Kingdom of Saudi Arabia ‫اململكة العربية السعودية‬

Ministry of Education ‫وزارة التعليم‬

Qassim University ‫جامعة القصيم‬
Unaizah College of Engineering ‫كلية اهلندسة بعنيزة‬

Subject: Manufacturing Processes

Code: ME 335
Semester: 411 (1441/2019)
Exam/Test Type: First Midterm
Time: 90 min

Student Name:…… ………………‫…………………………………منوذج إجــــابة‬.

Student ID No.:………………Model Answer……………………………

Marks Notes
Questions
Allocated Obtained Outcomes Percentage
1 23 5.3

2 21 4.85

3 21 4.85

Total 15

Instructions:
1. Attempt in All questions.
2. Your answer should be clear and well organized.
3. Pencil is not allowed
4. Answer questions using blue or black ink
5. Every sheet must include the name and ID of the candidate
Subject: Manufacturing Processes Code: ME 335 Semester 392

(Question 1) (23 points)

(a) State factors affected in choosing the casting method. (3 points)
- Melting temperature of the cast material
- Castings Size - Castings complicity - Number of castings
- Required surface finish - Cost

(b) The molten metal into the riser should be solidified at certain time after that in
the cavity. Explain. (2 points)

- This is in order to feeding the casting during solidification to compensate its

shrinkage.

(c) State the affected parameters of solidification rate for casting. (3 points)

- Mold material - Thermal properties of casting metal

- Pouring temperature relative to melting point
- Fluidity of the molten metal
- Castings volume - the projected area of the casting
- Heat transfer ratio

(d) What is meant by the term superheat? What is its importance in casting
operations? (5 points)

- Superheat is the temperature difference above the melting point at which the molten
metal is poured.
- Superheating refers to the amount of heat that is removed from the molten metal
between pouring and solidification. Therefore, it is important to keep its fluidity
during pouring.

(e) Which die casting machines usually have a higher production rate, cold-chamber
or hot-chamber, and why? (4 points)

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

- Hot chamber; because the furnace is a part of the machine and the molten
metal is not handled.

(f) Compare between direct and indirect extrusion processes. (6 points)

Item Direct extrusion Indirect extrusion

Alternative name Foreword Backward or reverse

Sketch Drawing

Force direction with

The same Opposite
respect to metal exit
Length of product Long Short
Friction Force Higher Lower
Ram Higher strength Lower strength
Mounted at the opposite end of
Die mounted to the ram
the container

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

(Question 2) (21 points)

(a) A rolling operation reduces a 25 mm thick plate to 17 mm in two equal passes.
The starting plate is 200 mm wide. Roll radius = 200 mm and rotational speed =
12 rev/min. The work material has a strength coefficient = 600 MPa and a strain
hardening coefficient = 0.22. Determine:
(i) roll force, (ii) roll torque, and (iii) power required for each pass. (9 points)

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

(b) A hot upset forging operation is performed in an open die. The initial diameter of
the workpart is 25 mm, and height of 50 mm. The part is upset to a diameter = 50
mm. The work metal at this elevated temperature yields at 85 MPa. Coefficient of
friction at the die-work interface = 0.40. Determine:
(i) final height of the part, and (ii) maximum force in the operation. (5 points)

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

(c) A true centrifugal casting operation is to be performed in a horizontal

configuration to make cast iron pipe sections. The sections will have a length =
42.0 in., outside diameter = 8.0 in, and wall thickness = 0.50 in. If the rotational
speed of the pipe = 500 rev/min, determine the G-factor. Is the operation likely
to be successful? (1 inch = 25.4 mm). (4 points)

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

(b) State the affected parameters of drawing process. (3 points)

- Lubrication type - reduction (drawing) ratio

- Metal properties (hardness, ductility, ….) - Die material
- Drawing force

(c) (21 points)

a) Indicate the following sentences with ( ) or (), then correct the false one
(15 points)
i. The function of the riser is to compensate the shrinkage in molten metal during

solidification. ( )

ii. On a high extrusion ratio, it is preferred to use one die opening. () multi

iii. The extrusion pressure is higher at the beginning of the process than that at the end.

( )

iv. The billet inlet temperature is affected by the extrusion speed and pressure. ( )

v. The cold working produces a high residual stresses. ( )

vi. The rolling can be done if tan α (bite angle) larger than the coefficient of friction (µ).

() less

vii. At the neutral plane of the rolling, the friction is maximum. () zero

viii. Coefficient of friction in rolling depends on lubrication, work material, and working

temperature. ( )

ix. The strain hardening exponent (n) is high for hot working. () zero

x. The rolled metal is slower at inlet than at the exit. ( )

Student Name:………………………………… Student ID:……………………………………..

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Subject: Manufacturing Processes Code: ME 335 Semester 392

b) Choose the correct answer (3 points)

i) In sand casting, the volumetric size of the pattern is which of the following
relative to the cast part?

- Bigger - same size - smaller.

ii) The production of tubing is possible in ………… extrusion process(es).

- direct - indirect - either

c) Fluidity in casting is influenced by some factors; state these factors. (3 points)

1- Characteristics of Molten Metal: (Viscosity; Surface tension; Inclusions and
Solidification pattern of the alloy)
2- Casting Parameters (Mold design; Mold material; Degree of superheat; Rate of
pouring; Heat transfer and Castability)

End of Exam Paper

Student Name:………………………………… Student ID:……………………………………..

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