1.

(a) Explain why a casting may have a lightly different shape than the pattern used to
make the mold.
(b) Describe the advantages and limitations of hot-chamber ad cold-chamber die
casting processes, respectively.

2. The thickness of the wall of a cup is assumed to be the same as that of the blank
(see figure). Thus t1 = t2 = t.
(a) If the bottom radius r of the cup is ignored, and the outside surface of the cup is
assumed to have the same area as the blank, show that
D=(d2 +4dh)1/2
(b) In the case where the radius r is large, t is small in comparison and may be
neglected. Thus the area of the outside corner at the bottom of the cup is a part of
a toroid of minor radius and may be approximated as At =π2 r (d-0.7r)/2. If the
outside area of the cup is assumed to have the same area as the blank, show that
D=[(d-2r)2+4d(h-r)+2πr (d-0.7r)]1/2

3. Propose the most appropriate material and manufacturing process, and discuss the
reasons of your selection for the following products:
(a) paper clips (annual production 2 million pieces)
(b) machine screws (annual production 500,000 pieces)

4. Springback is a common problem in bending process. Explain how and why the
extent of springback changes with R/T, where R is the bend radius and T is the
material thickness.

5. Give at least three non-conventional machining methods. Classify these processes

according to the appearance of the applied energy. Select one non-conventional
machining process which you are most familiar with, explain the principle and
 variables of the process.

6. Draw Mohr’s circles (three dimensional state of stress) for

a. Uniaxial tension
b. Uniaxial compression
c. Biaxial tension
d. Triaxial unequal tension
e. Uniaxial tension plus biaxial compression
Illustrate all normal stresses and shear stresses on the physical plane as well as on
the Mohr circle.

7. Explain the concept of process optimization. Using milling process as an example,

listing the process parameters should be considered, propose the objective function
and the constraints for optimization.

8. A 40-mm high cylindrical specimen with 40 mm diameter is being compressed to

10 mm high between flat plates at a speed of 0.1 m/sec. Determine:
(1) the engineering strain rate
(2) the true strain rate
(3) the engineering strain
(4) the true strain ; and
(5) estimate the final diameter

9. The figure below shows a schematic illustration of four different types of metal
flow in direct hot extrusion
a. Outline the conditions under which these different flow patterns are obtained?
b. What are the two main factors which influence these kinds of metal flow?

10. In drawing, friction increases the drawing force, because work has to be supplied
to overcome that friction. Using the slab method of analysis and on the attached
figures, derive the drawing stress σ in terms of yield stress, Do, Df, friction
coefficient μ, die angle α
11. Shown in this figure is the direct extrusion under ideal deformation. Determine
(1) the extrusion ratio R ;
(2) the absolute value of the true strain ;
(3) the energy dissipated in plastic deformation per unit value for a perfectly
plastic material with a yield stress Y ;
(4) the work done on the billet ; and
(5) the extrusion pressure at the ram

12.
(a). Describe the effect of clearance between punch and die on the shearing process.
(b). What is fine blanking in the shearing operation?

13. A solid cylindrical workpiece made of 304 stainless steel is 150 mm in diameter
and 100 mm high. It is forged by open-die forging at room temperature with flat
dies to a 50-percent reduction in height. We can estimate the force F required from
 the following formula:
F=Y1πr2(1+2ur/3b)
Where Y1 is the flow stress of the material, u=0.2 is the coefficient of the friction,
and r and b are the radius and the height of the workpiece, respectively.
(a) Estimate the radius from volume constancy.
(b) Determine the absolute value of the true strain.
(c) Calculate the forging force F.

14. When a short cylinder is compressed plastically between two flat plates, the
finished part has a slightly conical rather than flat ends. Describe the cause and
magnitude of this effect and sketch the cross section of the finished part.

15. Explain what changes could occur to all the related process variables as the scale
of the traditional machining process is reduced by an order of one, two or three
(10 to 1000 times).

16.
(a) The actual falling mass of a steam hammer is 550 kg, the cylinder is 250 mm in
diameter, and the stroke is 685 mm. The mean average steam pressure is 550 kPa.
What is the energy of the hammer blow? What is the average work force exerted
by the hammer if it travels 3.2 mm after striking the workpiece?
(b) A free-falling drop hammer weight 680 kg and drops 0.9 m. With what velocity
does it strike? What is the energy of the blow? What average force is exerted if
ram travels 1.6 mm after striking the workpiece? What diameter of cylinder for
stem at an average pressure of 700 kPa is required to quadruple the capacity of
this hammer?

17. Define machinability of a material in metal cutting operations. Explain how to

construct the machinability data base for a material.

18. Make a list of the independent variables that influence the cutting force in turning
of a steel rod on a lathe and explain how they influence the cutting force.

19. Calculate the energy required to punch a 2 inch diameter hole in a 1/2 inch thick
plate of hot rolled structural steel.

20.
(a) Derive the tool’s velocity of a mechanical shaper (see attached figure) in term of
crank’s angular velocity and links’ lengths.
(b) Explain why this shaper is a quick-return mechanism.

21.
(c) The actual falling mass of a steam hammer is 550 kg, the cylinder is 250 mm in
diameter, and the stroke is 685 mm. The mean average steam pressure is 550 kPa.
What is the energy of the hammer blow? What is the average work force exerted
by the hammer if it travels 3.2 mm after striking the workpiece?
(d) A free-falling drop hammer weight 680 kg and drops 0.9 m. With what velocity
does it strike? What is the energy of the blow? What average force is exerted if
ram travels 1.6 mm after striking the workpiece? What diameter of cylinder for
stem at an average pressure of 700 kPa is required to quadruple the capacity of
this hammer?

22.As shown in the attached figure, a circular bar 100 mm diameter and
600 mm long must be turned down to 80 mm diameter of its length.
The force components measured by dynamometer are Fx = 292 kg ,

Fy = 112 kg , and Fz = 1813 kg respectively along x, y, and z axes. The

rotational speed of spindle is 80 rpm. Determine (1) the power

consumption at tool tip; and (2) the reaction forces at the head-stock
and tail-stock.

23.Define the value of normal anisotropy R of a rolled sheet metal. Explain how
normal anisotropy may influence the sheet metal forming processes.

24.Explain the potential benefits of residual stress to a part or product. List some
methods by which beneficial residual stress can be obtained.

25.Make a list of the independent variables that affect the extrusion pressure. Explain
why?

26.Explain the advantage and limitations of cold, warm and hot working of metals,
 respectively.

27.Assume a 0.38 mm feed and 1.57 mm depth of cut in machining a diameter 50 mm

bar of SAE 1020 steel (see figure),
(a) Determine the rpm of spindle if the cutting speed is 1.5m/s.
(b) What is the metal removal rate in cubic minimeter per minute as a function of the
average cutting speed?
(c) Determine the chip width and the chip thickness
(d) What is the approximate horsepower at the spindle?
(e) If the spindle efficient = 92%, what motor horsepower is expected?

28.Two pieces being cast have the same volume but different shapes. One is a sphere
and the other a cube. Which piece will solidify faster. Calculate and explain.

29.Suggest possible choice of materials for the following components. Indicate the
economic and property requirements to justify your selection and describe the
manufacturing method.
(a) coin
(b) gas turbine blade

30.How do you categorize the differences in terms of important material properties

involved between the traditional machining processes and the non-traditional
machining processes?

31.Estimate the limiting drawing ratio (LDR) that you would expect from a sheet
metal, which, when stretched by 23% in length decreases in thickness by 10%.
The figure below shows the effect of average normal anisotropy on LDR for a
variety of sheet metals.
32.Draw a sketch of hot rolling of bars showing the process geometry and kinematics
of the process. Give the significant process variables of this process.

33.Estimate the clamping force for a die casting machine in which the casting is
rectangular with projected dimensions of 100 mm×200 mm. Would your answer
depend on whether or not it is a hot-chamber or cold-chamber process?

34.A three-fluted drill (point angle 2θ ) is used to drill a hole having

diameter d mm and depth A mm . The drilling conditions are:
rotational speed n rpm , the feed V f mm/sec . Determine:

(1) drilling time tm ,

(2) chip thickness ac ,

(3) chip width A c ,

(4) chip area Ac

(5) metal-removal rate in terms of volume.

35.A 1/2 inch thick plate of alpha brass is uniformly cold worked to final thickness of
1/4 inch. The strain hardening behavior of this metal is given by σ = 100000ε0.5
psi. From the cold worked plate, a standard tensile specimen is produced whose
 gage section is 0.75 inches wide by 0.25 inches thick (i.e. the plate thickness after
cold working ). It is then subjected to a tensile test. Calculate the maximum load
in pounds force you would expect to observe.

36.
(a) What is the quick-return mechanism of a shaper?
(b) The stroke of a shaper is 550 mm. Its quick-return mechanism is shown by the
figure. The average cutting speed suggested is 20 m/min. Determine the frequency
of the shaper.

37.Suggest suitable materials and manufacturing process for the production of

connecting rod for a motorcycle engine. Explain how the choice of material and
process for such a component will be influenced by economic factor.

38.A tensile specimen of annealed brass has gage dimensions of l0=50 mm and
A0=129mm2. It supports a maximum load of 53.4 kN and at that load the original
area has been uniformly reduced by 40%. If a second annealed specimen of
identical starting dimensions were loaded in tension until the induced true strain
was 1/2 the magnitude of the strain hardening exponent, n, what load in kN would
be required to reach this condition?

39.Can milling processes (see the attached figure) produce a perfect flat surface?
Prove this mathematically.
40.List three types of mold and die materials in casting process. Under each type of
material, list the casting processes that are used, and explain why these processes
are suitable for that particular mold or die material.

41.A twelve-ounce beverage container company manufactures beverage containers in

the popular 12-ft oz (0.36-liter) size. With production exceeding 7.5 million cans
daily, material efficiency is absolutely necessary. The can is composed of three
pieces: the body, top, and the pull ring. The rivet connecting the pull ring to the top
is formed from the top during the mechanical joining process. The container body
is blanked from 3004-H19 aluminum coils, and the layout is shown in figure 1. An
intermediate cup is formed without any change in thickness. The cup is then drawn
in a horizontal drawing machine, and metal is ‘ironed’ to a sidewall thickness of
0.140 mm. The bottom thick remains unchanged. The can is trimmed to a final
height of 133.4 mm to give an even edge for rolling to the lid.
(a) Determine the “metal efficiency,” that is, the final metal volume in the can as
related to the original metal volume in the coil.
(b) What is the metal efficiency of the can to the 144.78 mm blank? [Disregard the
1.3-mm radius.]
(c) If the 3004-H19 aluminum coil stock costs US$ 1.293/kg and the
density=2715kg/m3, find the material cost of each can.
(d) Assume that waste is recovered and recycled at US$0.606/kg. What is the material
cost lost in waste per can?
(e) For a production of 1 million cans daily, what are the material costs lost in waste?
42.In closed die forging the load increases rapidly at the end of the forming cycle.
Why does this occur?

43.Explain why the maximum reduction per pass in wire drawing should increase
with increasing strain-hardening exponent n.

44.Describe as much as you can about the various physical and chemical properties of
a material. Explain how they affect the manufacturing processes. As examples, use
any one type of material and any two types of processes to explain.

45.A cylindrical specimen made of annealed 4135 steel is 150 mm in diameter and
100 mm in height. It is upset by open-die forging with flat dies to a height of
50mm at room temperature. Assuming that flow stress σ is σ = κεn, K=1015 MPa,
n=0.17 for this material and that the coulomb’s friction coefficient μ=0.15, derive
the average-pressure formula and calculate the force required at the end of the
stroke.

46.Explain the reasons why we should be interested in residual stress developed in

workpiece made by the forming processes. Give one example and explain what
 kind of stress and how it is developed during the process.

47.A rigid-perfect plastic material has a yield strength of Y. For an orthogonal cutting
process with shear angle φ and negligible friction, what is the specific cutting
force (N/mm2) of this material? What is the expected temperature rise of this
material? Make all assumptions as needed.

48. Define “formability” in sheet metal forming. State the factors (variables) which
affect the formability. What is the Forming Limit Diagram (FLD)? How to apply
FLD, combined with forming analysis, on die design and process design of sheet
metal forming?

49. Describe as much as you can about the various mechanical properties of a material.
Explain how they affect the manufacturing processes. As example, use any one type
of material and any two types of processes to explain.

50. The general formula for the complete solidification time is:
Solidification time = C(volume/surface area)2
Now three pieces of castings have the some volume but different shapes. One is a
sphere, one a cube, and the other a cylinder with height that is equal to the diameter.
Which piece will solidify the fastest and which one the slowest?

51. Explain with examples why high speed machining promises improved efficiency
and quality for the machining process. What aspects of machine tool technology are
involved and are critical in order to achieve the full benefit of high speed
machining?

52. The figure shows the idealized model of continuous-chip formation of a shaping
process. Data from a test also are shown in this figure. Determine the shear angle in
terms of cutting ratio and rake angle.
53. Consider a single phase metal such as commercially pure copper that has been
cold rolled to a condition of 30% cold work. If specimens from the cold piece are
heated to different evaluated temperatures, each for the same time of 45 minutes,
different microstructure will result. Sketch a typical hardness versus temperature
curve you would expect and discuss in reasonable detail why such a curve results.
You may wish to include sketches to show the different microstructures connected
with various regions of your plot. Please indicate the relative hardness level of the
initially cold worked material that has not been heated above room temperature.

54. Explain why a closed die hot forging usually needs several passes. What is the
function of the gutter in a forging die? What is the design rule for the gutter
dimension?

55. In drilling operation using the twist drill, the rotational frequency of a drill is 5 s-1,
the feed is 0.25 mm , the major cutting edge angle is 60°, and the drill diameter 12
 mm. Assuming that the specific cutting energy for the work material is 2×109 j/m3,
(20%) calculate
(a) The maximum metal-removal rate, in μm3/s
(b) The undeformed chip thickness, in millimeters
(c) The undeformed chip length, in millimeters
(d) The power required
(e) The drill torque in netton-metres

56. Shown in this figure is a cutoff process.

(1) Give the definition of orthogonal cutting.
(2) Give the relative velocity of the cutting tool with respect to the work-piece.
(3) Give the direction of the major cutting edge of the cutoff operation.
(4) Prove that when γ=0 the cutoff process is orthogonal cutting process.

57. An annealed copper strip, 9 in.(228mm) wide and 1.00 in. (25mm) thick, is rolled
to a thickness of 0.8 in. (20mm). The roll radius is 12 in. (300mm) and rotates at
100 rpm. Note that the roll force is determined from
F = LwYavg ,
Where L is the roll-strip contact length, w is the width of the strip, and Yavg is the
average true stress of the strip in the roll gap.
(a) Estimate the approximate value of L from simple geometry of the given figure.
(b) Determine the absolute value of the true strain that the strip undergoes in this
operation.
(c) Note that annealed copper has a true stress of about 12,000 psi in the unstrained
condition. Find the average stress Yavg = (true stress+12,000)/2.=?
 (d) Calculate the roll force in this operation.
(e) Find the power in this operation.

58.In metal forming analysis, propose at least 2 friction models for workpiece-tooling
interface. Explain how to determine the friction coefficients.

59. A 12 mm diameter high-speed standard drill is machining steel that possesses a

unit power of 3.0 kw/cm3/sec. The cutting velocity is set at 12 m/min and the feed
rate is 40 mm/mim. Neglecting the effects of the chisel edge, determine the power
required for this operation as well as the torque acting on the drill.

60. Give a relationship showing the important process variables that affect the tool life
in metal cutting.

61. Assuming a steel has four different types of stress-strain relationship as shown
below.
 a. Explain and list in order the amount of heat generated in one stroke of forging
process.
b. For sheet steel, explain and list in order the extent of springback in a 90 degree
bending process.

62. It is desired to submerge arc weld 1/2” thick plates of oil quenched 1080 steel and
annealed 4340 (eutectoid of 0.45%C) with 0.1%C wire of 1/8” dia. If 30 volts and
800 amperes are used, what welding velocity, if welded on both sides will result in
the weld joint having an axial tensile load capacity equal to that of the plate?
Assuming the cooling rate at the weld be 30oF/sec at 1300oF.

63. Prove that shaping an inclined surface is an orthogonal cutting process (see the
attached figure).

64. Explain how a cast structure is converted into a wrought structure by hot rolling.

65. List major cutting parameters and cutting condition and describe how they affect
 the machining economics of a metal removal process for mass-produced part.

66. Explain the differences in the specific energies (total energy per unit volume of
material removed) for forming, cutting and grinding processes.

67. An important property of metals is the fracture toughness.

Explain why this is important in the most basic sense.

68. Compare and explain the features, advantages and limitations for open-die forging,
closed die forging, and cold heading.

69. Burs or flashes are commonly found in parts made from machining, casting and
forging. Explain how they are formed and how they can be avoided.

70. Make a sketch of typical engineering stress-strain curve for a mild steel. List and
show all the related mechanical properties on the sketch.

71. Refer to the sketch of bar drawing below. A 24” long bar having an initial
diameter d1 is machined for a 6” length to diameter d2=0.505” to enable the
gripper to exert the force F to draw the remaining 18” through the die. Assume
perfect lubrication and original material to be 3004-0 aluminum having σy =14.9
ksi; Su=22 ksi; εu=0.25 and εf =1.1. What is the maximum value of d1 that be
drawn?

72. List five major groups of materials used for cutting tools. Rate these materials in
various categories of cutting performance evaluation.

73. A flat strip of steel, 0.25” by 2” by 24”, originally straight and flat is ground on
one of the 2×24 inch faces. The ground part bows up such that the ground surface
is the inner radius or surface of the curve bar. Give two reasons for this bowing or
distortion.
74. Make a summary of the types of defects found in deep drawing process; include
brief comments on the reasons for these defects.

75. Show how a casting riser might be effective though smaller than the production
cast part.

76. Using thin strip forging as an example, explain “friction hill”. If the central
portion of the die-workpiece interface is sticking friction and the outer portion is
slipping friction, construct the stress equilibrium equations and plot the pressure
distribution on the die surface.

77. An annealed metal, whose strain-hardening behavior is given by σ = 750ε0.25 MPa

is subjected to a plastic deformation that induced plastic strain of ε1 = 0.26 and ε2
= -0.2 where ε1 and ε2 are principal strains in 1 and 2 directions respectively.
Estimate the ideal plastic work per unit volume that is expended during this
operation.

78. A bar of an annealed metal is uniformly cold worked an unknown amount. From
the cold worked bar a standard tensile specimen, having a gage diameter (do) of
0.505 inch and a gage length (lo) of 2 inches, is made. When a tensile test is
conducted on this specimen, the following results were determined:
a. elastic modulus, E=20×106 psi
b. Poisson’s ratio =0.3
c. yield load=5000 pounds force
d. diameter at ultimate load = 0.425 inch
e. diameter at fracture = 0.375 inch
You are told that an annealed specimen of this metal shows a plastic true
stress-strain behavior described by σ = kεn and that n=0.5. What would be the
likely tensile strength Su of the annealed metal?

79. Describe how to determine the condition for cutting titanium on a lathe at
minimum cost.

80. List four possible ways of manufacturing a cup-shaped steel part with diameter, D,
height, H, and wall thickness, T. Considering the material and process selected,
quantity and the geometrical feature of the parts, describe the economical and
 technological factors that will affect the selection of appropriate type of
manufacturing process.

81. Explain the reasons to generate earing defect in deep drawing? How to avoid the
earing defects?

82. In machining cast iron using silicon nitride cutting tools, what is the usual mode
of wear of the cutting tool and why?

83. Describe in general the processes required in making a high quality transmission
shaft for a high speed machine. Start from the raw material selection to the
completion of final product.

84. Name four main types of tool wear. Why is one type of wear dominant in
rough/interrupted cutting of steel when we use Al2O3 cutting tools?

85. Make a list of the independent variables that influence the punch force in deep
drawing of a cylindrical cup and explain why and how they influence the force.

86. What is surface integrity and why is it important? How is it affected by the
machining conditions?

87. Explain the possible reasons why a knife cuts batter when it is moved back and
forth. Consider factors such as the material cut, friction, and the dimensions of the
knife.

88. List by categories of your choice all processes used to modify the surface
properties and characteristics of mechanical components or parts.

89. Explain the undesirable effects of residual stress on a part or product. Use one
example to show why the residual stress exists and how it can be eliminated.

90. Explain and estimate the forces required for the following processes.
91. A. Using an orthogonal cutting process as an example, explain how the dependent
cutting variables such as force, temperature, tool wear, etc. might change as the
cutting speed keeps increasing.
B. As in A, What and how material properties including mechanical, physical and
chemical properties, of workpiece and tool will affect the cutting behaviors?

92. A surface 8 in. wide by 20 in. long is rough milled with a depth of cut 0.25 in. A
16 tooth cemented carbide cutter face mill 6 in. in diameter is used. The material is
cast iron.
(a) What us the cutting length?
(b) Estimate the cutting time if V = 120 ft/min and tooth chip load=0.0012 inches
per tooth revolution.
(c) Find the cutter revolutions per minute.

93. Explain the function of the blank holder in a cup drawing. Describe the role of
draw beads in the pressworking of sheet metal.

94. Is there any difference in the tendency for shrinkage void formation for metals
with short freezing and long freezing ranges, respectively? Explain.

95. Explain the different properties of thermosetting plastics and thermoplastics. For
each group, list two materials and their industrial applications.

96. Most annealed ductile metals show a strain hardening behavior described by σ =
kεn . Discuss two physical interpretations of the exponent n.

97. What is “ flashless forging ”? Please give the design considerations for flashless
forging. Also suggest the possible tool designs for flashless forging.
98. (1) What are the advantages and disadvantages of making parts by powder
metalluragy?
(2) State the methods of manufacturing seamed and seamless tubes individually.

99.List the conventional machine tools and address briefly their functions.

100. Propose the most appropriate material and process, and discuss your reasons of
your selection for office paper stapling machine (annual production : 500,000
pieces)

101. A steel rod is turned on a lathe from 4.3” to 4.0” diameter for a length of 10”.
The generalized tool life equation for this particular operation is
VT 0.1f 0.8d0.3=8
The tool changing time is 1.5 minutes. What cutting speed will result in maximum
production rate if a feed of 0.02 inch per revolution is used?

102. Under what conditions would you have a normal pressure distribution in forging
a workpiece as shown below? Explain.

103. Why we get center fracture during rod rolling?

104. For a material A to be able to cut material B, what is required of the properties of
A and B?

105. Explain briefly (a) the meaning of size effect, and (b) the reason why size effect
occurs.

106. List the categories of casting processes and address briefly their
features.