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14.What is hardness?
Resistance to permanent indentation
Good hardness generally means material is resistant to scratching and wear
15.Which of the following are the three basic types of static stresses to which a material can
be subjected (three correct answers): (a) compression, (b) hardness, (c) reduction in area,
(d) shear, tensile, (f) true stress, and (g) yield?
16.If stress values were measured during a tensile test, which of the following would have
the higher value: (a) engineering stress, or (b) true stress?
17.Which one of the following types of stress-strain relationship best describes the
behaviour of brittle material such as ceramics: (elastic and perfectly plastic, b) elastic and
strain hardening, (c) perfectly elastic, or (d) none of the above?
18.Most hardness tests involve pressing a hard object into the surface of a test specimen
and measuring the indentation that results: (a) true, or (b) false?
19.Viscosity can be defined as the ease with which a fluid flows: (a) true, or (b) false?
20.Define the density as a material property.
Density = weight per unit volume
21.Explain with aid of sketches the difference between melting characteristics between a
pure metal element and an alloy. Temp alloy
temp
pure
Time
Time
22.In heating of most metal alloys, melting begins at a certain temperature and concludes at
a higher temperature. In these cases, which of the following temperatures marks the
beginning of the melting: (a) liquidus , or (b) solidus?
23.What is the effect of the temperature on the mechanical properties such as; strength,
hardness and ductility?
Strength and hardness decrease and ductility increase
ductility
temp
25. What is the range of carbon percentages which defines an iron-carbon alloy as steel?
0.2
26. What is the effect of the carbon percentage on the mechanical properties of steel?
Strength and hardness increase and ductility decrease
ductility
27. Which of the following properties or characteristics are inconsistent with the metals (
two correct answers): (a) good thermal conductivity, (b) high strength, (c) high electrical
resistivity , (d) high stiffness, or ionic bonding?
28. Which of the following alloying elements are most commonly associated with stainless
steel (two best answers): (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e)
tungsten?
29. By the aid of schematic drawing, show the basic elements of the sand casting mold.
30. What are the three types of heats that are associated with heating the metal to molten
temperature sufficient for casting?
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal
34. A casting with a higher volume-to-surface area ratio cools and solidifies more (a) quickly,
or (b) slowly than one with a lower ratio.
35. Patternmakers account for solidification shrinkage and thermal contraction by making
mold cavity size (a) bigger, (b) smaller than that of the final product.
36. The riser must be designed to freeze (a) before, (b) after the main casting in order to
satisfy its function.
40. What are the two main functions of the rotating rolls?
Pull move and pressing.
41. Define with aid of sketches blanking and punching as shear metal cutting process.
Blanking - sheet metal cutting to separate piece (called a blank) from surrounding
stock
Punching - similar to blanking except cut piece is scrap, called a slug
42 With aid of sketch, explain the relation between the punch diameter and the die size in shear
metal cutting.
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50- What are the two basic categories of cutting tools in machining? Give two example of
operations that use each of the tooling types.
The two categories are :(1) single-point tools, used in operations such as turning and boring
(2) multiple-edge cutting tools, used in operations such as milling and drilling
51 -Define the Machining process with aid of sketches. What are the advantages and
disadvantages of this process.
Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
52- Define the turning process with aid of sketches. What are the applications of turning?
Single point cutting tool removes material from a
rotating work piece to form a cylindrical shape
53- Define the drilling process with aid of sketches. What are the applications of drilling?
Creates a round hole in a work part
Compare to boring which can only enlarge an existing hole
Cutting tool called a drill or drill bit
Machine tool: drill press
Uses a consumable electrode consisting of a filler metal rod coated with chemicals that
provide flux and shielding.
57A group of welding processes that use a combination of heat and pressure to accomplish
coalescence.
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-Both use filler metals to permanently join metal parts, but there is no melting of base
metals
-When to use brazing or soldering instead of fusion welding:
Metals have poor weld-ability
Dissimilar metals are to be joined
Intense heat of welding may damage components being joined
Geometry of joint not suitable for welding
High strength is not required
61-
Filler metal Tm greater than 450C (840F) but less than Tm of base metal(s) to be
joined.
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80Explain compression molding, blow molding and injection molding in terms of; definition,
schematic drawings and applications.
Blow Molding
Molding process in which air pressure is used to inflate soft plastic into a mold cavity
Applications:
Important for making one-piece hollow plastic parts with thin walls, such as bottles
Injection Molding:
Polymer is heated to a highly plastic state and forced to flow under high pressure into a
mold cavity where it solidifies and the molding is then removed from cavity
Applications:
Compression Molding
Applications:
A widely used molding process for thermosetting plastics.
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