2.

810 Manufacturing Processes and Systems

Quiz #1
October 19, 2015
90 minutes
Open book, open notes, calculators, computers with internet off.
Please present your work clearly and state all assumptions.

Name: ______________________________

Problems:
1. How were these parts made?

/ 20 points

2. Viscoelastic behavior of medieval glass.

/ 15 points

3. Maximum extrusion rate for FDM.

/ 20 points

4. Sheet metal springback.

/ 25 points

5. Maximum material removal rate.

/ 20 points
__________
/ 100 points

Name: _________________________

Problem 1. How were these parts made? (20 points)

Please examine the four parts you have been given (due to limited quantities, you will need to share
the parts with other students, so please be considerate).
For each part, please write down your observations on:
a) what material(s) the part is made of;
b) the process(es) with which is was made (if multiple processes were used to make the
part, try to identify all of them).
Please explain the reasoning behind all of your answers. Answers without an explanation will not
receive full credit.
1. Pipe fitting
Material(s):
Reasons:

Process(es):
Reasons:

2. Window screen clip

Material(s):
Reasons:

Process(es):
Reasons:

Name: _________________________

3. Bushing
Material(s):
Reasons:

Process(es):
Reasons:

4. Screw anchor (half)

Material(s):
Reasons:

Process(es):
Reasons:

Name: _________________________

Problem 2. Viscoelastic behavior of medieval glass. (15 points)

It has been observed that the glass in the windows of ancient cathedrals in Europe is thicker on the
bottom than on the top. Some have speculated that this difference in thickness is due to gravity and
the viscous flow of glass over the approximately 800 years they have existed. Using the hypothetical
data and trend lines from the figure below, please use your knowledge of viscoelastic phenomena to
either support or reject this claim.
Note: The trend in the figure is hypothetical, so you should not use any knowledge you may already
have about this problem to influence your answer. There is, however, a calculation you have learned
that could help resolve this issue.

Name: _________________________

Problem 3. Maximum extrusion rate for Fused Deposition Modeling (FDM). (20 points)
Slide 29 from John Hart's presentation, reproduced below, shows the nozzle for the so-called Fused
Deposition Modeling (FDM) Additive Manufacturing process for thermoplastics. An ABS filament
approximately 1 mm in diameter is pushed through the heating zone (Zone I) where it melts, and is
then reduced in area for printing. We are concerned with the maximum rate at which plastic can be
pushed through this zone and still be guaranteed that the output is fully melted (at the point where it
enters Zone II).
Referring to the figure, assume the diameter of the heating zone is dl = 1.0 mm and its length is ll =
1.25 cm. Its walls are maintained at 260C with an electric resistance heater. Please make an
estimate for the maximum rate at which the ABS filament can be fed into the heating zone (in
meters/second).
Note: The chart from the textbook by Lienhard for conductive heat transfer in cylinders is given for
reference.

Name: _________________________

Transient temperature distributions in a long cylinder of radius ro at three positions.

r/ro = 0 is the centerline. (Lienhard, Fig 5.8)

Name: _________________________

Name: _________________________

Problem 4. Sheet metal springback. (25 points)

An engineer is building a bicycle frame from titanium (elastic modulus E = 103 GPa, yield strength
Y = 550 MPa) and needs to bend a 1.5 mm thick strip of titanium so that the resulting angle is =
60 degrees, as shown in the figure. The length of the arc formed by the bend must be s = 6 cm. He
knows he needs to overbend the strip in order to compensate for springback. Please approximate the
angle to which he should bend it initially.

h = 1.5 mm

= 60

Name: _________________________

Problem 5. Maximum material removal rate. (20 points)

Consider a very large Invar tool being built for curing a graphite epoxy composite (Invar is a high
temperature nickel alloy). To make this tool, approximately 3 x 106 cm3 of this material needs to be
removed by milling using a single 25 kW spindle.
(a) With the given spindle power limitations, estimate the shortest cutting time possible to remove
this material.

(b) Assume you are using a 4-tooth, 10 cm diameter milling cutter and the maximum general
purpose cutting conditions for high temperature nickel alloys (from your textbook). Assuming that
the depth of cut cannot exceed 6 mm, recalculate the shortest cutting time.