth of indentation
c. CO2+C→ 2CO c. Diameter of indentation
d. FeO +CO → Fe + CO2 d. Time of loading

24. To make 1 ton of pig iron in a Blast 28. What kind of indenter is used in a Brinell
Furnace, it will take approximately: test?
a. 2 tons of iron ore, 1 ton of water, 0.5 tone of a. Steel cone
limestone, and 0.5 ton of gases.
b. Steel ball
b. 2 tons of iron ore, 1 ton of coal, 1 tone of
limestone, and 0.5 ton of gases. c. Steel cylinder

c. 1 tons of iron ore, 1 ton of coke, 0.5 tone of d. Pyramid-shaped indenter

water, and 0.5 ton of gases.
d. 2 tons of iron ore, 1 tone of coke, 0.5 tone of 29. The maximum possible draft in a rolling
limestone, and 3.5 tons of gases. operation does NOT depend on which of the
following parameters

25. Plain carbon steels are designated in the a. Roll width

AISI code system by which of the following b. Roll diameter
a. 01XX c. Motor torque
b. 10XX d. coefficient of friction between roll and work
c. 11XX
d. 12XX
30. Diameter of a roller = 600 mm, in order to
achieve maximum possible draft of 6.75 mm in
26. Which of the following is usually the one pass, the minimum coefficient of friction
percentage of carbon for medium carbon steel? between rolls and work need to be

a. Up to 0.2% a. 0.17

b. 0.2-0.5% b. 0.15

c. 0.5-1.2% c. 0.12

d. 1.2-2.1% d. 0.10

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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. (25 points) A disc of 40 cm radius and 5 cm thick is cast of pure aluminum in a sand mold
casting operation. Aluminum melts at 660 C, but the pouring temperature will be 800C. The heat of
fusion of aluminum = 389.3 J/g, density  = 2.70 g/cm3 and specific heat C = 0.88 J/g-C. Assume the
specific heat has the same value for solid and molten aluminum.

(a) Based on Chvorinov's rule T = Cm (V/A)2, design a cylindrical shape raiser with height = radius. What is
minimum volume for this riser? (10 points)

(b) The metal is heated up in a crucible furnaces with a power of 10 KWatt (J/s), starting from a room
temperature of 25C. Assume there is no heat lose, how long it will take to heat 3000 cm3 of the metal to
the pouring temperature? (5 points)

(c) If die casting is used instead to make above part, how the followings are going to be affected?
(1) Solidification time
(2) Surface roughness
Explain your answer (5 points)

(d) If the mold is heated up:

(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?
Explain your answer (5 points)

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Problem 2. (20 points) Tensile test specimen A begins to neck at a true strain = 0.22 and true stress
= 257 MPa. Tensile test specimen B reaches ultimate tensile strength at engineering strain = 0.2 and
engineering stress = 210 MPa.
(a) What is true strain and true stress when specimen B begins to neck? (5 points)
(b) Which material (A or B) has a higher tensile strength and why? (10 points)
(c) Find out flow curve equation ( ) for material A. (5 pts)

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Problem 3. (25 points) A low-carbon steel plate is 300 mm wide and 25 mm thick. It is reduced in
one pass in a two-high rolling mill to a thickness of 20 mm. Roll radius = 600 mm, coefficient of
friction between the material and rolls = 0.5, and the material is fed into the rolling mill at 1 m/s.
Strength coefficient = 500 MPa, and strain hardening exponent = 0.25. Assume there is no change
in the steel plate width before and after rolling, determine:
(a) True strain imposed on the steel plate by rolling. (5 points)
(b) Maximum reduction possible per single pass. (5 pts)
(c) Average flow stress. (5 points)
(d) minimum power required to perform the operation. (10 points)

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