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GEORGIA INSTITUTE OF TECHNOLOGY George W. Woodruff School of Mechanical Engineering ME 4210 MANUFACTURING PROCESSES AND ENGINEERING Summer 2011 Test #2 July 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 test is closed book and notes. This test is 90 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.

Question #1 (40 points) Consider the following sheet metal bending operation: a) Determine the maximum speed for the following metal bending operation. (25 points) b) Determine the punch and die angles required. (15 points) yield stress (yield) stress at maximum elongation (UTS) elastic modulus (E) maximum elongation (UTS) metal thickness (t) material width (b) final part angle required (part) die width (2l) coefficient of friction () Press power 28 MPa 45 MPa 54 GPa 18% 1.8 mm 3250 mm 90 degrees 75 mm 0.21 1.5 kW

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Question #2 (30 points) You are turning a cylinder of metal on a lathe. The initial diameter of the cylinder is 75 mm. The final diameter is 72 mm. The length of cut is 150 mm. The tool can withstand a temperature of 1400C. Room temperature is 20C. Determine the power to make the cut. The metal being cut has the following properties: Melting temperature (Tm) = 1668C Density () = 4510 kg/m3 Specific heat (c) = 519 J/kg-C Thermal conductivity (k) = 17 W/m-C Specific cutting energy (u) = 3.0 W-s/mm3 0C = 273K

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Question #3 (30 points) Consider the production of an iron alloy car frame by resistance welding of two sheets that are 1.5 mm thick each. a) Determine the time for each weld required. (25 points) b) Determine the cost of electricity to weld one years car production. (5 points)

Electrode diameter Density of alloy Resistivity of alloy Specific heat capacity of alloy Heat of fusion of alloy Melting point of alloy Efficiency of process Room temperature Current available Number of welds per car Number of cars produced per year Cost of electricity

6 mm 7,200 kg/m3 11.8 x 10-6 -m 0.465 kJ/kg-C 272 kJ/kg 1,425C 35% 20C 2,000 A 1,200 50,000 $0.1099/kW-hr

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