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On my honor, I pledge that I have neither received nor provided improper assistance in the completion of this test.

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GEORGIA INSTITUTE OF TECHNOLOGY George W. Woodruff School of Mechanical Engineering ME 4210 MANUFACTURING PROCESSES AND ENGINEERING Spring 2011

Test #1 February 14

Be sure to list all assumptions. Write legibly. One, two-sided page of hand-written notes is allowed; it must be handed in with your worked solutions (put your name on your sheet of notes). Otherwise, the exam is closed book and notes. This exam is 50 minutes long. Use the data provided with the test for all calculations. Show your work and write your answers in the exam in the space after the questions. You may write on both sides of the paper.

Problem #1 (50 points) You are sand casting a copper component. The component can be modeled as a plate with dimensions 50 cm by 25 cm by 0.5 cm. The copper is poured at 120 C above its melting temperature. The sands temperature is 35 C. Calculate the conservative, allowable pouring time as constrained by heat transfer. If the sprue/runner/gate system has a diameter of 0.5 cm, determine the upper and lower values of velocity at the gate that are allowable.

Note: I have provided separate material properties for room and molten temperatures; be sure to use the correct ones.

Material properties for Casting:

Data for solid materials (room temperature) Material Specific (kJ/kg-oC) 1.16 0.90 0.44 1.03 0.38 0.46 0.434 heat Density (kg/m3) Thermal conductivity (W/m-oC) 0.60 222 92.1 154 394 75.4 59

Sand Aluminum Nickel Magnesium Copper Iron Steel

1500 2700 8910 1740 8960 7870 7832

Data for liquid materials at their melting points Material Melting point (oC) 660 1453 650 1083 1537 Density (kg/m3) Latent heat of Thermal solidification conductivity (fusion) (W/m-oC) (kJ/kg) 396 94 297 384 220 211 139 49.4 Specific Viscosity heat (mPa-s) (kJ/kg-oC) 1.05 0.73 1.38 0.52 0.34 4.5 4.1 1.24 3.36 2.2

Aluminum Nickel Magnesium Copper Iron

2390 7900 1585 7960 7150

Note: temperature in Kelvin = temperature in Celsius + 273

Your answer to Problem #1: (continue on back of sheet)

Problem #2 (50 points) You are forward (direct) extruding a cylindrical part with an initial diameter of 200 cm and an initial length of 500 cm at 1100 C. The part has a final diameter of 158 cm. The die has a flat bottom. The metal being forged has a melting temperature of 1500 C. The metal has K = 960 MPa, n = 0.1, C = 160 MPa, and m = 0.07. The ram moves at 18 m/min. Determine which material model that you will use (strain hardening or strain rate). For a safety factor of 3, determine the yield stress of the ram.

Note: temperature in Kelvin = temperature in Celsius + 273

Your answer to Problem #2: (continue on back of sheet)

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