Due to 06 May 2013 QUESTIONS

CASTING 1) While various cast metals contract during solidification, ductile cast iron (nodular cast iron) expand. Why? 2) Write the reasons for porosity formation in sand casting. 3) How can casting defects be detected? Give 3 different examples with figures. Explain how these defects can be eliminated or decreased.

EXTRUSION

1) Explain the direct and indirect extrusion. Give some examples of their application. What is the type of the extrusion process we performed in the lab section? 2) Give at least three examples of extrusion defects (with figures and brief explanation) Propose a remedy for center burst defect. 3) Show the typical plot of ram pressure vs. ram stroke. Explain the plot briefly. 4) Derive the strain rate equation for extrusion (not the average strain rate, strain rate as a function of x, x being the distance from the entry of the die) 5) A 30 in-long cylindrical billet whose diameter is 1.5 in is reduced by indirect extrusion to a diameter 0.375 in. Die angle=90o. In the Johnson equation, a=0.8 and b=1.5. In the flow curve for the work metal, K=75000 lb/in2 and n=0.25. Determine: a. Extrusion ratio b. True strain (homogenous deformation) c. Extrusion strain d. Ram pressure e. Ram force f. Power if the ram speed=20 in/min.

ROLLING

1) Discuss the effects of hot and cold rolling on the mechanical properties of a material. 2) Give examples of rolling defects (with figures and a brief explanation) 3) Write down the dimensions of the part and calculate the volume of the part: a. At the end of casting

Due to 06 May 2013

b. At the end of extrusion c. At the end of rolling Explain the volume change in each step. 4) What is isotropy and anisotropy? Explain if the material we processed during lab section is isotropic or not. 5) What is Poissons Ratio? a. For the material we processed in lab, what do you expect the relation between the strains in transverse directions due to rolling? Explain this expectation in terms of Poissons ratio. b. By comparing the thickness and width of the part before and after rolling, calculate the ratio of strains in transverse directions and discuss your calculation with your expectation. If they do not match. Give the reasons of this consequence. NOTE for the question # 5 in Rolling: Check Figure 1. Assume that we processed the part (applied rolling) in x direction. So; x direction is the longitudinal direction and y and z directions are the transverse directions.

Figure 1.