BASIC MANUFACTURING PROCESS

ASSIGNMENT-II

1. What is the difference between the traditional ceramics and the new ceramics, as
far as raw materials are concerned?

2. List the basic steps in the traditional ceramics processing sequence.

3. What happens to a ceramic material when it is sintered?

4. What is glazing in traditional ceramics processing?

5. What are some design recommendations for ceramic parts?

6. What is an autoclave?

7. What is the sequence of processing steps required to produce finished rubber

goods?

8. Name the four basic categories of processes used to shape rubber.

9. What are the three basic steps in the manufacture of a pneumatic tire?

10. What are some of the reasons why plastic shaping processes are important?

11. What are the different Fiber Orientations? Explain with neat figures.

12. What is a ceramic and list some examples?

13. Are ceramics brittle in nature if so, explain with a neat figure their behavior due
to different loading?

14. Define how ceramics are classified and give at least two examples for each?

15. Define a composite material and describe different types of composites?

16. What are components in a composite explain them in detail?

17. Describe how fibers are oriented in composites with a neat sketch?

18. Name the two basic categories of casting processes.

19. What properties determine the quality of a sand mold for sand casting?

20. What are some of the general defects encountered in casting processes? Name and
briefly describe them by a neat sketch.

21. True centrifugal casting is performed horizontally to make copper tube sections.
The tubes have a length = 1.0 m, diameter = 0.25 m, and wall thickness = 15 mm.
(a) If the rotational speed of the pipe = 700 rev/min, determine the G-factor on the
molten metal. (b) Is the rotational speed sufficient to avoid "rain?" (c) What volume
of molten metal must be poured into the mold to make the casting if solidification
shrinkage and solid thermal contraction for copper are = 4.5% and = 7.5%,
respectively (both are volumetric contractions

22. Identify some of the important advantages of shape-casting processes.

23. What is the relationship known as Chvorinov's rule in casting?

24. Identify the three sources of contraction in a metal casting after pouring.

25. The length of the downsprue leading into the runner of a mold = 200 mm. The
cross-sectional area at its base = 400 mm2. Volume of the mold cavity = 0.0012
m3. Determine (a) velocity of the molten metal flowing through the base of the
downsprue, (b) volume rate of flow, and (c) time required to fill the mold cavity.

26. A disk-shaped part is cast out of aluminum. Diameter of the disk = 650 mm and
thickness = 16 mm. If the mold constant = 2.2 sec/mm2 in Chvorinov's rule, how
long will it take the casting to solidify?

27. In casting experiments performed using a certain alloy and type of sand mold, it
took 170 sec for a cube-shaped casting to solidify. The cube was 50 mm on a side.
(a) Determine the value of the mold constant in Chvorinov's rule. (b) If the same
alloy and mold type were used, find the total solidification time for a cylindrical
casting in which the diameter = 50 mm and length = 50 mm.
28. Total solidification times of three casting geometries are to be compared: (1) a
sphere with diameter = 10 cm, (2) a cylinder with diameter and length both = 10
cm, and (3) a cube with each side = 10 cm. The same casting alloy is used in all
three cases.
(a) Determine the relative solidification times for each geometry.
(b) Based on the results of part (a), which geometric element would make the best
riser?
(c) If the mold constant = 3.5 min/cm2 in Chvorinov's rule, compute the total
solidification time for each casting.

29. Solidification involves the transformation of the molten metal back into the solid
state. The solidification process differs depending on whether the metal is a pure
element or an alloy.
(a) How does solidification of alloys differ from solidification of pure metals?
(b) Define Chvorinov’s rule and explain it.

30. A mold has a downsprue of length = 6.0 cm. The cross-sectional area at the bottom
of the sprue is 0.5 cm2. The sprue leads into a horizontal runner which feeds the
mold cavity, whose volume = 75 cm3.
(a) Determine the velocity of the molten metal flowing through the base of the
downsprue,
(b) The volume rate of flow
(c) The time required to fill the mold cavity.

31. Molten metal can be poured into the pouring cup of a sand mold at a steady rate
of 1000 cm3/s. The molten metal overflows the pouring cup and flows into the
downsprue. The cross section of the sprue is round, with a diameter at the top =
3.4 cm. If the sprue is 25 cm long, determine the proper diameter at its base so as
to maintain the same volume flow rate.

32. A mold sprue is 20 cm long, and the cross sectional area at its base is 2.5cm². The
sprue feeds a horizontal runner leading into a mold cavity whose volume is
1560cm³.
(a) Determine the velocity and volumetric flow rate of the molten metal flowing
through the base of the downsprue.
(b) Determine the time required to fill the mold cavity.
(c) What will happen to the time required to fill the mold cavity if the cross-sectional
area at the base of the downsprue is decreased? Explain your answer.