Manufacturing

 Processes  (INME  4055)  

2nd  Exam  
Student  Number:  ___________________________                                Name:________________________________  
Section:  _____7:30AM_____9:00AM__________     Date   :  November  25th,  2013  
Notes:  This  is  an  open  book  examination.  Items  needed  are  calculators,  pencils,  pens  and  rulers.  
This  exam  consists  of  two  parts.  Please  write  in  a  clear  and  concise  manner.    
Total  Points  =  100     Time  Allowed  :  120  minutes  
-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐  
1. (20 points) A bending operation is to be performed on the part shown in the figure below.
The dimensions are as follows: sheet thickness = 3.0 mm, inside bend radius of B1= 5.0 mm
and inside bend radius of B2 = 10.0 mm. Other dimensions are shown in millimeters.
Determine the blank size required, the force required for each bending and the angle for each
V-die and the radius of the bending punch for each bending.  
Note: the V-die used for this operation has an opening of 48mm, the length of the bending
part is 200mm (width – dimension out of the drawing) and the material has a Yield Strength
of 500MPa, Tensile Strength of 600MPa and a elastic modulus of 200GPa.
Hint:  For  the  estimation  of  the  die  radius,  consider  that  the  first  term  (term  to  the  cube,  
right  of  the  equation)  is  very  small.  You  must  calculate  the  initial  radius  as  the  final  
3
Ro ! Roσ yield $ Roσ yield
= 4# & −3 +1
Rf " Et % Et
radius  is  given  in  the  drawing                                                                  

For  B1    
K    
 
 
Bend    
Allowance  
 
 
 
For  B2    
K    
 
 
Bend    
Allowance  
 
 
 
Length  of    
flat  regions  
 
 
 
Total  length    
of  the  blank  
 
 
Bending    
Force  (B2)  
 
 
 
Die  Bending    
radius  (B2)  
 
 
 
Die  Bending    
Angle  (B2)  
 
 
 

2. (35 points) Calculate the elastic modulus, percentage of load and stresses in the fibers and the
matrix of a composite material. The composite is made of an epoxy matrix and 20% of fibers.
The fibers are either (a) high modulus carbon fiber, or (b) Kevlar 29 fibers. The fibers are
continuous and uniaxially aligned. The dimensions of the composite are as follows: Thickness
= 0.5mm , width = 100mm (direction 2) and length (in the direction of the aligned fibers
300mm – direction 1).
For the fiber that give the higher strength, if the composite supports a force of 2000N in the
direction of the fibers, determine the strains in the direction of the fibers (ε1), in the transverse
direction (ε2) and in the thickness direction (e3) and the final dimensions of the composite.
Hint: Consider that the matrix and fibers are elastic until fracture.
 for isotropic materials

Epoxy High Modulus Carbon Fiber (a) Kevlar 29 (b)

Density (g/cm3) 1.2 1.95 1.44
UTS (MPa) 105 2000 2600
E (GPa) 15 400 65.0
Poisson 0.4 0.45 0.35
G Isotropic isotropic isotropic

G f Gm
G12 =
ν 12 = ν f V f +ν mVm G f Vm + GmV f
density-composite

E-composite (a)
In the direction
parallel (E1) and
perpendicular (E2) to
the fibers

E-composite (b)
In the direction
parallel (E1) and
perpendicular (E2) to
the fibers

Fraction of load
supported by fiber (a)

Fraction of load
supported by fiber (b)

Force in matrix and

fiber (a)

Force in matrix and

fiber (b)
Stress and strain of
the composite at
fracture (a)

Stress and strain of

the composite at
fracture (b)

Which fiber will you

choose for higher
elongation at
fracture?
Which fiber will you
choose for higher
strength at fracture?
For the fiber that give the composite the higher strength
Poisson 12

Poisson 21

G12

Compliance matrix or
equations

Strain in the direction

1

Strain in the direction

2

Strain in the direction

3

Shear strain in 12
Final dimensions of
the composite

3. (20 points) A large washer was cut from an aluminum sheet alloy (2024) of 3mm thick. The
outside diameter of the washer is three times its inside diameter. The aluminum alloy has a
tensile strength of 400MPa. The maximum force measured during the operation was 180000N.
If the punching and blanking operations are performed simultaneously determine the following:
The maximum inner and outer diameters possible for the given force (in integer mm).
The diameter of the punch and die for the blanking operation. The diameter of the punch and die
for the blanking operation.

Performed Punching Operation

Simultaneously
Diameters (before
considering
allowance)
(round the number
down to the integer
millimeter)

Allowance

Punching Operation
Diameter of the
punch

Diameter of the die

Blanking Operation
Diameter of the
punch

Diameter of the die

4. (25 points) Questions (circle your answer when necessary):

When extruding a viscoelastic polymer of a square section through a die, the die opening must be
a square section of the same dimensions (TRUE – FALSE ).

Comminution: It is defined as the breaking up of large solid particles by mechanical means

( TRUE - FALSE )

When working with powders, higher densities are achieved (at the same compacting pressure)
with smaller size particles ( TRUE – FALSE ).

Blow molding is a typical process used to produce a plastic ball ( TRUE – FALSE )

In the same material, hot isostatic pressing (HIP) will give a material of higher and uniform
density than by compact pressing and sintering ( TRUE – FALSE ).

Cutlery is mainly produced by hot forging ( TRUE – FALSE )

In a sheet metal, the material propensity to earing is determined by the planar anisotropy ratio
( TRUE – FALSE ).

The more isotropic is the steel sheet, the more suitable for its use as car chassis ( TRUE –
FALSE ).

For a material with a melting point of 1085oC, the sintering temperature is …..

In metal infiltration, gravity is the main force that draws the metal liquid of the filler into the
pores ( TRUE – FALSE ).

The “Gob” is a term applied to a slurry of copper particles for impregnation ( TRUE – FALSE ).

The Float Process is used to produce complex shapes of glasses ( TRUE – FALSE ).

The mechanical behavior of a viscoelastic material is determined by the rate of deformation

(strain rate) ( TRUE – FALSE ).

Anisotropic means which one of the following:

(a) composite materials with composition consisting of more than two materials,
(b) properties are the same in every direction,
(c) properties vary depending on the direction in which they are measured, or
(d) strength and other properties as a function of curing temperature.

In the same material, hot isostatic pressing (HIP) will give a material of higher and uniform
density than by compact pressing and sintering ( TRUE – FALSE)
Which of the following metals is used as the matrix metal in nearly all WC cemented carbides
(cermets)?
(a) aluminum, (b) chromium, (c) cobalt, (d) silver, (e) tungsten,

Match  the  number  with  the  description  of  the  following  polymers  
(h)  Vulcanize  rubber    ..........................  
(i)  Polypropylene  ................................  
(j)  Polyvinylchloride  ...........................  
(k)  octane  ............................................  
(l)  Tetrafluoroethyline  ........................  

1               2                         3      

4                                       5  
A  polymer  for  the  surface  of  a  non-­‐sticking  pan  _________________________________  
Which of the following processes is not associated with the production of plastic sheet and film
(more than one)?
(a) blown-film extrusion process,
(b) calendering,
(c) chill-roll extrusion,
(d) doctor blade method, or
(e) slit-die extrusion.

In powder metallurgy, as particle size increases, interparticle friction

(a) increases, or
(b) decreases.

A screen with 325 mesh count has wires with a diameter of 0.001377 in.
(a) the maximum particle size that will pass through the wire mesh is …………..,
(b) the of the opening is ………………
(c) the percent open space is …………..