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2017 – 2018

Mechanical Engineering Department


Mid semester examination, III rd semester
Manufacturing Technology I (ME214)
Total Time = 1 hour Symbols have usual meanings. Max. Marks = 25

1. (a) Compare no bake moulding process and sodium silicate moulding process
in metal casting. 3

Soln. No bake moulding:


Sand is mixed with a chemical binder (furan or urethane) /catalyst system.
Molded similar to green sand mould. After a specified period of time (from as
little as 10 sec to as long as the foundry requires depending upon mold size),
the sand mixture hardens. Cores etc are located.

Sodium silicate (Carbon dioxide) moulding:


Sand mixture is prepared as Green sand mmolding. However, liquid silicate
(e.g. sodium silicate, Na 2 SiO 3 ) is used as binder. Molded similar to green sand
mould. After molding, carbon dioxide gas is blown through the mould. The
molding mixture gets hardened. Cores etc are located.

1. (b) Develop a relation between the diameter and the height of a cylindrical
top riser. 3
𝜋𝜋
Soln. Volume of riser = v = 4 𝑑𝑑 2 ℎ where d/ h = diameter/height of riser
4𝑣𝑣
𝜋𝜋ℎ = 2
𝑑𝑑
Radiation is through curved surface and only top surface of the top riser.
𝜋𝜋 4𝑣𝑣
Surface area = A = 4 𝑑𝑑 2 + 𝑑𝑑 𝑑𝑑 21
𝑑𝑑𝑑𝑑 π 4𝑣𝑣
𝑑𝑑𝑑𝑑
= 2 d − 𝑑𝑑 2 = 0
π
Or, 2 d − 𝜋𝜋ℎ = 0
𝑑𝑑 = 2ℎ; h = d/2
1. (c) Design a top riser for 1.2 m x 1.0 m x 0.8 m mould cavity. The material of
the casting is aluminium with coefficient of linear solid shrinkage 2% and
coefficient of linear liquid shrinkage 2.5%. Compare the solidification time of
the molten metal in the top riser and molten metal in the mould cavity.
Modify the dimension of the riser if required. 4

Soln. Shrinkage in the cavity = v s = 3 x 0.025 x (1.2 x 1.0 x 0.8) m3

Volume of riser = v = 3 x v s =

3 8𝑣𝑣 3 3 x 0.025 x (1.2 x 1.0 x 0.8)


d = 2h = � 𝜋𝜋 = � 𝜋𝜋
= 0.24 m

Solidification time:
𝑣𝑣 𝑛𝑛
𝑡𝑡 = 𝑘𝑘 � �
𝐴𝐴

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𝜋𝜋 2 2
𝑑𝑑 ℎ𝑣𝑣
𝑡𝑡𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = � 4
𝜋𝜋 2 � if k = 1 & n = 2
𝑑𝑑 +𝜋𝜋𝜋𝜋 ℎ
4

𝜋𝜋 2 𝑑𝑑 2
𝑑𝑑 ( )𝑣𝑣 𝑑𝑑
=� 4
𝜋𝜋 2
2
𝑑𝑑 � = 6 = 0.04
𝑑𝑑 +𝜋𝜋𝜋𝜋 ( )
4 2

1.2 x 1.0 x 0.8 2


𝑡𝑡𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = �2x{1.2 x 1.0+1.2 x 0.8+1.0 x 0.8}� = 0.026

𝑡𝑡𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 > 𝑡𝑡𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

Hence, the dimension of riser is efficient.

1. (d) Compute the buoyancy force acting on the cope.


Assume the weight density of liquid aluminium = 0.265 N/cm3. 3

Soln. Assuming the height of the sprue equal to the height of riser and let 1.2 x 1.0
be the top surface of the cavity, the buoyancy force acting on the cope is
1.2 x 1.0 (x 0.12)x 0.265 x 106= 38.16 kN
2. (a) Discuss the use of lubricant in forging operation. Give examples. 3

Soln.

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2. (a) Derive a relation to show that friction affects the rolling process. Relate
the radius of roll and the draft. 4

Soln. Let N = force at the entry normal to the surface


F r = tangential friction force
For an unaided entry of the work-piece in the roll:
F r cosα –Nsinα ≥ 0
While
F r = µN (Coulomb friction)
Where
µ = co-efficient of friction = tan β
β = angle of friction
Hence
Tan β ≥ tan α
Β≥α
Hence, angle of friction should be more than or equal to the angle of bite for
an unaided rolling.

Draft = ∆h = ho – hf
= 2 (R – R cos α)
= 2R (1 - cos α)
=Rα2
Where
1-cos α = 2 sin2 (α /2)
And, α ≈ 0
2. (c) Compute the number of passes required to roll 20 mm thick 1112
annealed steel to 2.4 mm thick without applying any axial force.

Assume roll diameter = 200 mm and coefficient of friction between the roll 3
material & the steel = 0.2

Soln. For unaided rolling:


Maximum Draft = ∆h = h o – h f
=Rα2
=100 x {tan-1(0.2)}2 = 3.9 mm
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Number of passes = (20 – 2.4)/3.9 = 4.5 ≈5 passes

2. (d) Discuss alligatoring defect of rolled products. 2

Soln. During rolling the sheet splits into two or more number of layers. The is
known as alligatoring. It results from inhomogeneous deformation of the
material during rolling or from defective cast ingot (such as piping).

OR

2’. (a) Derive the magnitude of the maximum reduction per pass while drawing a
cylindrical metal specimen. 3

Soln. During drawing the drawing stress can’t exceed tensile stress of the material.

𝐴𝐴𝑖𝑖
𝜎𝜎𝑑𝑑 = 𝑌𝑌𝑌𝑌𝑌𝑌 � � = 𝑌𝑌
𝐴𝐴𝑓𝑓

𝐴𝐴𝑖𝑖
𝑙𝑙𝑙𝑙 � �=1
𝐴𝐴𝑓𝑓
𝐴𝐴𝑖𝑖
= 𝑒𝑒
𝐴𝐴𝑓𝑓
𝐴𝐴𝑖𝑖 −𝐴𝐴𝑓𝑓 1
Maximum reduction/pass = =1− = 0.63 = 63%
𝐴𝐴𝑓𝑓 𝑒𝑒

2’. (b) Calculate minimum number of passes required to draw 25 mm diameter


6061-O aluminium alloy specimen to 8.0 mm wire. 3

Soln. 𝐴𝐴 𝑖𝑖 𝑑𝑑 𝑖𝑖2
Dimension after 1st pass = = = 𝑒𝑒
𝐴𝐴 𝑓𝑓 𝑑𝑑 12
𝑑𝑑𝑖𝑖 25
𝑑𝑑1 = = = 15.16 𝑚𝑚𝑚𝑚
√𝑒𝑒 √2.72
15.16
Dimension after 2nd pass = = 9.12 mm
√𝑒𝑒
9.12
Dimension after 3rd pass = = 5.57 mm
√𝑒𝑒
Minimum 3 passes.
Alternate solution:
𝐴𝐴𝑖𝑖 𝑑𝑑𝑖𝑖2 𝑑𝑑12
= 𝑥𝑥 𝑥𝑥 … . = 𝑒𝑒 𝑛𝑛
𝐴𝐴𝑓𝑓 𝑑𝑑12 𝑑𝑑22

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𝐴𝐴 𝑑𝑑 2 25 2
𝑛𝑛 ≥ 𝑙𝑙𝑙𝑙 �𝐴𝐴 𝑖𝑖 �= 𝑙𝑙𝑙𝑙 �𝑑𝑑 𝑖𝑖2 � = 𝑙𝑙𝑙𝑙 � 82 � = 2.3
𝑓𝑓 𝑓𝑓
Minimum 3 passes
2’. (c) Compute the force required to draw the above specimen in the first and
the last pass. For computing flow stress, assume K and n from the Table 1
given below. 4

Soln. Drawing force in 1st pass:

252
𝜀𝜀1 = 𝑙𝑙𝑙𝑙 � �=1
15.162

𝐾𝐾𝜀𝜀 𝑛𝑛 205𝑥𝑥10.2
Ȳ= = = 170.83𝑃𝑃𝑃𝑃
𝑛𝑛 + 1 0.2 + 1
𝐴𝐴𝑖𝑖 𝜋𝜋
𝐹𝐹 = Ȳ𝐴𝐴𝑓𝑓 𝑙𝑙𝑙𝑙 � � = 170.83𝑥𝑥 𝑥𝑥15.162 x1 = 30835.6 MN
𝐴𝐴𝑓𝑓 4

Drawing force in 3rd Pass:


9.12 2
𝜀𝜀1 = 𝑙𝑙𝑙𝑙 � 2 � = 0.262
8
𝐾𝐾𝜀𝜀 𝑛𝑛 205𝑥𝑥0.2620.2
Ȳ= = = 130.7 𝑀𝑀𝑀𝑀𝑀𝑀
𝑛𝑛 + 1 0.2 + 1
𝐴𝐴𝑖𝑖 𝜋𝜋
𝐹𝐹 = Ȳ𝐴𝐴𝑓𝑓 𝑙𝑙𝑙𝑙 � � = 130.7𝑥𝑥 𝑥𝑥82 x0.262 = 1721.3 MN
𝐴𝐴𝑓𝑓 4
2’. (d) Discuss direct and indirect extrusion. 2

Soln. In direct extrusion direction of extrusion force and the direction of extruded
part is same. Moreover, the whole specimen in the extrusion chamber
moves. Energy if required to overcome thus the friction force.

In indirect extrusion direction of extrusion force and the direction of


extruded part is opposite. Moreover, the whole specimen in the extrusion
chamber does not move. Thus, the specimen need not to work against the
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friction force.

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Table 1. Values for K and n at room temperature.

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