ME 310

WASHINGTON STATE UNIVERSITY

FALL SEMESTER, 2012 Campus: Pullman MANUFACTURING PROCESSES Exam 1 (Time allowed: FIFTY minutes)
NOTE:

Answer ALL questions. Circle only one answer. The marks for each question are as shown. Multiple answers carry zero points. If you make a mistake, mark a cross through your wrong choice and circle your next alternative.

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Students Name:

ID No:

SECTION A TRUEFALSE QUESTIONS

1. Circle the preferred choice. T T T T T T F F F F F F Yield stress is where plastic ow begins. During elastic deformation the volume of the specimen is constant. The plastic deformation is caused by the massive motion of dislocations. An alloy is a metal composed of two or more elements. Hardness tests involve the indentation of the surface of a test specimen. The theoretical strength of a material is smaller than the experimental. (6 marks)

SECTION B MULTIPLE CHOICE QUESTIONS

2. Which of the following is not point defect in a crystal lattice structure (a) Dislocation. (b) Interstitial. (c) Vacancy. (d) Shottky defect. 3. Dyring plastic deformation, plastic work is (a) Stored. (b) Converted to heat. (c) Converted to kinetic energy. (d) Non existant.

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4. In strainrate sensitive materials (a) As the strain rate increases, the yield stress remains constant. (b) As the strain rate increases, the yield stress increases. (c) As the strain rate increases, the yield stress decreases. (d) As the strain rate increases, the ultimate tensile stress decreases. 5. An FCC unit cell has (a) One atom at the center of the cell. (b) Atoms centered on all faces of its cell. (c) No atoms on its faces. (d) A triangular shape. 6. In steels, as the carbon content increases (a) The ductility increases. (b) The steel becomes more brittle. (c) The steel softens. (d) The mechanical properties of the steels remain unchanged. (10 marks) 7. What is the dierence between true and engineering strain? (2 marks) Answer: Engineering strain: e =

0 0

, True strain: = ln

8. 2.7 Show schematically the dierence between open-die and impresion-die forging. (2 marks)

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SECTION C PROBLEMS
9. A cylindrical bar specimen is tested in tension. The initial diameter of the bar is D0 = 12 mm, and its initial length is 0 = 50 mm. The following results were obtained: Yield load Pyield = 35 kN, nal length at fracture f rac = 69 mm, maximum load Pmax = 45 kN and occured at a length max = 60 mm. The modulus of elasticity E = 1011 Pa. Find: (a) The engineering yield stress, (b) The nal true stain, (c) The bar diameter at the maximum load (neglect elasticity), (d) The true Ultimate Tensile Stress, (e) The true elastic strain at yield. (15 marks)

Answer: (a) The yield stress is Y =

35 kN (0.12/2)2

= 309 MPa

(3 marks)

(b) The = ln 69 50 = 0.322

(3 marks)

2 2 (c) Neglecting elasticity, the diameter at the maximum load is: V0 = Vf r0 L 0 = rf Lf

or rf = r0

L0 Lf

2rf = 2r0

L0 Lf

Df = D0

L0 Lf

Df = 12

50 60

= 10.95 mm

(3 marks)

(d)The true ultimate tensile stress is U =

Pmax A

45 kN 50

60 10

= 477 MPa

(3 marks)

(e) The true elastic strain at yield is el =

309106 Pa 1011 Pa

= 0.00309

(3 marks)

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10. A strip of material obeys the power law relation = 1300.15 MPa. It has a thickness h0 = 25 mm and a width W = 500 mm. Its thickness is to be reduced to hf = 13 mm by a two-high rolling process with N = 30 rpm. If the radius of the rolls is R = 350 mm, determine the following: (a) The minimum coecient of friction, (b) The total power of the rolls, (c) The plastic work per unit volume. (15 marks)

Answer: (a) The minimum coecient of friction is: = h0 hf R =

2513 350

= 0.185

(4 marks)

(b) The total power of the rolls is P = 2T , = T =

FL 2

2 N 60

2 (30) 60

= rad/s.

LW , thus T = and F = Y
L2 2 WY

L2 2 WY .

Also P = 2( ) L= = ln = Y

. = L2 W Y 350(25 13) = 64 mm. MPa = 106.1 MPa. (7 marks)

R ( h 0 hf ) =
25 13

= 0.654. =

1300.15 1.15

Finally, P = (64 10

130(0.654)0 .15 1.15 3

)(0.5)(106.1 106 ) = 682 kW.

(c) The plastic work per unit volume is U =

d =

1300.15 d =

1301.15 1.15

= 69.37MJ/m3

(4 marks)

ATTACHMENT

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Equation Sheet
h0 hf = 2 R LW F =Y P = Fv = T = 2 N/60 T = F L/2 Draft Roll Force (per roll) Roll Power (per roll) Angular Velocity Torque (per roll) L= R ( h0 hf ) U=
0

Contact Length Deformation Energy True Strain Mean Yield Stress Forging Force

= ln ( f / 0 ) = K n /(n + 1) Y Ff = Y f 1 +
2rf 3h f

Af