Review Questions
Review Questions
Review Questions
1. In the equation K n , which represents the stress-strain curve for a material, what is the
significance of the exponent n?
2. A Rockwell A test was conducted on a material and a penetration depth of 0.15 mm was
recorded. What is the hardness of the material? What material would typically have such a
hardness value? If a Brinell hardness test were to be conducted on this material, give an estimate
of the indentation diameter if the load used was 1500 kg.
3. A metal has a strength coefficient K = 700 MPa and n = 0.2. Assuming that a tensile-test
specimen made from this metal begins to neck at a true strain of 0.2, show that the ultimate
tensile strength is 415 Mpa
4. If we assume that all the work done in plastic deformation is converted into heat, the
temperature rise in a workpiece is (1) directly proportional to the work done per unit volume
and (2) inversely proportional to the product of the specific heat and the density of the
workpiece. Using Fig. 1.1, and letting the areas under the curves be the unit work done,
calculate the temperature rise for (a) 8650 steel, (b) 304 stainless steel, and (c) 1100-H14
aluminum.
Figure 1.1: True stress-true strain curves in tension at room temperature for various metals.
The curves start at a finite level of stress: The elastic regions have too steep a slope to be
shown in this figure; thus, each curve starts at the yield stress, Y, of the material.
5. Explain why casting is an important manufacturing process, and what are the differences
between the solidification of pure metals and metal alloys?
6. The constant C in Chvorinov’s rule is given as 3s/mm2 and is used to produce a cylindrical
casting with a diameter of 50 mm and height of 125 mm. Estimate the time for the casting to
fully solidify. The mold can be broken safely when the solidified shell is at least 20 mm.
Assuming that the cylinder cools evenly, how much time must transpire after pouring the
molten metal before the mold can be broken?
7. A sprue is 300 mm long and has a diameter of 125 mm at the top. The molten metal level in
the pouring basing (which is much larger than the top of the sprue) is taken to be 75 mm from
the top of the sprue for design purposes. If a flow rate of 650 mm3/s is to be achieved, what
should be the diameter at the bottom of the sprue? Will the sprue aspirate? Explain.
8. The constant C in Chvorinov’s rule is given as 3s/mm2 and is used to produce a cylindrical
casting with a diameter of 50 mm and height of 125 mm. Estimate the time for the casting to
fully solidify. The mold can be broken safely when the solidified shell is at least 20 mm.
Assuming that the cylinder cools evenly, how much time must transpire after pouring the
molten metal before the mold can be broken?
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9. Pure aluminum is poured into a sand mold. The metal level in the pouring basin is 250 mm
above the metal level in the mold, and the runner is circular with a 10-mm diameter. What are
the velocity and rate of the flow of the metal into the mold? Is the flow turbulent or laminar?
10. Estimate the clamping force for a die-casting machine in which the casting is rectangular with
projected dimensions of 100mm X 175 mm. Would your answer depend on whether it is a hot-
chamber or cold-chamber process? Explain
11. In sand casting, it is important that the cope-mold half be weighted down with sufficient force
to keep it from floating when the molten metal is poured in. For the casting shown in Fig. 1.2,
calculate the minimum amount of weight necessary to keep the cope from floating up as the
molten metal is poured in. (Hint: The buoyancy force exerted by the molten metal on the cope
is dependent on the effective height of the metal head above the cope.)
Figure 1.2
12. In an orthogonal cutting operation, to = 0.13 mm, and cut V = 120 m/min, α = 10° and the width
=6mm. It is observed that tc = 0.23 width mm, FC = 500 N, and Ft = 200 N. Calculate the
percentage of the total energy that goes into overcoming’ friction at the tool-chip interface.
13. Refer to Fig. below and assume that D = 150 mm, w = 60 mm, l = 500 mm, d = 3 mm, v = 0.6
m/min, and N = 100 rpm. The cutter has 10 inserts, and the work-piece material is a high-
strength aluminum alloy. Calculate the material-removal rate, cutting time, and feed per tooth,
and estimate the power required.
(a) Face-milling operation, showing action of an insert; (b) climb milling; (c) conventional milling;
(d) dimensions in face milling. The width of cut, w, is not necessarily the same as the cutter radius.
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