EMG 4102 MATERIAL FORMING PROCESSES EXAM (Revised) - Printready

DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY
University Examinations 2019/2020 Academic Year
FOURTH YEAR SECOND SEMESTER EXAMINATION FOR THE DEGREE

OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING
EMG 4102: MATERIAL FORMING PROCESSES
DATE: 4TH DECEMBER 2019 TIME: 2.00 PM – 4.00 PM
INSTRUCTIONS
i. This examination contains FIVE questions.
ii. Attempt question ONE and any other TWO.
QUESTION ONE (30mks)

a) Explain the THREE types of centrifugal casting (6mks)
b) Using a neat sketch, explain in details the working principle of a flat rolling process
(4mks)
c) A continuous hot rolling mill has two stands. Thickness of the starting plate =25 mm
and width =300 mm. Final thickness is to be 13 mm. Roll radius at each stand =250
mm. Rotational speed at the first stand = 20 rev/min. Equal drafts of 6 mm are to be
taken at each stand. The plate is wide enough relative to its thickness that no increase
in width occurs. Under the assumption that the forward slip is equal at each stand,
determine
i. Speed vr at each stand (3mks)
ii. forward slip, S. (2mks)
iii. Also, determine the exiting speeds at each rolling stand, if the entering speed
at the first stand =26 m/min (1mk).
d) Highlight FOUR ways which can be used to reduce the roll force during rolling
(2mks)
e) What is the difference between shell mould casting and investment casting? (2mks)
f) Describe any THREE types of additives that are used in polymer processing to alter
their properties (6mks)
Page 1 of 4
g) What is the function of the following parts in a sand casting process?
i. Riser (1mk)
ii. Core (1mk)
h) Highlight FOUR advantages of die casting (2mks)
QUESTION TWO (20mks)
a) Mention FOUR factors that affect fluidity (2mks)

b) Explain FIVE qualities of a good sand mold (5mks)
c) Explain the difference between hot rolling and cold rolling and give two advantages
of each process? (5mks)
d) A 42.0-mm-thick plate made of low carbon steel is to be reduced to 34.0 mm in one
pass in a rolling operation. As the thickness is reduced, the plate widens by 4%. The
yield strength of the steel plate is 174 MPa and the tensile strength is 290 MPa. The
entrance speed of the plate is 15.0 m/min. The roll radius is 325 mm and the rotational
speed is 49.0 rev/min. Determine
i. The minimum required coefficient of friction that would make this rolling
operation possible, (1mk)
ii. Exit velocity of the plate (2mks)
iii. Forward slip (2mks)
e) Highlight any FOUR advantages of cold extrusion over hot extrusion process as a
bulk forming process (4mks)
QUESTION THREE (20mks)
a) With neat sketches describe in detail the difference between direct and indirect
extrusion processes and mention one limitation of each processes (5mks)
b) A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect
(backward) extrusion to a 20 mm diameter. The die angle is 90o. The Johnson
equation has a= 0.8 and b=1.4, and the flow curve for the work metal has a strength
coefficient of 800 MPa and strain-hardening exponent of 0.13. Determine
i. Extrusion ratio (1mk)
ii. True strain (homogeneous deformation) (1mk)
iii. Extrusion strain (1mk)
iv. Ram pressure (1mk)
v. Ram force. (1mk)
Page 2 of 4
c) The total solidification times of three casting shapes are to be compared: a sphere, a
cylinder, (in which the length-to-diameter ratio =1.0), and a cube. For all three
geometries, the volume =1000 cm3. The same casting alloy is used in the three cases.
i. Determine the relative solidification times for each geometry. (6mks)
ii. Based on the results of part (i), which geometric element would make the best
riser? (1mk)
iii. If the mold constant = 3.5 min/cm2 in Chvorinov’s rule, compute the total
solidification time for each casting (3mks)
QUESTION FOUR (20mks)

a) An injection moulding machine has two units: injection unit and clamping unit.
Mention two functions of each unit (4mks)
b) Describe any THREE defects associated with the metal extrusion process (3mks)
c) Explain any FOUR types of defects experienced in metal casting (4mks)
d) Explain the TWO problems associated with turbulence in metal casting process (2mk)
e) In principle, what is the difference between cold-chamber die casting and hot-
chamber die casting. Mention at least two types of alloys that are cast in each of the
process
(4mks).
f) Describe any THREE defects that are observed in a drawing process (3mks)
QUESTION FIVE (20mks)
a) A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an
opening that is to 2.1 mm. The entrance angel of the die is 18° degrees. Coefficient of
friction at the work-die interface is 0.08. The work metal has a strength coefficient of
450 MPa and a strain hardening coefficient of 0.26. The drawing is performed at room
temperature. Determine:
i. Area reduction (2mks)
ii. Draw stress (3mks)
iii. Draw force required for the operation (1mk).
b) Describe the THREE main classifications of polymers (6mks)
c) Injection moulding and extrusion are the most widely used shaping process in
polymer processing. In each process, describe THREE design considerations that
apply (6mks)
Page 3 of 4
d) State any FOUR defects observed in injection molded parts (2mks)
Page 4 of 4

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DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

University Examinations 2019/2020 Academic Year

FOURTH YEAR SECOND SEMESTER EXAMINATION FOR THE DEGREE

EMG 4102: MATERIAL FORMING PROCESSES

DATE: 4TH DECEMBER 2019 TIME: 2.00 PM – 4.00 PM

QUESTION ONE (30mks)

QUESTION TWO (20mks)

a) Mention FOUR factors that affect fluidity (2mks)

QUESTION THREE (20mks)

QUESTION FOUR (20mks)

QUESTION FIVE (20mks)

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