DRAFT Exam sheet: 0

EvaExam MT 1617 end term exam AKL

Rhine Waal University of Applied Sciences Prof. Dr.-Ing. Alexander Klein MBA
Faculty of Technology and Bionics Manufacturing Technology 2016/2017 end term exam
35 minutes, max. 35 points (14+21)

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EvaExam MT 1617 end term exam AKL

1. Open questions. Please write a brief answer into the box. If you need room for scribbling, use any
space outside the answer boxes. Only the content of the boxes will be regarded for marking. Please
give a brief answer (no long sentences) [Continue]
1.1 What does "tesselation" mean in the context of manufacturing?
Please give a brief and crisp answer.
(3 pts)

1.2 Explain the difference between a pattern and a mold in sand casting.
(3 pts)

1.3 In a manufacturing technology that was explained in the lecture, there is a workpiece that is called the "green".
1) What does it mean? In which technology is it created?
2) At which stage of the value chain is the workpiece called the "green"?
3) What are the most striking mechanical properties of such a piece?
(3 pts)

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EvaExam MT 1617 end term exam AKL

1. Open questions. Please write a brief answer into the box. If you need room for scribbling, use any
space outside the answer boxes. Only the content of the boxes will be regarded for marking. Please
give a brief answer (no long sentences) [Continue]
1.4 1) What does "EDM" stand for?
Please name the full words that name this manufacturing technology
2) What are the advantages of EDM compared to milling? Please name at least two.
(1 + 2 = 3 pts)

1.5 1) What is the most important difference between stretch forming and bending with regard to the stresses in the
workpiece during the process?
(2 pts)

2. Single choice questions, i.e. exactly one answer is correct.

right answer +1 point
wrong answer -1 point
no answer: zero points

make sure you check the box and make corrections in the right way (see explanation on top of the exam header)

2.1 Fused deposition modeling is an additive manufacturing technology in which ...

powder is used as raw material
a fiber is used as raw material

2.2 In deforming, stretch forming and bending are competing technologies to create curved sheet metals. Which one has
the lower springback effect?
bending
stretch forming

2.3 What is one of the main differences between deep drawing and strech forming?
In deep drawing, the maximum thickness of the sheets that can be deformed is higher than in stretch forming
In deep drawing, the sheet thickness remains constant wheras is gets thinner in stretch forming

2.4 Ironing is a ...

sheet metal forming technology
bulk forming technology

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EvaExam MT 1617 end term exam AKL

2. Single choice questions, i.e. exactly one answer is correct.

right answer +1 point
wrong answer -1 point
no answer: zero points

make sure you check the box and make corrections in the right way (see explanation on top of the
exam header) [Continue]
2.5 Right or wrong? Hydroforming can be used to manufacture hollow workpieces with complex geometry cost efficiently
in large quantities.
Wrong
Right

2.6 In the standard DIN 8580ff, deforming techologies are categorized with regard to....
the temperature of the workpiece prior to deforming
the condition of stress in the workpiece during the deformation process

2.7 Tailored blanks are....

workpieces which are deformed close to the final desired workpiece shape which then are milled or ground to the final shape
sheet metal pieces that are welded together from different materials or thicknesses which then are used to
produce high-strength lightweight workpieces

2.8 With EDM, even ceramics can be machined, if ....

their hardness is below 2000 HV30
their electrical conductivity is above 1-10 S/m

2.9 One of the common electrode materials in EDM is....

titanium (titanium alloys)
graphite

2.10 The main disadvantage of EDM compared to milling is...

the low surface finish quality (high roughness)
the low productivity

2.11 The coating technology "electro plating" can be considered as a reversed...

PVD process
CVD process
ECM process
EDM process

2.12 Which technology has the capability to cut the thicker sheet metals?
Water jet cutting
Laser cutting

2.13 CAM software is used to....

generate CNC programs based on a CAD file of the finished workpiece and the blank
calculate the expected tool life of a cutting tool and the maximum heat temperature in the workpiece that will
occur during the milling process

2.14 Tribology is ...

a technology to refurbish deforming tools with a combination of chemical vapor deposition and laser ablation
the science (engineering discipline) of friction, lubrication and wear

2.15 The expression "tool and die repair" is most commonly used for...
the process of disassembling the die and replacing worn parts with fresh elements
the sequence of material addition and subsequent machining to final precise shape

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EvaExam MT 1617 end term exam AKL

2. Single choice questions, i.e. exactly one answer is correct.

right answer +1 point
wrong answer -1 point
no answer: zero points

make sure you check the box and make corrections in the right way (see explanation on top of the
exam header) [Continue]
2.16 What is the most common material to make deforming tools (dies)?
steel
ceramics
cemented carbide
diamond

2.17 What is one of the main advantages of additive manufacturing compared to subtractive manufacturing?
high degree of freedom with regard to workpiece geometry
high strength of workpieces that can be achieved (e.g. compared to milled workpieces with same workpiece dimensions)

2.18 How is the true strain of a deforming process calculated (referring to a simple upsetting process as explained in the
lecture)? (h. height, index 0 : prior to deforming)
phiz = ln (h0/h1)
phiz = ln (h1/h0)
phiz = (h1-h0)/h1

2.19 Strain hardening....

...can be undone by recrystalization glowing
... is an unwanted effect that can be considered as one of the main disadvantages of deforming technologies

2.20 Injection moulding is....

... a casting operation with lost mold
... a casting operation with reusable mold
... a mold-making process based on addictive manufacturing (fused deposition modeling)

2.21 In full-mould casting (where styrofoam is used to make patterns)...

... it is important to have a draft angle on all nearly vertical surfaces
... the mold is split in two parts which are called "cope" and "drag"
... the geometrical degree of freedom is higher than in sand casting with wooden patterns
... the geometrical degree of freedom is lower than in sand casting with wooden patterns

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