1 - Solve problem 3.75 of your textbook by hand using the full tableau showing all steps. Verify your solution graphically

.Which ONE of the following surface treatments can achieve an RMS surface smoothness in the range of 1nm? A. Grinding B. Conventional polishing C. Sand/powder blasting D. Wet and dry paper hand polishing E. Chemical mechanical polishing

Problem 2: How much faster can you cook a potato in a convection oven versus a standard oven? Assume that the potato can be approximated as a cylinder with a diameter of 3 cm and length of 4 cm, with density p=950 kg/m^3, thermal conductivity k=0.8 W/m*K, and specific heat Cp=4.6 kJ/kg*K. The air temperature in both ovens is 190°C. and the potato starts at 20°C. (a) Assuming a convection coefficient of h=8 W/m^2*K in a standard oven, is it appropriate to use a lumped capacitance approach? Calculate the time required to heat the potato to a temperature of 140°C. (b) Assuming h=15 W/m^2*K in a convection oven, is the same approach still appropriate? Calculate the time required to heat to the same temperature.

4. The figure below is the equilibrium phase diagram of iron-carbon system. Assume a eutectoidaustenite steel with 0.77wt.% of carbon, and this austenite steel will completely transform topearlite steel if decreasing the temperature along xx' to 727 °C and kept for sufficient longtime. The pearlite steel is a mixture of ferrite and cementite. Answer the questions below. (10') (1) Please calculate the fractions of ferrite and cementite in the pearlite steel. (Hint: Ferrite has 0.02 wt.% of carbon, Cementite has 6.67 wt.% of carbon).(2) Assume a hypo eutectoid austenite steel with 0.22 wt.% of carbon, and this hypo eutectoid steel will completely transform to the mixture of ferrite and cementite as well, if decreasing the temperature along yy’ to 727 °C and kept for sufficient long time. Calculate the fractions of ferrite and cementite in the formed mixture.(3) Compare the phase fractions in solution (1) with solution (2), explain why the eutectoid steel is stronger than the hypo eutectoid steel.

10. Why is friction a factor in determining the ram force in direct extrusion but not a factor in indirect extrusion? (2')

1. Define the difference between elastic and plastic deformation in terms of the effect on the crystal lattice structure. (2')

* Focus on FM additive technologies (the one we use in the lab) A FM stands for fused deposition modeling.

(a) What are the different types of furnaces used for casting processes? Briefly describe them. (b) A part resembling a connecting rod is cast in sand. Porosity is found in the shank and cavities in the heads. Show with appropriate design sketches a remedy for the head and two possible remedies for the shank. Explain in few sentences each. (c) What is allotropic transformation? What are the results of shrinkage in a casting?

Production of manufactured goods falls into one of three types. State and describe each type, and give two specific examples (company & product) of a product for each type. For each example you give,explain why you think that particular company manufactures that product in that particular way.

Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the ‘Traditional approach’ is more intuitive and what approaches are needed to move toward a JIT scenario? (15 marks) b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented (15 marks) c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.