Amp 2021-01

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AMP EXAM – 22-01-2021

Proff. Annoni, Demir, Strano

Question 1
You need to perform a keyhole welding of 3 mm thickness stainless steel plates. You can use a
fiber laser source with a power of 6 kW. The fiber core diameter is 400 μm and the numerical
aperture is NA=0.24.
Your laser head can be equipped with two different collimation lenses and two different focusing
lenses. All the lenses are characterized by a lens diameter of 60 mm, the focal lengths are:
-Focal length of first collimation lens, fcol1=80 mm;
-Focal length of second collimation lens, fcol2=120 mm;
-Focal length of first focusing lens, ffoc1=150 mm;
-Focal length of second focusing lens, ffoc2=200 mm.

Q: It is asked to choose the optical configuration able to weld correctly the stainless steel plates.

Assumption: the position of waist diameter is in the middle of thickness plates. The diameter of
the collimation lens must be at least 20% bigger than the collimated beam one (dc).

Sol
The first step is determine de half-angle of divergence at the exit of the fiber by the information
on Numerical Aperture:

𝜃" = sin'( 𝑁𝐴 = 0.24 𝑟𝑎𝑑 ≈ 14°

Using trigonometry it is valid the relationship:

𝑑6
𝜃" =
2𝑓689

From which as a function of different collimation lens it is possible determine the collimated beam
diameter (i.e. the value of dc must be check with the restriction on collimation lens diameter à
The diameter of the collimation lens must be at least 20% bigger than the collimated beam one
(dc))

With fcol1: 𝑑6( =38.8 mm < 0.2 Dlens (YES!)

With fcol2: 𝑑6: = 58.2 mm > 0.2 Dlens (NOT FEASIBLE!)

Considering the choice of fcol1 it is possible determine two different waist diameter as a function
of the two option of focusing lens.

"<=>?
With ffoc1 𝑑;( = 𝑑" ">=@?
= 0.75 𝑚𝑚

"<=>D
With ffoc2 𝑑;: = 𝑑" ">=@?
= 1 𝑚𝑚
Now considering the application it is necessary the check on the irradiance (>106 W/cm2) in the
worst condition, where we have an increase of beam spot dimension (top or bottom of the surface
considering the position of the waist).

:
𝑑6(
𝑑E( = F𝑑;( + ∆𝑧 : ∙K L = 0.84 𝑚𝑚
𝑓"86(

:
𝑑6(
𝑑E: = F𝑑;( + ∆𝑧 : ∙K L = 1.04 𝑚𝑚
𝑓"86:

O U
𝐼( = P D = 1.07 ∙ 10T 6V D
à FEASIBLE!
RS?
Q

O U
𝐼: = P D = 7.04 ∙ 10W 6V D
à NOT FEASIBLE!
RSD
Q

The correct answer is fcol1=80 mm and ffoc1=150 mm

Question 2
Which of the following statements are correct in waterjet cutting?
- In general, it is better to improve pressure to improve the cutting performance
- In general, it is better to reduce the orifice diameter to improve productivity
- At constant jet power, it is better to reduce the orifice diameter to improve productivity
- The jet power density (jet power / jet cross section area) does not depend on the orifice
diameter

Question 3
In EDM, why a pulsed material removal is needed?
- It is not needed
- It is needed for obtaining the extraction of the molten material thanks to the implosion of
the plasma bubble created by the spark
- It is necessary to allow an even material removal on the surfaces facing the tool
- It is needed to always keep the dielectric conductivity higher than a threshold

Question 4
Evaluate the machining cost of AWJ cutting of an alumina (AD-94) part, reported in the following
figure. Dimensions are given in mm. To compute the machining cost, use the feed rate in mm/min.
The piercing is carried at each hole center.
Sol
The total machining cost can be calculated as:

𝑐 (€) = 𝐶(€/𝑚𝑚) ∙ 𝑙6 (𝑚𝑚)

Where 𝑐(€/𝑚𝑚) is the unit cost and 𝑙6 (𝑚𝑚) is the cutting length.
The former is calculated from the AWJ cost model. The cutting model can be used to estimate the
feed rate:

;.cTT
𝑚𝑚 𝑁V ∙ 𝑝(.:W ∙ 𝑚̇f;.Tcg
∙ 𝑚̇h;.iji
K𝑣" ` bL =
𝑠 𝐶 ∙ 𝑑";.T(c ∙ ℎ

𝑑m: 2𝑝
𝑚̇f = 𝜌; 𝑐R ∙ 𝜋 ∙ F = 2.79 𝑘𝑔/𝑚𝑖𝑛
4 𝜌;
(
10 ∙ 350(.:W ∙ 2.79;.Tc ∙ 5.8;.iji ;.cTT
𝑣" = K L = 0.91 𝑚𝑚/𝑠
12000 ∙ 1.02;.T(c ∙ 5
𝑣" = 55 𝑚𝑚/𝑚𝑖𝑛
C (€/mm) = CA + CW + CE + CU

𝑚̇v
𝐶𝐴 (€/𝑚𝑚) = 𝑐hu ∙ = 3.19 ∗ 10'i
𝑣w

𝑄f ∙ 𝑐f |𝑝 |𝑝
𝐶𝑊 = = 𝑐f ∙ 𝑞f ∙ = 𝑐fu ∙
𝑣" 𝑣" 𝑣"

RD :∙(;€
𝑞f = 60 ∙ 0.65 ∙ 𝜋 ∙ ` j~ ∙ 10'T b • •?
= 1.49 ∗ 10'j

𝐶𝑊 (€/𝑚𝑚) = 1.02 ∗ 10'j



(;;;∙„… ∙† (;;;∙‹… ∙√†∙† †D
𝐶𝐸 (€/𝑚𝑚) = 𝑐ƒ ∙ T;∙T;∙‡ = 𝑐ƒ ∙ = 𝑐ƒu = 6.21 ∗ 10'j
<∙ˆ‰~Š T;∙T;∙ˆ‰~Š ∙‡< ‡<

1 𝐶V 𝐶m 𝑐’u
𝐶𝑈(€/𝑚𝑚) = • + ‘= = 9.46 ∗ 10'j
60 ∙ 𝑣" 𝑡V 𝑡m 𝑣"

𝐶(€/𝑚𝑚) = 4.85 ∗ 10'i

The cutting length, 𝑙6 :

𝑙6 (𝑚𝑚) = (50 𝑚𝑚 + 6 ∗ 10 𝑚𝑚) ∗ 𝜋 + 6 ∗ 5 𝑚𝑚 = 357,58 𝑚𝑚

The total cost is:

c (€) = 1.82

Question 5
You are required to produce a filter on pure Cu with a micro hole grid (ø20 µm) using laser drilling.
Which of the following are exploitable for the process to be employed? There may be more than
one correct answer.
- A ms pulsed CO2 laser is feasible
- A fs-pulsed active fiber laser
- A long focal lens and a small collimated beam
- A short focal lens and a large collimated beam
- A ns pulsed Nd:YAG laser operating at 3rd harmonic

Question 6
Your company needs to produce, by hydroforming, a stainless steel (AISI 304, flow stress law with
K=860 MPa, n=0.29, ε0=0.01) tube for an exhaust pipe. The starting tube has an outer diameter
OD=70 mm and wall thickness t0=2 mm. The minimum convex radius at the protrusion is Rmin=6
mm and the maximum cross section perimeter (figure) at the protrusion is Pcsmax=320 mm.
Your hydroforming press has a maximum pressure of 400 MPa, a maximum die closing force of
Fclosemax=29000 kN, maximum axial piston force of 980 kN, but only 1 active piston is available
with a maximum stroke of 300 mm, the other tube end must be sealed with a plug.

Q: Will the movable axial punch be the left or the right one?

- LEFT, with a guiding zone of about 350 mm

Sol
Since we have only 1 axial punch, it will be the left one, because it is closer to the protrusion and
this will reduce the axial force requirement due to friction

Question 7
Your company needs to produce, by hydroforming, a stainless steel (AISI 304, flow stress law with
K=860 MPa, n=0.29, ε0=0.01) tube for an exhaust pipe. The starting tube has an outer diameter
OD=70 mm and wall thickness t0=2 mm. The minimum convex radius at the protrusion is Rmin=6
mm and the maximum cross section perimeter (figure) at the protrusion is Pcsmax=320 mm.
Your hydroforming press has a maximum pressure of 400 MPa, a maximum die closing force of
Fclosemax=29000 kN, maximum axial piston force of 980 kN, but only 1 active piston is available
with a maximum stroke of 300 mm, the other tube end must be sealed with a plug.

Q: Is the available maximum axial piston stroke enough to form the part?

- Yes, because the available maximum axial piston stroke is more than enough

Sol
Yes, because the expected dax/Li stroke will be equal to about 0.2*1000=200 mm, and the total
available stroke is 300
Question 8
What is the meaning of “minimum chip thickness” effect in mechanical microcutting?
- It means that the chip thickness must be small to reduce the cutting forces
- It means that the chip thickness must be larger than a certain critical value to form the chip
- It is a valid concept only for turning operations
- It means that if the chip thickness is too small, ploughing takes place at the workpiece
surface

Question 9
You have at your disposal a pulsed laser source (Nd:YAG) in ms regime. Your laser source is
characterized by a pulse width, τ=45 ms, a duty cycle, δ=30%. It is asked to realize a surface heat
treatment with 120 W laser power on a Titanium substrate of 5 mm thickness with a speed of 180
mm/min. The treatment is realized along a linear track and it requires 4 pulses in order to achieve
the desired condition of temperature. The thermophysical and optical properties of the employed
material are:

-Initial temperature Ti=20 °C;


-Thermal conductivity, k=18 W/mK;
-Density, ρ=4512 kg/m3;
-Specific heat capacity, cp=519 J/kgK;
-Optical absorption, A=28%;

Q: It is asked to determine the temperature of heat treatment considering the provided


constraints. (Calculate the spot diameter (ds) that fullfills the given requirements).

Assumption:
-The pulse shape is rectangular;
-The power distribution of the laser beam is uniform;
-The track width is equal to the spot dimension;
-At the switching on of each pulse, the cooling effect of the previous pulse is negligible.

Sol
Starting from the number of pulses it is known that:

𝑡™mš
n”•–—˜— = = 4 𝑝𝑢𝑙𝑠𝑒𝑠
𝑡š8š
Where ttot can be determine as:

𝜏 𝜏 𝜏
𝛿= = → 𝑡š8š = = 150 𝑚𝑠 = 0.15 𝑠
𝜏 + 𝑡8"" 𝑡š8š 𝛿

In this way it is possible determine the interaction time tint as:

𝑡™mš = 𝑡š8š ∙ n”•–—˜— = 600 𝑚𝑠

With this information it is possible the calculation of spot diameter as:


𝑑E
𝑡™mš = → 𝑑E = 𝑡™mš ∙ 𝑣 = 1.8 𝑚𝑚
𝑣

The spot diameter is needed to obtain the value of heat source as:

𝑃∙𝐴 W
𝑞8uu = : = 1.32 ∙ 10g :
𝜋𝑑E 𝑚
4
Four pulses are needed in order to reach a desired temperature Tf. The absence of cooling effect
between to consecutive pulses is another assumption of the problem. In this way it is possible
superimpose the effects for the three pulses. Considering that the heat treatment realized on the
surface (x=0) the ierfc(0) can be substituted by 1/√𝜋, obtaining:

𝑞;"
𝑇(" = 𝑇hV£ + ¥|4𝛼𝑡š8š − |4𝛼(𝑡š8š − 𝜏)¨ = Tvª« + 𝑞;" ∙ 𝐵
√𝜋𝑘

𝑇:" = 𝑇(" + 𝑞;" ∙ 𝐵 = Tvª« + 𝑞;" ∙ 𝐵 +𝑞;" ∙ 𝐵= Tvª« + 2𝑞;" ∙ 𝐵

𝑇i" = 𝑇:" + 𝑞;" ∙ 𝐵 = Tvª« + 𝑞;" ∙ 𝐵 +𝑞;" ∙ 𝐵 + 𝑞;" ∙ 𝐵= Tvª« + 3𝑞;" ∙ 𝐵

‹-" √j®¯
𝑇" = 𝑇i" + = Tvª« + 3𝑞;" ∙ 𝐵 + 𝑞;" ∙ 𝐶
√°±

And:

𝑇" = 𝑞;uu ∙ (3𝐵 + 𝐶 ) + 𝑇hV£ = 942 °𝐶

Question 10
In Plasma Arc Cutting, the stand off distance...

Q: Complete the sentence.

- ... can be kept to a constant value, thanks to a closed loop control on the arc current
- ... must be kept to a relatively low but constant value, except when the torch is turned on
onto the sheet
- ... is not very important, because the beam has always an energy which is much larger than
strictly required to pierce the sheet
- ... should be as small as possible, provided that the torch tip protection cup does not touch
the sheetcap
- ... it must be controlled so that the arc voltage is minimised

Question 11
A workpiece requires plunge EDM due to the presence of a single rectangular pocket with
dimension (LxWxH) equal to 5 cm x 1 cm x 0.1 cm. You have to produce 2000 parts but the plunge-
EDM operators suddenly left your company, leaving the production batch unfinished.
The new operator wants to setup the same ton and I trying to keep the batch quality as much as
steady as possible, but the old operator left without informing about the current ton (discharge
time) and I (Current) levels he used to produce the first 1000 parts in the last week.
The following information are available:
1. Electrode Material: Copper (ρ= 9 g/cm3)
2. Workpiece Material: Steel (ρ= 7.8 g/cm3)

3. N° tools used in the last week = 5


4. Weight of a worn tool: 160 g
5. Weight of the new tool: 250 g

6. Weekly production of parts: 1000 (on 2 shift - 5 days)


7. Working Time per shift= 8 hours/shift
8. Active cutting time per shift = 5 hours/shift

Sol
Ntool=5
Nwp=1000
Tweek= N°shift*Tavail_shift*days_week=5*2*5=50 h / week
Vtot_wp= L*W*H= 5*1*0.1= 0.5 cm3 /worpiece
Twp= Tweek / Nwp =50 / 1000 = 0.05 h= 3 min /worpiece
MRRwp= Vtot_wp /Twp=0.1667 cm3/min = 166.7 mm3/min

Ttool= Tweek / Ntool =50 / 5 = 10 h = 600 min


W_tool wear= Wtool_new- Wtool_old= 250 – 160 = 90 g /tool
V_tool wear = W_tool wear / ρ_copper= 90 / 9 = 10 cm3 / tool
MRR tool = V_tool wear / Ttool = 10 / 600 = 0.01667 cm3 / min = 16.67 mm3/min

Basing on the graph:


MRR (cm3/h)
workpiece
Legend:
15 50 85 120 155 I=30A
I=20A

tool

12.5 20 27.5 35 42.5 t on [μs]


ton=20 μs and I=20 A
Therefore the correct answer is:

ton=20 μs, I =20A (MRR workpiece= 166.7 mm3/min)

Question 12
In Ultrasonic Machining (USM), with reference to the figure, which of the following sentences is
correct?

Q: Select the answers (multiple choices are possible)

- HSS, ruby and all other materials above the dashed line are good candidates for USM tools
- Brass, sapphire, graphite and all other materials below the dashed line have poor
machinability in USM
- Germanium is the material with the best machinability, among the listed ones
- Machining of quartz is less expensive than machining of agate
- HSS is the material with the best machinability, among the listed ones
- Mica is the best option for a tool material, among the listed ones

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