ME EN 4060; Fall 2013 Mid-term Exam 1 Mid-Term Exam 1 110 points ‘Thursday, October 10, 2013; 10:45 am — 12:05 pm Closed book and Closed Notes Time guideline: 110 points in 80 min. Manage time appropriately Name: SOLUTIONS UNID: PROBLEMS (each question is worth 15 points) 1. Determine the value of the strain-hardening exponent for a metal that will cause the average flow stress to be 75% of the final flow stress after deformation. Also, briefly describe strain-rate sensitivity and why it is important for manufacturing? ¥ = 0.75%; Ke") = 0.75 + (Ke” ieralleg (Ke") 1 Ten 07 n= 1/3 = 0333 The effect of strain rate on strength properties is known as strain rate sensitivity. As temperature is increased, strain rate plays a more important role in determining flow stress. This is important in hot working because deformation resistance of the material increases so dramatically as strain rate is increased. We see that even in cold working, strain rate can have an effect, if small, on flow stress. In hot working, the effect can be significant.ME EN 4060; Fall 2013 ‘Mid-term Exam 1 2. Aoylindrical riser is to be used for a sand casting mold. For a given (constant) cylinder volume, determine the diameter-to-lenath ratio that will maximize the time to solidify. You need to use calculus to arrive at your answer. Why is calculation of total solidification time for different areas of a casting mold critical? Solution: To maximize Tis, the V/A ratio must be maximized. Cylinder volume V = mD*L/4, L = 4VATD* Cylinder area A = 2177/4 + mDL ‘Substitute the expression for L from the volume equation in the area equation: A D2 + mI D712 + mD(4VATD? ) = 172 + 4V/D Differentiate the area equation with respect to D: dA/dD = 1D - 4V/D? = 0 Rearranging, 1D = 4VID* D=4VAr D=(4vmy* From the previous expression for L, substituting in the equation for D that we have developed, L= 4VAnD? = 4Vin(4 Vir)" = (4VIr) Thus, optimal values are D = L = (4V/m)°*®, and therefore the optimal D/L ratio = 1.0ME EN 4060; Fal 2013, Mig-tarm Exam 4 3. Acylindrical part is upset forged in an open die. Initial geometry is Dp = 70 mm and hy = 55 mm. Final height desired = 30 mm. Coefficient of friction at the die-work interface is 0.15. The work material has a flow curve defined by strength coefficient of 475 MPa and a strain hardening exponent of 0.25. Determine the force in the operation (a) to begin plastic yielding of the workpiece, and (b) at the final h = 30 mm. ay TD = qo mm hoe SS ™Mm hy= 30™™ ke Mas MP. f= Os N=0-2S re Loe VeTDL = Tf) SS | areous me fe ue) © @ g2 0-002 A Oe Ye xs" = har (oor) = 100s Mig he S5S-S5 (9002) = Sh Im . A=V = 2Ub6y.% = . ShH-7 Kye I+ CHD = Force : Fe mints ve A a 07st) (100- us) (3856-16) = Mare. IN (0 ¢. © CB) obot Zest-ik mm 4 = Ks" 2 Aas Gbob)” a Alt) - : y AW = Usihit . aesss mm =>D tnd “Gy #8 Kye tt QAMD ols oF LD BI = regs = Yevce: Fe Chieis) (ait) (s0ss-5) = 557 Lgataen?(ME EN 4060; Fall 2013, Mid-term Exam 1 4, Pure aluminum is being poured into a sand mold. The metal level in the pouring basin is 250 mm above the metal level in the mold, and the downsprue and runner are circular with a 10 mm diameter. What is the velocity and rate of the flow of the metal into the mold at the base of the downsprue? Is the flow turbulent or laminar? The density of pure ‘aluminum is 2700 kg/m? and the viscosity of the molten aluminum is 0.0015 N-s/m?. The Reynolds number can be calculated using Re= 222 n Answer! 2 250mm P= 2400 3/n3 D= lo mm ys Ooi N-S/mn> Vela V= Yagn whe ge 7815 nm)» Ve 2 (4815) (25°) = QUIS mm = a9 “hs Rebs G2 VA — whate Az BD - aT Co. aesu ne eye AM 4 gowME EN 4060; Fall 2013 Mid-term Exar + 6. Aplate that is 250 mm wide and 25 mm thick is to be reduced in a single pass in a rolling mill toa thickness of 18 mm. The roll has a radius = 500 mm, and its speed = 25 m/min. The work material has an ultimate tensile strength of 530 MPa, strength coefficient of 825 MPa and a strain hardening exponent of 0.21. If the coefficient of friction between the rolls and the plate is found to be 0.15, is this operation feasible in a single pass? If Unfeasible, what coefficient of friction will make this operation feasible? How can we increase this coefficient of friction? Also, once you determine if the coefficient of friction is. feasible, determine (a) rol force and (b) power required to accomplish this operation. Asner: W250 ™m foe 2smm tg 1mm R>s 00mm kK=325MPa nN=0-2) Peer, 2bSM d= tot, = B2578 =+mm Snag = MOR = Uae mm (SF) Since dna > do the operalin besible un Srna ange Poss - Le Roe eS Soy = STILMM A) \ > ks" gs (03295) | ¥ fn ee) 2 212-46 MPa. fe: Fo Ywe = Gi2ty Care) (stu) = 34 44] (2 2285.5 F984 YY 2 3) ar (oS) ie 6 326 rer ed Pe oT NE L = 27 (01326) Cty, we) 69-10 015% 21ST ON b we 18:0? KW) a, Prcten Cooffitind & apenas om lubvehon Work rmalenal awd — Working Jenpuodtans -ME EN 4060; Fall 2013, Mid-term Exam 1 6. A sheetmetal drawing operation is performed on 3. 0 mm stock. The part is a cylindrical cup with height = 50 mm and inside diameter = 70 mm. Assume the comer radius on the punch is zero. (a) Find the required starting blank size Ds. (b) Is the drawing operation feasible? Briefly discuss the problems that may occur when operating this process - given the information given above. Solution: Use surface area computation, assuming thickness t remains constant. Cup area = wall area + base area = 1Dph + TDp:Do/4 = m(70)(50) + 0.2511(70)? = 14,846 mm”. Blank area = 11Dp"Dp/4 = 0.7855D»" Do Setting blank area = cup are: 0.7855De- Di= 14,846 Dy? = 14,846/0.7855 = 18,900 Do= 137.48 mm Test for feasibility: DR = Dv/Dp= 137.48/70 = 1.964; /D»= 3/137.48 = 0.0218 = 2.18%. These criteria values indicate that the operation is feasible; however, with a punch radius Ro= 0, this shape would be difficult to draw because the drawing punch would act on the metal like a blanking punch.ME EN 4060; Fall 2013 Mid-term Exam 1 SHORT ANSWER QUESTIONS (5 POINTS EACH) 4. Why is turbulence during pouring of molten metal in sand casting undesirable? Elaborate on all possible reasons. ‘Answer. Turbulence causes the following problems: (1) it accelerates formation of oxides in the solidified metal, and (2) it causes mold erosion or gradual wearing away of the mold due to impact of molten metal. 2. Name, sketch, and briefly describe two casting defects common to all casting processes. ‘Answer. (a) Misruns, which are castings that solidify before completely filing the mold cavity. Typical causes include (1) fluidity of the molten metal is insufficient, (2) pouring temperature is too low, (3) pouring is done too slowly, and/or (4) cross-section of the mold cavity is too thin. (b) Cold Shuts, which occur when two portions of the metal flow together but there is a lack of fusion between them due to premature freezing. Its causes are similar to those of a misrun. (© Cold shots, which result from splattering during pouring, causing the formation of solid globules of metal that become entrapped in the casting. Pouring procedures and gating system designs that avoid splattering can prevent this defect. (@) Shrinkage cavity is a depression in the surface or an intemal void in the casting, caused by solidification shrinkage that restricts the amount of molten metal available in the last region to freeze. It offen occurs near the top of the casting, in which case it is referred to as a “pipe.” The problem can often be solved by proper riser design. (@) Microporosity consists of a network of small voids distributed throughout the casting caused by localized solidification shrinkage of the final molten metal in the dendritic structure. The defect is usually associated with alloys, because of the protracted manner in which freezing occurs in these metals. (f) Hot tearing, also called hot cracking, occurs when the casting is restrained from contraction by an unyielding mold during the final stages of solidification or early stages of cooling after solidification. The defect is manifested as a separation of the metal (hence, the terms tearing and cracking) at a point of high tensile stress caused by the metal's inability to shrink naturally. guRe 1122 some ‘commun detects ‘eating: 3} mun, (ena sex cot ‘ha srinkage cat, {eheveropocosty, ond ‘ot tet,ME EN 4060; Fall 2013 Mid-term Exam 1 3. Explain why internal cracking (such as centerburst or chevron cracking) occurs in ‘extrusion processes. Answer. Centerburst defect is an internal crack that develops as a result of tensile stresses along the centerline of the workpart during extrusion. Although tensile stresses may seem unlikely in a compression process such as extrusion, they tend to occur under conditions that cause large deformation in the regions of the work away from the central ‘axis. The significant material movement in these outer regions stretches the material ‘along the center of the work. If stresses are great enough, bursting ocours. Conditions that promote centerburst are high die angles, low extrusion ratios, and impurities in the work metal that serve as starting points for crack defects. The difficult aspect of centerburst is its detection. It is an internal defect that is usually not noticeable by visual observation. Other names sometimes used for this defect include arrowhead fracture, center cracking, and chevron cracking. 4, Why is friction generally undesirable in metal forming operations? Answer. Reasons why friction is undesirable in metal forming include the following: (1) it inhibits metal flow during deformation, causing residual stresses and product defects; (2) it increases forces and power required; and (3) it increases wearing of the tools.ME.EN 4060; Fall 2013 Mig-torm Exam 4 INFORMATION SHEET TO BE PROVIDED WITH THE EXAM (CLosep Book aNp CLosep NoTEs) CASTING Heat Energy H= pV [C,(Tu-To) +He+ Gi (Tp-Tm)) METAL FORMING & BULK DEFORMATION You are expected to know fundamental expressions for flow stress, strain, average flow stress, etc. ROLLING dag = HER Indirect extrusion: p = Y, & For complex shapes Die shape factor: K.=0.98+ 0.02(& C. Indirect extrusion: p=K ¥; & F =p Ao for Direct extrusion F=p Anmfor Indirect extrusion Direct extrusion: p= Kx Y, (+ % FORGING 04D K,=1 Shape factor: 8! "!* EXTRUSION Extrusion ratio: 7, = 4 4 Pressure: p= ¥, Inrx Johnson's equation &x=a+b Inn Values of a and b will be provided ‘WIRE DRAWING (not on test) enn Ay eee Ae 7, we Ay 71+ \pn a ( +ilpmte D = 0,88+0.12— 6 +0125 +D,ME EN 40 pring 2012 Midterm Exam 1 (October 4, 2012) ‘SHEETMETAL WORKING Cutting c= Act (Aewill be provided) F=StL=(0.7 TS)th Bending Bend allowance A, =20(R+K,,t) 360 Maximum bending force Ky TSwt D D= die opening: Keywill be provided Drawing F Technical feasibility tests Drawing ratio (<2) pr 2 D Reduction (< 50%) t/Ds> 1% Feaogits 2-00] where F = drawing force, TS = tensile stre F, =001sra[D} -(0,+221428,))] 10