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IME 450 Manufacturing Process and Tool Engineering Winter 2015

Homework #1

Due: Beginning of class Tuesday, January 13.

Refer to notes and Chapters 3, 4, 6, 13, and 26 in Groover 5th ed. to answer the following
questions using a separate sheet of paper.
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2.
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6.
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8.
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See Section 26.2 (and internet sources) and read about ferrite, cementite,
austenite, bainite, pearlite, and martensite:
a) What is the composition and microstructure of ferrite?
b) Which form is unstable at room temperature (i.e., exists only at high
temps)?
c) Which form of steel is the hardest?
d) Which is not really steel but a ceramic carbide compound?
e) Which form has a Body Centered Tetragonal (BCT) structure?
f) Which is a form of steel produced with the slowest cooling rate?
g) What cooling strategy produces a needle or feather-like mixture of ferrite
and Fe3C?
See section 6.2 (or internet sources) and explain the primary compositional
difference between type 440 and type 430 stainless steel, and state how it
affects the general processing and properties of these two.
Use the density of tin at room temperature (20oC) given in Table 4.1 in the text
to estimate its density at 230oC, just prior to melting. Note that the coefficient
for thermal expansion is defined for linear dimensions only.
Use Table 4.2 to determine the amount of energy (J) needed to raise the
temperature of a plate of tin as in the previous problem. Assume the plate is
inch thick and measures 6 x 10 inches.
Use the internet to find the heat of fusion for tin and give the total energy (J)
required to melt (from room temperature) the tin plate in the previous
problem. Also determine how long it would take with a 90% efficient, 10
kilowatt furnace.
List at least five elemental metals that could be cast in an iron (steel) die
casting mold. See Chapter 4 and/or 6.
Consider 7075-T4 aluminum in Section 6.3.
a) What is the major alloying element in this type of aluminum?
b) What kind of strengthening (tempering) treatment has been applied?
c) How does its strength compare to typical aluminums (e.g. 6061-T6)? Note
that our mold blocks will be made of this alloy.
Degree of Polymerization of a polymer is the average number of monomer
chains in each molecule (see 8.1). How does the Degree of Polymerization
affect the strength properties and processing characteristics for the polymer?
Consider the discussion of linear, branched, or cross-linked polymers in
sections 8.1.2 and 8.1.3.
a) Which general types of polymers form a cross-linked structure?
b) Which type of structure tends to form crystals: linear, branched, or crosslinked?
c) Which type of stereoregularity (i.e., tactic arrangements) tends to form the
most crystalline structure?
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IME 450 Manufacturing Process and Tool Engineering Winter 2015

10.

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Two different polypropylene blends have been used in the lab for molding.
One is described as highly crystalline (96%), while the other has a low crystal
structure (45%). How would you expect these two polymers to behave
differently
a) during molding (i.e. considering melting temperature, viscosity)?
b) as functional parts (i.e., considering density, strength, stiffness, thermal
resistance, opacity)?
Consider thermoplastic polystyrene as described in Chapter 8 Section 8.2:
a) What is its chemical formulation?
b) What engineering components or applications is it used for?
c) What is its density and stiffness? Is it clear?
d) What are its glass transition and melting temperatures?
e) Compare its strength to HDPE and polypropylene.
From Section 13.1, explain what makes a fluid a Newtonian fluid and describe
how typical polymer melts differ from Newtonian fluids.
Problem 3.30 on page 81 in Groover 5th ed.
Problems 6.5 on page 158 in Groover 5th ed.
Problem 6.6 on page 158 in Groover 5th ed.

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