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Old Midterm Problems

The document contains a series of midterm problems related to engineering concepts, including measurements, casting solidification times, and forces required for various manufacturing processes. Each problem is followed by a detailed solution, providing calculations and formulas used to arrive at the answers. Topics covered include plug gage design, Chvorinov's rule, roll force calculations, extrusion force and power, shear force for cutting, and press force for forging.

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ranshan.kirushnamoor
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7 views2 pages

Old Midterm Problems

The document contains a series of midterm problems related to engineering concepts, including measurements, casting solidification times, and forces required for various manufacturing processes. Each problem is followed by a detailed solution, providing calculations and formulas used to arrive at the answers. Topics covered include plug gage design, Chvorinov's rule, roll force calculations, extrusion force and power, shear force for cutting, and press force for forging.

Uploaded by

ranshan.kirushnamoor
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Old Midterm Problems

Note: Answers on your midterm will be multiple choice questions

1. (SI units) A GO/NO-GO plug gage will be designed to inspect a 75.00 ± 0.25 mm
diameter hole. A wear allowance of 5% of the total tolerance band is applied to the GO
side of the gage. The GO Size is?

2. In the casting of steel under certain mold conditions, the mold constant in Chvorinov's
rule is known to be 5.6 min/cm2, based on previous experience. The casting is a cylinder
whose height is = 45 cm and dia = 10 cm. Determine how long it will take for the casting
to solidify.

3. A steel casting has a cylindrical geometry with 4.0 in diameter and weighs 20 lb. This
casting takes 6.0 min to completely solidify. Another cylindrical shaped casting with the
same diameter to length ratio weighs 12 lb. This casting is made of the same steel, and
the same conditions of mold and pouring were used. Determine: the mold constant in
Chvorinov's rule if for steel, ρ = 490 lb/ft3

4. A 400mm thick x 1000mm wide steel slab is rolled on 500mm dia. Rolls. If friction is
µ=0.32, and a roll speed of 1.2m/s, what is the roll force if the slab is rolled to maximum
depth? (K=120 MPa, n=0.1)

5. A 30mm dia. billet at 750 C is extruded through a die with a 325mm2 cross sectional
area. Calculate the required a) force and b) power to extrude at 25mm/sec. (K=425MPa)

6. A sheet metal shear is to cut a 3mm thick sheet that is 2m wide. If the guillotine blades
are 8 degrees, what is the force required to cut the sheet? (TS = 450MPa)

7. A steering A-frame is forged in a flashless forging. Calculate the press force if the
volume is 21,000mm3 and the projected area is 4200mm2. The original height is 7mm,
K=950MPa, Kf = 8.0 and n=0.12.
Answers:

1. The tolerance band is 0.50 mm. Wear allowance = 0.05(0.50) = 0.025 mm. The GO gage
will inspect the minimum hole diameter =75.00 – 0.25 = 74.75 mm. As the gage wears,
the dimension will decrease and allow unacceptable parts, so the wear allowance is
added to it. GO Size = 74.75 + 0.025 = 1.8688 mm

2. Solution: Volume V = PI x 5^2 x 45 = 3,534.3 cm3


Area A = 2(PI x 5^2) + PI x 10 x 45 = 1,570.8 cm2
Chvorinov’s rule: TTS = Cm (V/A)^2 = 5.6(3534.3/1570.8)^2 = 28.4 min

3. For steel, ρ = 490 lb/ft3 = 0.2836 lb/in3


Weight W = ρV, V = W/ρ = 20/0.2836 = 70.53 in3
Volume V = πD2L/4 = π(4)2L/4 = 4πL = 70.53 in3
Length L = 70.53/4π = 5.61 in
Area A = 2πD2/4 + πDL = 2π(4)2/4 + π(4)(5.61) = 95.63 in2
(V/A) = 70.53/95.63 = 0.7375
Cm = 6.0/(0.7353)2 = 11.03 min/in2

4. Dmax = u^2 x R = .32^2 x 250 = 25.6 mm


L = (250 x 25.6)^0.5 = 80mm
E = ln (400/(400-25.6))
Ybar f = (120 x10^6 x E^0.1) / (1+0.1) = 83.14MPa
F = 83.14MPa x 1000mm x 80mm = 6.65 MN

5. E = ln (a0/Af) = ln ( PI x 15^2)/325 = 0.777


Yf = 425MPa x (330.2) ^ 1 = 330.2
F = 330.2 MPa x 706.9mm2 = 233.4 KN

6. F = 0.7 x t x L x TS
L = t/tan(alpha) = 3/tan 8 = 21.35mm
F = 0.7 x 3mm x 21.35mm x 450MPa = 20.2 KN

7. havg = V/A = 21000/4200 = 5


Eavg = ln (h0 / havg) = ln (7/5) = 0.336
Yfavg = K (Eavg)^n = 950MPa (0.336)^.12 = 833.6MPa
F = Kf x Kfavg x At = 8.0 x 833.6 MPa x 4200mm2 = 28.0 MN

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