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1.

What are the four categories of engineering materials used in manufacturing?


Answer. The four categories of engineering materials are (1) metals, (2) ceramics, (3) polymers,
and (4) composite materials, which consist of non-homogeneous mixtures of the other three
types.

1.2 Identify the four types of permanent joining processes used in assembly.
Answer. The four types are welding, brazing, soldering, and adhesive bonding.
1.3 A company invests $750,000 in a piece of production equipment. The cost to install the equipment
in the plant = $25,000. The anticipated life of the machine = 12 years. The machine will be used
eight hours per shift, five shifts per week, 50 weeks per year. Applicable overhead rate = 18%.
Assume availability = 100%. Determine the equipment cost rate if (a) the plant operates one shift
per day and (b) the plant operates three shifts per day.
Solution: (a) For a one-shift operation, hours of operation per year H = 50(1)(5)(8) = 2000 hr/yr.
Using Eq. (1.8),
Ceq = (750,000 + 25,000)(1.18)/(60 12 2000) = $0.635/min = $38.10/hr
(b) For a three-shift operation, hours of operation per year H = 50(3)(5)(8) = 6000 hr/yr.
Ceq = (750,000 + 25,000)(1.18)/(60 12 6000) = $0.212/min = $12.70/hr
Note the significant advantage the company has if it runs three shifts per day rather than one
shift.
1.4 A stamping press produces sheet-metal stampings in batches. The press is operated by a worker
whose labor rate = $15.00/hr and applicable labor overhead rate = 42%. Cost rate of the press =
$22.50/hr and applicable equipment overhead rate = 20%. In one job of interest, batch size = 400
stampings, and the time to set up the die in the press takes 75 min. The die cost $40,000 and is
expected to last for 200,000 stampings. Each cycle in the operation, the starting blanks of sheet
metal are manually loaded into the press, which takes 42 sec. The actual press stroke takes only 8
sec. Unloading the stamping from the press takes 13 sec. Cost of the starting blanks = $0.23/pc.
The press operates 250 days per year, 7.5 hours per day, but the operator is paid for 8 hours per
day. Assume availability = 100% and scrap rate = 0. Determine (a) cycle time, (b) average
production rate with and without setup time included, and (c) cost per stamping produced.
Solution: (a) Cycle time Tc = 42 + 8 + 13 = 63 sec = 1.05 min
(b) Including setup time, Tp = 75/400 + 1.05 = 1.2375 min
Rp = 60/1.2375 = 48.485 pc/hr
Excluding setup time, Rc = 60/1.05 = 57.143 pc/hr
(c) Equipment cost rate Ceq = 22.50(1.20)/60 = $0.45/min
Die cost per piece Ct = 40,000/200,000 = $0.20/pc
Labor cost rate CL = 15.00(1.42)/60 = $0.355/min
This labor cost should be adjusted for the fact that although the press operates 7.5 hr/day, the
operator is paid for 8 hr. CL = 0.355(8/7.5) = $0.379
Finally, cost per stamping Cpc = 0.23 + (0.379 + 0.45)(1.2375) + 0.20 = $1.456/pc
1.5 In a long-running high-production operation, the starting work part cost = $0.45 each, and cycle
time = 0.75 min. Equipment cost rate = $28.00/hr, and labor cost rate = $21.00/hr. Both rates
include overhead costs. Tooling cost = $0.05/pc. Availability of the production machine = 96%,
and the scrap rate = 3%. Determine (a) production rate and (b) finished part cost.
Solution: (a) Production rate, including effect of availability (60/0.75)(0.96) = 76.8 pc/hr
However, because of the 3% scrap rate, the production rate of acceptable parts is
Rp = 76.8(1 0.03) = 74.5 pc/hr
(b) Factoring in availability and scrap rate, part cost is
Cpc = 0.45/0.97 + ((21 + 28)/60)(0.75/(0.97 0.96)) + 0.05 = $1.172/pc
2.1

What is the difference between primary and secondary bonding in the structure of materials?

Answer. Primary bonding is strong bonding between atoms in a material, for example to form a
molecule; while secondary bonding is not as strong and is associated with attraction between
molecules in the material.
2.2

What are some common point defects in a crystal lattice structure?


Answer. The common point defects are (1) vacancy - a missing atom in the lattice structure; (2)
ion-pair vacancy (Schottky defect) - a missing pair of ions of opposite charge in a compound; (3)
interstitialcy - a distortion in the lattice caused by an extra atom present; and (4) Frenkel defect an ion is removed from a regular position in the lattice and inserted into an interstitial position not
normally occupied by such an ion.

2.3

Define the difference between elastic and plastic deformation in terms of the effect on the crystal
lattice structure.
Answer. Elastic deformation involves a temporary distortion of the lattice structure that is
proportional to the applied stress. Plastic deformation involves a stress of sufficient magnitude to
cause a permanent shift in the relative positions of adjacent atoms in the lattice. Plastic
deformation generally involves the mechanism of slip - relative movement of atoms on opposite
sides of a plane in the lattice.

2.4

How do grain boundaries contribute to the strain hardening phenomenon in metals?


Answer. Grain boundaries block the continued movement of dislocations in the metal during
straining. As more dislocations become blocked, the metal becomes more difficult to deform; in
effect it becomes stronger.

2.5

What is the difference between crystalline and noncrystalline structures in materials?


Answer. The atoms in a crystalline structure are located at regular and repeating lattice positions in
three dimensions; thus, the crystal structure possesses a long-range order which allows a high
packing density. The atoms in a noncrystalline structure are randomly positioned in the material,
not possessing any repeating, regular pattern.

1.

State Hooke's law.


Answer. Hooke's Law defines the stress-strain relationship for an elastic material: = E, where E
= a constant of proportionality called the modulus of elasticity.
2.

Define the recrystallization temperature for a metal.


Answer. The recrystallization temperature is the temperature at which a metal recrystallizes (forms
new grains) rather than work hardens when deformed.

3.

(SI Units) A tensile test provides the following flow curve parameters: strain-hardening exponent =
0.25 and strength coefficient = 500 MPa. Determine (a) flow stress at a true strain = 1.0 and (b) true
strain at a flow stress = 500 MPa.
Solution: (a) Yf = 500(1.0).25 = 500 MPa
(b) = (500/500)1/.25 = (1.0)4.0 = 1.00

4.

(A) (SI Units) A tensile test specimen has a gage length = 50 mm and its cross-sectional area = 100
mm2. The specimen yields at 48,000 N, and the corresponding gage length = 50.23 mm. This is the
0.2 percent yield point. The maximum load of 87,000 N is reached at a gage length = 64.2 mm.
Determine (a) yield strength, (b) modulus of elasticity, and (c) tensile strength. (d) If fracture occurs
at a gage length of 67.3 mm, determine the percent elongation. (e) If the specimen necked to an
area = 53 mm2, determine the percent reduction in area.
Solution: (a) Y = 48,000/100 = 480 MPa
(b) s = E e. Subtracting the 0.2% offset, e = (50.23 - 50.0)/50.0 - 0.002 = 0.0026
E = s/e = 480/0.0026 = 184.6 x 103 MPa
(c) TS = 87,000/100 = 870 MPa
(d) EL = (67.3 - 50)/50 = 17.3/50 = 0.346 = 34.6%
(e) AR = (100 - 53)/100 = 0.47 = 47%

5.

(USCS Units) A ceramic specimen is tested in a bending test. Its width = 0.50 in and thickness =
0.25 in. The length of the specimen between supports = 3.0 in. Determine the transverse rupture
strength if failure occurs at a load = 1250 lb.

Solution: TRS = 1.5FL/bt2 = 1.5(1250)(3.0)/(0.5 x 0.252) = 180,000 lb/in2


4.1.

How does solidification of alloys differ from solidification of pure metals?


Answer. Pure metals solidify at a single temperature equal to the melting point. Most alloys
(exceptions are eutectic alloys) start to solidify at the liquidus and complete solidification occurs
at the solidus, where the liquidus is a higher temperature than the solidus.

4.2. What are some of the factors that affect the fluidity of a molten metal during pouring into a mold
cavity?
Answer. The factors include (1) pouring temperature above the melting point, (2) metal alloy
composition, (3) viscosity of the liquid metal, and (4) heat transfer to the surroundings.
4.3.
Pure copper is heated to cast a large rectangular plate in an open mold. The plates length = 20
in, width = 10 in, and thickness = 2 in. Compute the amount of heat that must be added to the metal to
heat it from ambient temperature (75F) to a pouring temperature of 2100F. The amount of metal heated
will be 10% more than what is needed to fill the mold cavity. Density, melting point, and specific heat of
the solid metal can be found in Tables 4.1 and 4.2. The specific heat of copper in the molten state = 0.090
Btu/lbm-F, and its heat of fusion = 80 Btu/lbm

U mp=c s ( T m T 0 ) + hf + cl ( T pT m )
Solution: Volume of rectangular plate V = (20 x 10 x 2) = 400.0 in3
Volume of copper to be heated = 400(1 + 10%) = 440.0 in3
Assuming To = 75 F and using Eq. (10.1),
H = 0.324 x 440{0.092(1981 - 75) + 80 + 0.090(2100 - 1981)} = 142.35{175.35 + 80 + 10.71}
H = 37,930 Btu
4.4.
The flow rate of liquid metal into the downsprue of a mold = 0.8 L/sec. The cross-sectional
area at the top of the sprue = 750 mm2, and its length = 175 mm. What area should be used at the base of
the sprue to avoid aspiration of the molten metal?

=2 gh
Solution: Flow rate Q = 0.8 L/s = 800,000 mm3/s
Velocity v = (2 x 9810 x 175)0.5 = 1853 mm/s
Assuming volumetric continuity, area at base A = 800,000/1853 = 432 mm2
4.5.
A riser in the shape of a sphere is to be designed for a sand casting mold. The casting is a
rectangular plate, with length = 200 mm, width = 100 mm, and thickness = 18 mm. If the total
solidification time of the casting itself is known to be 3.5 min, determine the diameter of the riser so that it
will take 25% longer for the riser to solidify.

T =Cm

V
A

( )

Solution: Casting volume V = LWt = 200(100)(18) = 360,000 mm3


Casting area A = 2(200 x 100 + 200 x 18 + 100 x 18) = 50,800 mm2
V/A = 360,000/50,800 = 7.0866
Casting TTS = Cm(7.0866)2 = 3.50 min
Cm = 3.5/(7.0866)2 = 0.0697 min/mm2
Riser volume V = D3/6 = 0.5236D3
Riser area A = D2 = 3.1416D2
V/A = 0.5236D3/3.1416D2 = 0.1667D
TTS = 1.25(3.5) = 4.375 min = 0.0697(0.1667D)2 = 0.001936D2
D2 = 4.375/0.001936 = 2259.7 mm2
D = 47.5 mm

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