Manufacturing Processes (INME 4055) 1 Exam

Manufacturing
Processes (INME 4055)

1st Exam
Student Number: ___________________________ Name:________________________________
Section: _____7:30AM_____9:00AM__________ Date : October rd, 2013
Notes: This is an open book examination. Items needed are calculators, pencils, pens and rulers.
This exam consists of two parts. Please write in a clear and concise manner.
Total Points = 100 Time Allowed : 120 minutes
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1. (20points) Casting: In casting experiments performed using a certain alloy and type of
sand mold, it took 155 sec for a cube-‐shaped casting to solidify. The cube was 50 mm on a
side. (a) Determine the value of the mold constant in Chvorinov's rule. If the same alloy and
mold type were used, find the total solidification time for a cylindrical casting in which the
diameter = 30 mm and length = 50 mm. Assume n=2
Cube
Volume

Area

V/A

Cm

Cylinder
Volume

Area

V/A

TST

2. (25 points) Forging: A cold heading operation is performed to produce the head on a
steel nail. The strength coefficient for this steel is 600 MPa, and the strain hardening
exponent is 0.22. The coefficient of friction at the die-‐work interface is 0.14. The wire stock
out of which the nail is made is 5.00 mm in diameter. The head is to have a diameter of 9.5
mm and a thickness of 1.6 mm. The final length of the nail is 120mm.
(a) What length of stock must project out of the die in order to provide sufficient volume of
material for this upsetting operation?
(b) Compute the maximum force that the punch must apply to form the head in this open-‐
die operation.

Volume of the nail
head

Area of the nail prior
to upsetting

Height of the stock
that must project out
to provide enough
volume material for
the operation
True strain

Flow Stress

Area after upsetting
operation

Shape Factor

Force

3. (25 points) Rolling: A 300 mm-‐wide 6061-‐O aluminum alloy strip is rolled in thickness
from 20 to 15 mm. The rolls are 1 m in diameter and operate at 60 rpm. The uniaxial flow
stress for the aluminum alloy can be expressed as σ = 205ε0.20 (MPa) and the coefficient of
friction between the strip and the rollers is 0.12. Steels rolls with C=2.3x10-‐11Pa-‐1. Only
consider one calculation for roll flattening. Determine the following:

Required Draft and the
percentage reduction

What is the maximum
possible draft for this
process? Is the
required draft lower
that the Maximum
possible?
True Strain

Average Flow Stress
Required

Contact Length and
average height

Factor
(1+(µ*L)/(2*h-‐
average)

Required Rolling Force

New Radius due to
flattening

New Contact Length

New Factor
(1+(µ*L)/(2*h-‐
average)

Required Force

Required Rolling
Torque

Required Power

4. (30points) Wire Drawing: In a wire drawing operation, a spool of wire with a diameter of
5.0 mm is to be drawn in three passes each with 25% of reduction. All the dies are made
with an entrance angle of the die is 9° degrees and the coefficient of friction at the work-‐die
interface is 0.08.
The work metal has a strength coefficient of 450 MPa and a strain hardening exponent of
0.30. The drawing is performed at room temperature.
Determine the exit speed at each of the dies if the power of the motor used for the drawing
at each pass should not exceed 2.5kW.

Diameter and
true strain
after first
pass.

Diameter and
true strain
after second
pass

Diameter and
true strain
after third
pass

Average Flow
Stress after
first pass

Average Flow
Stress after
second pass

Average Flow
Stress after
the third pass

(1 + µ/α )

φ for the first
die

φ for the
second die

φ for the
third die

Drawing
stress (first
die)

Drawing
stress
(second die)

Drawing
stress (third
die)

Required
force (first
die)

Required
Force
(second die)

Required
Force (third
die)

Entry and
Exit velocity
First Pass

Entry and
exit velocity
Second pass

Entry and
exit velocity
third pass

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