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Q1: 11.Identify the three sources of contraction in a metal casting after pouring (2').See Answer
Q2: 3. What is the mechanism by which carbon strengthens steel during heat treatment and quenching? (hint: martensite formation) (2')See Answer
Q3: Why are chemical stability and inertness important in cutting tools?See Answer
Q4: The accompanying illustration shows a cast-steel valve body (left) that is machined to the shape shown on the right. Identify the surfaces that are to be machined. What type of machine tool (Lathe, Drilling Machine, ... etc.) would be suitable to machine this part? What type of machining operations are involved and what is the sequence of these operations (try to present your answer using clear sketches). See Answer
Q5: Explain how you would go about producing a tapered shape on a workpiece by turning?See Answer
Q6: Determine the pump efficiency (ratio of power of pump and the input electric power) of an Electrokinetic pump consisting of a single straight microfluidic channel with a circular cross section, with the information provided below: The microchannel is etched in glass, and has a diameter of 80 µm and a length of 12mm. The electrical potentials at the inlet and outlet ports are 1200 V and 0 V, respectively. The viscosity, ŋ and relative dielectric constant, ɛ, of the liquid are 103 kg/m-sec and 78,respectively. The dielectric constant of vaccum is ɛo = 8.85x10-14 F/cm. Assume zeta potential, to be -38 mV. Assume the fluid is homogenous and the electrical impedance (resistance, R) of the filled channel is 1200 MQ.See Answer
Q7: Problem 2 (a): A mold has a down sprue of length = 6.0 in. The cross-sectional area at the bottom of the sprue is 0.5 in. The sprue leads into a horizontal runner that feeds the mold cavity, whose volume = 75 in. Determine (a) the velocity of the molten metal flowing through the base of the down sprue, (b) the volume rate of flow and (c) the time required to fill the mold cavity. Problem 2(b): The total solidification times of two casting shapes are to be compared: (1) a sphere with diameter = 1.0 in., (2) a cylinder with diameter and length both= 1.0 in. The same casting alloy is used both cases. (a) determine the relative solidification times for each geometry, (b) Based on the results of part (a), which geometric element would make the best riser? (c) If Cm = 18.0 min/in in Chvorinov's rule, compute the total solidification time for each casting. Use n=2.See Answer
Q8: Problem 3a: An RR robot has two links of length 0.75 m and 1.0 m, respectively. Assuming that the global coordinate system is defined at J1, determine the following: (a)The coordinates of the end-effector point if the joint rotations are 35 degrees at both joints as shown in the handout. (b)Joint rotations if the end-effector is located at (1.875, 0.45). Problem 3b: The telescopic arm of an industrial robot obtains its vertical motion by rotating about a horizontal axis. The total range of rotation is 90 degrees. The robot possesses a 12 bit storage capacity for this axis. When fully extended, the robot telescoping arm measures 45 in.from the pivot point. When fully retracted, the arm measures 25 in. from the pivot point.Determine (a) the robot's control resolution for this axis in degrees of rotation,(b) the robot's control resolution on a linear scale in both the fully extended and fully retracted position, (c) sketch the side view of the work volume for this axis.See Answer
Q9: A volume of 10 in. long, 5 in. wide and 0.5 in. thick is to be removed by a face milling cutter. The cutter is 3 in. diameter and has a six teeth. The maximum depth of cut is 0.3 in.Assume feed = 0.1 ipr and cutting speed = 200 fpm.What are the feed speed, spindle rpm and cutting time? The cutting force for turning a stainless-steel shaft using HSS tool can be predicted asFe = 150,000 f.80 a.0.95The recommended speed is 200 fpm and the feed is 0.03 ipr. The diameter of the work piece is 3inches and the final diameter is 2.8 in. The part is 4 in. long.A 10 hp motor is used to drive the machine, which has an efficiency of 0.85.What is the maximum depth of cut, based on the power-consumption constraint? How long will it take to finish the workpiece?See Answer
Q10: List and explain factors that contribute to poor surface finish in Machining processes.See Answer
Q11: 1.4(A) A machine tool is used to machine parts in batches. In one batch of interest, the starting piece is a casting that costs = $6,00 Each, Batch quantity = 30. The actual machining time in the operation=6.86 min. Time to load and unload Each work piece = 3.0 min. Cost of the cutting tool = $3.00, and E achtool must be changed every 10 pieces. Tool change time = 2.5 min. Setup time for the batch = 1.75 hr.Hourly wage rate of the operator = $15.00/hr, and the applicable labor overhead rate = 60%. Hourly equipment cost rate = $20.00/hr, which includes overhead. Assume availability = 100% and scrap rate =0.See Answer
Q12: (a) Make a flow chart for fabrication process of SINX membrane shown in picture (a). (b) If you want to make a 2 mm x 2 mm SİNX membrane, what is the opening area in back side? How long does it take to etch? (c) If you want to make a 2 mm x 4 mm SiNx membrane, what is the opening area in the backside? How long does it take to complete the etching? (d) If you want to keep 2 um thick Si film beneath the 2 mm x 2 mm SİNX membrane,what will you do? Give the etching time too.See Answer
Q13: 12.(A) (SI units) When casting low carbon steel under certain mold conditions, the mold constant in Chvorinov's rule = 4.0 min/cm^2. Determine how long solidification will take for a rectangular casting whose length = 30 cm, width =15 cm, and thickness= 20 mm. (2')See Answer
Q14: 13.(SI units) Total solidification times of three casting geometries are to be compared: (1) a sphere with diameter = 10 cm, (2) a cylinder with diameter and length both casting alloy is used in all three cases. (a) Determine the relative solidification times for each geometry. (b) Based on the results of part (a), which geometric element would make the best riser? (c) If the mold constant = 3.5 min/cm? in Chvorinov's rule, compute the total solidification time for each casting. (6')= 10 cm, and (3) a cube with each side = 10 cm. The sameSee Answer
Q15:Industry 4.0 (14.0) - principles and applications a) Describe the principles of Lean manufacturing (approx. 200 words) b) Describe the principles of i4.0 from manufacturing and business perspective (approx. 200-300 words)See Answer
Q16:Watch the video on manufacturing Lego blocks ("LEGO Bricks In The Making" by The LEGO group) https://www.youtube.com/watch?v=C30iy9eekzk a) List the manufacturing process chain from raw material (plastic granulate / pellets) to a box with a LEGO set. (an example of a manufacturing process chain is shown in Fig. 1) b) What elements of i4.0 Lego uses in their production line; how and why they make it efficient (100 words)See Answer
Q17:3. Watch the video on the Toyota plant (by Futurist Keynote Speaker Patrick Dixon) https://www.youtube.com/watch?v=rt65167tZIQ a) List and describe at least 2 LEAN and 2 industry 4.0 mentioned in the video (100- 200 words) b) List and describe at least 2 manufacturing processes shown in the video (approx.. 200 words)See Answer
Q18:Imagine you are a production engineer in a large production facility making electrical fittings. The facility has approx. 30 injection moulding machines with moderate level of automation, although not connected with each other and not fitted with sensors. Propose how you can modify the moulding machines to upgrade the factory floor to access the benefits of i4.0, also describing what these benefits are. (200-400 words)See Answer
Q19:2 state two main functions of a mould used in metal casting process 2 marksSee Answer
Q20:4 the cu ni phase diagram is shown below temperature c 1600 1500 1400 1300 1200 1100 1000 1 i t 1 1085 c 0 cu 8 20 20See Answer

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