Module Code PRDT01C04

Final Examination
2011/2012

Module Title
Production Technology 2
Module Leader Semester
Iman El-Mahallawi Two
Equipment allowed
Non-programmable calculator

Instructions to Students

Answer FOUR QUESTIONS Only.

The exam paper is FOUR PAGES long, not including this page, with the
following content:
2 pages for questions, 1 page for needed data.
The allocation of marks is shown in brackets next to each question.
Write your answers in the answer book provided, not on the exam papers.
Submit exam paper with the answer book.

This examination is TWO hours long.

[Turn Over only when instructed to do so]

PRDT01C04 PRODUCTION TECHNOLOGY 2 Final Exam - May 2012

1
ANSWER Four OF THE FOLLOWING QUESTIONS:

Q1 Describe using sketches the following, emphasizing the fundamentals of the required
processes:
(a) Basic elements of a sand-casting processes. [10 marks]
(b) Flat rolling of billets to sheets annotating the work-piece-roll contact area and [10 marks]
relationships.
(c) Gating system requirements to fill the sand mould cavity. [5 marks]
[Total 25]

Q2 Give reasons for the following:

(a) Molten metal must be superheated above melting temperature before casting. [5 marks]
(b) Lubricants are used during cold forming processes. [5 marks]
(c) The final process for producing flat sheets is usually cold rolling. [5 marks]
(d) Lost wax method is preferred for producing fine intricate parts. [5 marks]
(e) Parts made from ceramic materials are made by powder metallurgy. [5 marks]
[Total 25]

Q3 A small foundry desires to produce 10 pieces of the cast iron cover plate shown in figure
(1).
(a) Suggest and describe the appropriate casting process giving reasons for [5 marks]
your suggestion.

(b) Calculate the diameter and suggest the location of required feeders (assume [10 marks]
feeding distance = 4t).

(c) Design a proper gating system using the following data: Pouring time [10 marks]
t=kW, K=0.8 for cast iron. Flow efficiency factor = 0.7. Density of cast
iron 7.2 g/cm3. Yield 60%. Gating ratio 1:1:1 for Cast Iron. Pouring level
200 mm above mould level. g= 980 cm2/sec. Make necessary assumptions to
proceed.
[Total 25]

2
 PRDT01C04 PRODUCTION TECHNOLOGY 2 Final Exam - May 2012

Q4 Suppose that you have been employed at a small rolling mill and you have
been assigned to produce 1000 tons of 5 mm thick flat sheets of AISI 1020
low carbon-steel . Knowing that the radius of the rolls on the line are 200
mm and that they rotate at 200 rpm, answer the following questions and
make necessary decisions:
(a) If you have two options for buying the raw material coil: 8 mm thick x 180 mm [5 marks]
wide, and 8 mm thick x 200 mm wide, which coil shall you buy and why?
(b) Estimate the flow stress needed at the beginning of the rolling process and at the [10 marks]
end using the equation =kn? Use the data supplied in Table (1).

(c) Estimate the roll force, F (= Contact area*Yaverage), and the power needed for
[10 marks]
producing the final product. Power (MN.m)= Force (MN)*L (m) / 2
Use figure (2) and table 1 to find missing data.

[Total 25]

Q5 You are asked to produce stepped reduction in a closed die forging process:
(a) Upon reviewing the process data sheet you have found that the instructions say [5 marks]
that the process is to be hot forging, what does this mean?

(b) Calculate the hot forging force (at beginning and end of process) needed for [10 marks]
reducing thickness of a cylindrical part made of 1020 steel that is 100 mm high
(h0) and 50 mm radius (r0) to 70 mm high considering the coefficient of friction
() be 0.2. F= Average stress * Contact Area * (1+2r/3h)
Use figure (2) and table (1) to find missing data.

(c) Illustrate a comparison using sketches between open and closed die forging and [10 marks]
industrial applications for each.

[Total 25]

3
 Fig. (1) Cover plate

Fig. 2 True stress true strain curves in tension at room temperature for various metals. (after S.
Kalpkjan; Manufacturing and Engineering technology, 2006).

4
Table (1): Typical values for K and n for some materials at RT. (after S. Kalpkjan; Manufacturing
and Engineering technology, 2006).

5
 Model Answer
ANSWER Four OF THE FOLLOWING QUESTIONS:

Q1 Describe using sketches the following manufacturing operations emphasizing the

fundamentals of the required processes:
(a) Basic elements of a sand-casting processes. [10 marks]
The answer should include: melting moulding core making pouring
breaking mould and fettling.
The student may use diagram or box sketches to show main steps and their
correlation to each other in terms of which comes first and where do they meet
such as melting and moulding being consequential and then they meet.
A perfect answer will briefly describe what is meant by each stage like melting
is done in furnaces of different sizes and energy sources moulding is making
the mould either expendable or permanent, the mould must include a cavity of
the required dimensions gating and feeding extra cavities are made of
designed sizes and attached to the ain cavity the core making operation
produces the cores which maintain the internal shape of the cavity.
(b) Flat rolling of billets to sheets annotating the work-piece-roll contact area. [10 marks]
The production of flat sections is done by rolling billets produced by continuous
casting between two rolls of specific diameters; the roll diameter is selected to
suit the width of the input material and accordingly the product. A contact area
is generated between the workpiece and the roll where this area is characterised
by a certain length L = square root R(h) and the width of the piece. The
conditions between the roll and the work piece is to promote the advance of the
rolled part in a forward direction, this is accompanied by a reduction in the
thickness of the work piece and an increase in the speed of the moving work
piece.
(c) Gating system requirements to fill the sand mould cavity. [5 marks]
The gating system should deliver the liquid metal to fill the mould cavity before
the completion of the solidification process and thats why the pouring rate
should be fast, yet the pouring rate shouldnt be too fast to promote turbulence
of the molten metal. Thats why the gating system consists of a pouring basin, a
down sprue and a chock area followed by a runer and ingates to control the
speed of the molten metal as it enters the cavity. The most important issue is to
discuss how the speed of the molten metal is controlled via the area design of
the different parts of the system.

Q1 Give reasons for the following:

(a) Molten metal must be superheated above melting temperature. [5 marks]
The student need to refer to the following; Fluidity size of casting distance
between moulds and the melting section.
(b) Lubricants are used during cold forming processes. [5 marks]
6
 The student should discuss the friction generated between the tool or die and the
work piece and how lubricants are effective in reducing the friction coefficient
and accordingly reducing the load needed for the process.
(c) The final process for producing flat sheets is usually cold rolling. [5 marks]
The student should discuss the advantages of cold working on producing cleaner
surface, better dimensional control, and homogeneous thickness.
(d) Lost wax method is preferred for producing fine intricate parts. [5 marks]
Because it is difficult to produce removable patterns for such parts and the only
way is to get rid of the pattern by another mean rather than mechanical
removing which is melting in this case. Also a complete answer will refer to the
good surface quality produced by the moulding slurry used in lost wax method.
(e) Parts made from ceramic materials are made by powder metallurgy. [5 marks]
Because of their high melting point which make them unsuitable for casting, and
brittleness which make them unsuitable for metal forming.
[Total 25]

Q3 A small foundry desires to produce 10 pieces of the cast iron cover plate shown in figure
(1).
(a) Suggest and describe the appropriate casting process giving reasons for your [5 marks]
suggestion.
Based on the simple shape and the small number of pieces the student should
select sand casting. The student should describe the casting process not in a
general form but exactly for this part describing the pattern and following
moulding steps.
(b) Calculate the diameter and suggest the location of required feeders (assume
feeding distance = 4t).
Modulus of cover plate = V/ SA
Volume = 350x150x15 = 787500 mm3
Surface Area = (350+150)*2*15 + 350*150*2 = 120000 mm2
Modulus = 6.5625
Modulus of feeder = 1.2 * 65.625 = 7.875
Diameter of feeder = 6* 7.875 = 48 mm
Assume feeding distance = 4*t = 4*15 = 60 mm, number of feeders will be
350/n+1 = 60 n +1 = 6 n = 5 [10
marks]
Design a proper gating system using the following data:
(c)
Pouring time t=kW (kg) , K=0.8 for cast iron.
Flow efficiency factor = 0.7. [10 marks]

7
 Density of cast iron 7.2 g/cm3.
Yield 60%.
Gating ratio 1:1:1 for steel.
Pouring level 200 mm above mould level.
g= 980 cm2/s
Assume any missing data you need.
Weight of casting = 787500 mm3 / 1000 =787.5 cm3 * 7.2 g/ cm3= 5670 g =
5.67 kg
Considering yield = 9.5 kg
Pouring time = 0.89.5 kg = 2.5 s
Chock area = weight / density * 2gh *C = 9500 / 7.2* 2*980*20 = 9.5/1425.5
= 6.7 cm2
Area of runners = 6.7 cm2
area of ingates = 6.7 cm2
Best solution 2 runners and multiple ingates across the length.
[Total 25]

Q4 Suppose that you have been employed at a small rolling mill and you have
been assigned to produce 1000 tons of 5 mm thick flat sheets of AISI 1020
low carbon-steel . Knowing that the radius of the rolls on the line are 200
mm and that they rotate at 200 rpm, answer the following questions and
make necessary decisions:
(a) If you have two options for buying the raw material coil: 8 mm thick x 180 mm [5 marks]
wide, and 8 mm thick x 200 mm wide, which coil shall you buy and why?
I will chose 180 mm since the roll diameter is 200 mm. the reason is to avoid
spreading which will cause the width to increase and it will not be desired that
the width exceeds the diameter of the roll.
(b) Estimate the flow stress needed at the beginning of the rolling process and at the [10 marks]
end using the equation =kn? Use the data supplied in Table (1).
At the beginning of the process, the flow stress = 220 MPa from the figure.
At the end by using =kn = ln 8/5 = 0.47 =530 * 0.470.26 = 435.5 MPa
the rolling force = the flow stress * the contact area = 435.5 MPa * LRh =
220*200*(8-5) = 5389 MN

(c) Estimate the roll force, F (= Contact area*Yaverage), and the power needed for
[10 marks]
producing the final product. Power (MN.m)= Force (MN)*L (m) / 2
Use figure (2) and table 1 to find missing data.
The rolling force will be estimated by finding the average flow stress =
(220+435.5)/2 = 328 MPa the rolling force = the flow stress * the contact area =
220 MPa * LRh = 328*200*(8-5) = 8035 MN

8
 [Total 25]

Q5 You are asked to produce stepped reduction in a closed die forging process:

(a) Upon reviewing the process data sheet you have found that the instructions say [5 marks]
that the process is to be hot forging, what does this mean?
Hot forging means deformation above the recrystallistion temperature.

(b) Calculate the hot forging force (at beginning and end of process) needed for [10 marks]
reducing thickness of a cylindrical part made of 1020 steel that is 100 mm high
(h0) and 50 mm radius (r0) to 70 mm high considering the coefficient of friction
() be 0.2. F= Average stress * Contact Area * (1+2r/3h)
Use figure (1) and table (1) to find missing data.
At beginning F= 220 * (50)2 /4 * 100 (1+2 * 25 * 0.2 / 3 * 100)
At end F= flow stress at end * (final diameter)2* 70 (1+2 * 0.5 final diameter
* 0.2 / 3 * 70)
To find flow stress at the end calculate = ln 100/70 = 0.36
=530 * 0.360.26 = 406 MPa
To find final diameter use constancy of volume relationship final area =
(50)2/4 * 100 / 70 = 2805 mm3
Final diameter = 60 mm
At end F= 406 * (60)2/4 * 70 (1+2 * 0.5 * 30 * 0.2 / 3 * 70) =

(c) Illustrate a comparison using sketches between open and closed die forging and [10 marks]
industrial applications for each.

[Total 25]