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Q1: 2) [6 points] Calculate the annual savings in gasoline and Ib CO, that would result from switching from a 19 mpg truck to a 34 mpg car. Assume the vehicle is driven 9,500 miles per year. (Note: the combustion of 7.5 gal of gasoline generates 150 lb of CO2).See Answer
Q2: Determine the shape factors for particles of the following ideal shapes: (a) sphere, (b) cubic. (4') (Hint:K, = AD/V, where A, V are the surface area and volume of your particles, D is the diameter of a sphere with equivalent volume to your particle)9.See Answer
Q3: 7. What are the three processing steps in precipitation hardening? (2')See Answer
Q4: 8. Identify some of the important advantages of shape-casting processes. (2')See Answer
Q5: 11.Identify the three sources of contraction in a metal casting after pouring (2').See Answer
Q6: 3. What is the mechanism by which carbon strengthens steel during heat treatment and quenching? (hint: martensite formation) (2')See Answer
Q7: 2. What is the difference between full annealing and normalizing? (2')See Answer
Q8: Why are chemical stability and inertness important in cutting tools?See Answer
Q9: The accompanying illustration shows a cast-steel valve body (left) that is machined to the shape shown on the right. Identify the surfaces that are to be machined. What type of machine tool (Lathe, Drilling Machine, ... etc.) would be suitable to machine this part? What type of machining operations are involved and what is the sequence of these operations (try to present your answer using clear sketches). See Answer
Q10: List the methods by which cutting fluids are applied in actual machiningoperations.f turningfdrilágSee Answer
Q11: Can cutting fluids have any adverse effects? If so, what are they?See Answer
Q12: How would you go about measuring the effectiveness of cutting fluids?See Answer
Q13: What are the major properties required of cutting-tool materials?See Answer
Q14: Explain how you would go about producing a tapered shape on a workpiece by turning?See Answer
Q15: Determine the pump efficiency (ratio of power of pump and the input electric power) of an Electrokinetic pump consisting of a single straight microfluidic channel with a circular cross section, with the information provided below: The microchannel is etched in glass, and has a diameter of 80 µm and a length of 12mm. The electrical potentials at the inlet and outlet ports are 1200 V and 0 V, respectively. The viscosity, ŋ and relative dielectric constant, ɛ, of the liquid are 103 kg/m-sec and 78,respectively. The dielectric constant of vaccum is ɛo = 8.85x10-14 F/cm. Assume zeta potential, to be -38 mV. Assume the fluid is homogenous and the electrical impedance (resistance, R) of the filled channel is 1200 MQ.See Answer
Q16: Titanium-nitride coatings on tools reduce the coefficient of friction at the tool-chip interface. What is the significance of this?See Answer
Q17: Why does temperature have such an important effect on the life of cuttingtools?See Answer
Q18: Problem 3a: An RR robot has two links of length 0.75 m and 1.0 m, respectively. Assuming that the global coordinate system is defined at J1, determine the following: (a)The coordinates of the end-effector point if the joint rotations are 35 degrees at both joints as shown in the handout. (b)Joint rotations if the end-effector is located at (1.875, 0.45). Problem 3b: The telescopic arm of an industrial robot obtains its vertical motion by rotating about a horizontal axis. The total range of rotation is 90 degrees. The robot possesses a 12 bit storage capacity for this axis. When fully extended, the robot telescoping arm measures 45 in.from the pivot point. When fully retracted, the arm measures 25 in. from the pivot point.Determine (a) the robot's control resolution for this axis in degrees of rotation,(b) the robot's control resolution on a linear scale in both the fully extended and fully retracted position, (c) sketch the side view of the work volume for this axis.See Answer
Q19: Problem 2 (a): A mold has a down sprue of length = 6.0 in. The cross-sectional area at the bottom of the sprue is 0.5 in. The sprue leads into a horizontal runner that feeds the mold cavity, whose volume = 75 in. Determine (a) the velocity of the molten metal flowing through the base of the down sprue, (b) the volume rate of flow and (c) the time required to fill the mold cavity. Problem 2(b): The total solidification times of two casting shapes are to be compared: (1) a sphere with diameter = 1.0 in., (2) a cylinder with diameter and length both= 1.0 in. The same casting alloy is used both 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 Cm = 18.0 min/in in Chvorinov's rule, compute the total solidification time for each casting. Use n=2.See Answer
Q20: Problem 4a: Describe the two RP processes - Fused Deposition Modeling (FDM) and Stereo lithography Apparatus (SLA) based on (1) the process (in some details), (2) the energy source, (3) work volume, (4) material, (5) costs, (6) advantages and (7) disadvantages. Problem 4b: Describe briefly with figure one of the four AM of metals processes you have studied. What are the post processing methods you can consider for the process you have just selected?See Answer

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