Professional Documents
Culture Documents
MEE20005
MEE20005
MEE20005
1 1 mark
2 1 mark
3 1 mark
4 1 mark
5 1 mark
6 1 mark
7 1 mark
8 1 mark
9 1 mark
10 2 marks
11 2 marks
12 2 marks
13 1 mark
14 1 mark
15 1 mark
16 2 marks
17 2 marks
18 8 marks
19 2 marks
20 2 marks
21 1 mark
22 2 marks
23 1 mark
24 1 mark
25 2 marks
26 1 mark
27 2 marks
28 2 marks
29 2 marks
30 2 marks
QUESTION 1. [1 mark]:
Figure 1 below relates Young’s Modulus to Density. Choose the most appropriate alternative from
the list below.
A. The area identified as ‘B’ belongs to the class of metals.
B. The area identified as ‘C’ belongs to the class of ceramics.
C. The area identified as ‘A’ belongs to the class of metals.
D. The area identified as ‘F’ belongs to the class of ceramics.
E. The area identified as ‘A’ belongs to the class of composites.
F. The area identified as ‘B’ belongs to the class of foams.
B
A
C
F
Figure 1
QUESTION 2. [1 mark]:
According to the AISI-SAE designation for steels, the 4140 steel refers to:
A. Plain carbon alloy steel with 0.40% carbon (1XXX)
B. Cr-Mo alloy steel with 0.40% carbon
C. Plain carbon alloy steel with 4.00% carbon
D. Cr-Mo alloy steel with 4.00% carbon
E. Plain carbon alloy steel with 0.41% carbon
F. Cr-Mo alloy steel with 0.41% carbon
QUESTION 3. [1 mark]:
Figure 2 relates to physical, intrinsic properties of various materials. Parts (A) and (B) relate to two
different properties. The horizontal scales are only indicated for reference purposes. Choose the
most appropriate alternative from the list below.
A. Part (A) refers to the tensile strength of the materials.
B. Part (A) is the ratio of the tensile strength to density of the materials.
C. Part (B) refers to the tensile strength of the materials.
D. Part (B) is the ratio of the tensile strength to density of the materials.
E. Part (B) relates to the absolute electrical conductivity of the materials.
F. None of the above are correct.
A B
Figure 2
QUESTION 4. [1 mark]:
Figure 3 relates to 4 different classes of materials and their Young’s modulus. Refer to the
horizontal axis that is labelled “Type of Material”. Choose the most appropriate alternative from the
list below.
A. Material 1 belongs to the class of materials identified as “polymers”.
B. Material 1 belongs to the class of materials identified as “metals”.
C. Material 1 belongs to the class of materials identified as “ceramics”.
D. Material 2 belongs to the class of materials identified as “metals”.
E. Material 2 belongs to the class of materials identified as “ceramics”.
F. Material 2 belongs to the class of materials identified as “composites”.
Figure 3
QUESTION 5. [1 mark]:
Figure 4 relates to a primary shaping process that is employed for a polymer-based material.
Several components of this device have not been identified. Choose the most appropriate alternative
from the list below.
A. Part A is the location where powder is injected into the device.
B. Part A is a heater that removes residual stresses.
C. Part B is the location where powder is injected into the device.
D. Part B is a segmental sleeve to add strength to the cylinder.
E. Part C is a component that allows the powder to be injected into the mold.
F. Part D is the location where powder is injected into the device.
A
Moul D
Granular
Nozzle
Cylinder
B
Heat C
Scre
Figure 4
A. The slag reaction during the refinement of steel ore involves the reaction of CaO, SiO2
and Al2O3.
B. The slag reaction during the refinement of steel ore involves the reaction of CaO and
CO2.
C. The slag reaction during the refinement of steel ore involves the reduction of iron oxide
to iron.
D. Heat in a blast furnace is generated by electrical energy from a plasma reaction.
E. The slag reaction occurs outside the furnace when the molten iron is recovered.
F. None of the above are true.
QUESTION 6. [1 mark]:
The diagram, Figure 5, shows five positions (A, B, C, D, and E) on a phase diagram that give rise
to the 5 different phase microstructures (1, 2, 3, 4, and 5).
Choose the microstructure that is most appropriate for Region C.
A. The most appropriate microstructure is 1.
B. The most appropriate microstructure is 2.
C. The most appropriate microstructure is 3.
D. The most appropriate microstructure is 4.
E. The most appropriate microstructure is 5.
F. The most appropriate microstructure is not shown in this figure.
Figure 5
QUESTION 7. [1 mark]:
Determine the approximate phase compositions (not “proportions”) that are present for the alloy 20
wt% Ag – 80 wt% Cu at a temperature of 800°C in Figure 6.
Cα CL Cβ
A. 8 wt% Ag 68 wt% Ag None
B. 68 wt% Ag 18 wt% Ag None
C. 79 wt% Ag 21 wt% Ag None
D. 68 wt% Ag 18 wt% Ag 12% wt% Ag
E. 18 wt% Ag None 98 wt% Ag
F. None of the above options
Figure 6
QUESTION 8. [1 mark]:
Refer to the iron-carbon phase diagram below (Fig.7) and select the most appropriate answer from
the list below. The maximum solid solubility of carbon in iron at the eutectoid temperature is:
A. 4.3 wt% carbon
B. 0.022 wt% carbon
C. 0.76 wt% carbon
D. 0.22 wt% carbon
E. 0.076 wt% carbon
F. None of the above
Figure.7
QUESTION 9. [1 mark]:
Determine the phases that are present for the alloy 15 wt% Sn – 85 wt% Pb at temperature of 275°C
in Figure 88.
A. α
B. β
C. α + β
D. γ
E. α + L
F. None of the above options
Figure 8
Consider a water-sugar binary phase containing dissolved sugar and undissolved sugar mixture. The
concentration of dissolved sugar can be increased by:
A. Removing undissolved sugar from the solution
B. Increasing the temperature of the solution and adding more sugar
C. Cooling the solution
D. Adding sugar to the solution when the solution is at its maximum solid solubility
E. Adding salt to the solution
F. None of the above are viable methods.
Suppose that a steel as shown in Figure 9 is cooled to 650°C from 760°C in less than 0.5 seconds
and held at this temperature. What is the minimum time it take for the austenite – pearlite reaction
to go to 100% completion?
A. 1 second
B. 15 seconds
C. 150 seconds
D. 1500 seconds
E. 15000 seconds
F. None of the above options
Figure 9
Given the Time-Temperature paths on the isothermal transformation diagram in Figure 10, what
are the final microstructures after each of the cooling paths?
1 2 3 4
A. Austenite Martensite Bainite Pearlite and Bainite
B. Austenite and Martensite Martensite and Fine pearlite
Martensite Bainite
C. Martensite Austenite Coarse pearlite Fine pearlite
D. Austenite Tempered Cementite Martensite
martensite
E. Austenite Bainite Martensite Tempered martensite
F. None of the above options
Figure 10
The question concerns grey cast iron. Choose the most appropriate alternative from the list below.
A. Grey cast iron consists only of pearlite and ferrite.
B. Grey cast iron is harder than white cast iron.
C. Grey cast iron has better machinability than ductile iron.
D. Grey cast iron has all the carbon in the form of graphite.
E. Grey cast iron should not be used under compression or wear conditions.
F. Grey cast iron is very difficult to machine.
The iron-carbon phase diagram in Figure 17 shows a 0.45%C hypoeutectoid plain-carbon steel
slowly cooled from 950°C to a temperature just slightly above 723°C. Calculate the weight percent
austenite and weight percent proeutectoid ferrite in this steel. Choose the correct alternative from
the table.
Austenite Ferrite
A. 40% 60%
B. 45% 55%
C. 55% 45%
D. 98% 2%
E. 60% 40%
F. None of the above options
Figure 17
Refer to the Fe-C diagram and set of microstructures below Figure 8, match the final
microstructure (1,2, and 3) to the correct location on the Fe-C diagram (A to E), under slow cooling
rate. (Hint: The answer is unique when the eutectoid phase is identified.)
B D
A C E
Figure 9 shows the microscope images of bainite and martensite microstructures. With reference to
Figure 10, choose the most appropriate statement that best describe these microstructures.
A. Microstructure 1 is martensite and is produced by Line 4
B. Microstructure 2 is bainite and is produced by Line 1
C. Microstructure 2 is bainite and is produced by Line 2
D. Microstructure 1 is martensite and is produced by Line 3.
E. Microstructure 1 is bainite and is produced by Line 4.
F. None of the above.
1 2
Figure 9
Figure 10
Suppose that a steel of eutectoid composition as shown in Figure 11 is cooled to 675°C from 760°C
in less than 0.5 seconds and held at this temperature for a long time. Once the reaction is complete,
which of the following will be the resulting microstructure:
A. Fine Pearlite
B. Coarse Pearlite
C. Bainite
D. Martensite
E. Tempered Martensite
F. Spherodite
Figure 115
This question refers to precipitation hardening. Select the most appropriate statement from those
provided below.
A. The alloy must be heated to a temperature below the solvus line into the “alpha + beta”
phase region and held for a period sufficient to dissolve the beta phase
B. The alloy is heated to a temperature above the solvus line into the alpha phase region and
held for a period sufficient to dissolve the beta phase
C. The alloy must be quenched to room temperature so that precipitates can form in the solid
solution.
D. The alloy is heated to a temperature below the solvus to cause precipitation of
coarse particles of the beta phase.
E. The alloy is heated to a temperature above ~ 725°C to cause precipitation of fine particles of
the beta phase.
F. The martensite phase is formed and this gives rise to the improved mechanical properties.
Figure 12 below represents a surface hardening process. Select the process from the alternatives
listed.
A. Magnetic hardening.
B. Flame hardening and quench.
C. Induction hardening.
D. PVD by means of induced currents.
E. Strain hardening by compression.
F. Thermal spray under a vacuum system.
Figure 12
The following statements refer to welding processes. Which one of these statements is considered
as an advantage of welding?
A. Impossible to dissemble joints without destroying detail parts.
B. Unbalanced heat input leads to distortion or residual stresses.
C. Heat of welding degrades base properties.
D. Joints of exceptional structural integrity that will not accidently loosen or dissemble.
E. Requires considerable operator skill.
F. An expensive process that requires a significant capital outlay
Refer to Figure 13 below and pick the best alternative for the list below.
A. Part (a) of the figure represents a butt joint.
B. Part (b) of the figure represents a lap joint.
C. Part (c) of the figure represents a tee joint.
D. Part (d) of the figure represents an edge joint.
E. None of these are butt joints.
F. Parts (a), (b), (c) and (d) all represent various forms of edge joints.
Figure 13
Figure 148 refers to a casting operation. Select the most appropriate statement from those presented
below.
A. The artefact indicated as ‘c’ represents a ‘core’.
B. The artefact indicated as ‘e’ represents the ‘riser’.
C. The artefact indicated as ‘a’ represents the ‘cope’.
D. The artefact indicated as ‘a’ represents the ‘drag.
E. The artefact indicated as ‘g’ represents the ‘parting line.
F. The artefact indicated as ‘j’ represents a ‘riser’.
Figure 148
Figure 159 below shows the influence of chill blocks or no chill blocks on a casting that has
geometry in the shape of an inverted ‘T’. Which two schematics are most representative of a good
casting operation?
A. Sub-figure A.
B. Sub-figure B.
C. Sub-figure C.
D. Sub-figure D.
E. Sub-figure E.
F. Sub-figure F.
Figure 159
Figure 16 indicates various casting defects. Which of these schematics is representative of a defect
that is known as a ‘cold shut’?
A. Sub-figure A.
B. Sub-figure B.
C. Sub-figure C.
D. Sub-figure D.
E. Sub-figure E.
F. Sub-figure F.
Figure 16
Choose the most appropriate alternative from the list below. In foundry work, a runner is which one
of the following:
A. A channel in the mould that leads from the downsprue to the main mould cavity.
B. Jargon that describes a foundryman who moves the molten metal to the mould.
C. A vertical channel into which molten metal is poured into the mould.
D. A part of the mould that is designed to allow gases to escape during the casting process.
E. A term to describe when molten metal escapes from the mould cavity.
F. An insert that is placed inside the mould cavity to assist in preferential cooling within the
mould.
The following question refers to the feature of a casting that is called “the riser”. Choose the TWO
most appropriate answers from the list below. [Note: 1 mark is subtracted for each incorrect
answer.]
A. A blind riser is completely enclosed within the sand mould and connected to the main cavity
by a channel to feed the molten metal.
B. An open riser is completely enclosed within the sand mould and connected to the main
cavity by a channel to feed the molten metal.
C. A side riser is completely enclosed within the sand mould and connected to the main cavity
by a channel to feed the molten metal.
D. A top riser is completely enclosed within the sand mould and connected to the main cavity
by a channel to feed the molten metal.
Question 1: [8 marks]
In an orthogonal cutting test with a tool of rake angle 10, the following observations were made:
Chip thickness ratio = 0.3, horizontal component of the cutting force = 1290 N, vertical component of the
cutting force = 1650 N.
From the Merchant’s theory, calculate:
(a) shear plane angle (1 mark)
(b) shear force along the shear plane and normal force on the shear plane (2 marks)
(c) friction force along rake face and normal force on the rake face (2 marks)
(d) coefficient of friction between the tool and chip, and friction angle, and (2 marks)
(e) resultant cutting force, R (1 mark)
(f) shear plane angle from the relation suggested by Merchant, and compare with the shear angle found in
(a) , find the relative error. (2 marks)
You may find the following formulae useful in attempting this question:
a)
b) e)
c) f)
d)
i. iii.
ii. iv.
(b) What are the two main functions of a cutting fluid in machining? (2 marks)
i.
ii.
(c) Explain why plain carbon steels show a rapid loss of their hot hardness, and what effect does it have
on the selection of cutting speed? (2 marks)
(d) What is the Merchant equation and what does this equation tell us about? (2 marks)
(e) Briefly discuss the influence of increasing shear plane angle, on cutting force, shear force,
power and temperature. (2 marks)
Question B3 [8 marks]
(a) Besides good accuracy and precision, what are the desirable attributes and features of a measuring
instrument? (2 marks)
(b) Give two common instruments used for angular measurement of a mechanical component.
(2 marks)
b) Why would you choose a cylindrical coordinate robot for the application based on your answer in part (b)
above? (2 marks)
Fig B4.
c) Five through holes (No:1 to 5) are to be machined dry on an aluminium workpiece with a diameter of
80 mm (see Figure B4) and the holes are located 3 mm away for the edge. The diameter of the HSS
cutter is 10.0 mm jobber drill. It is known that the overall plate thickness is 20 mm thick. The spindle
home position is located at the centrelines of AC and BD which is marked “O” and is 30 mm above
the top surface of the plate. The recommended cutting speed and the feed is listed in Table 1. Write
a complete NC program to machine the 5 holes starting from Hole 1 through to Hole 5 using an
absolute programming system based on the standardised system of codes (G and M codes are
provided on the last page of the booklet). Note: Angle AOB is in first quadrant of Cartesian
coordinate system. All the holes are equally spaced within the each quadrant.
N10
N20
N30
N40
N50
N60
N70
N80
N90
N100
N110
N120
N130
N140
N150
N160
N170
N180
N190
N200
N210
N220
N230
N240
N250
N260
N270
N280
Primary Exam, Semester 2 – 2016 Page 30 of 32
Swinburne University of Technology {MEE20005}
Faculty of Science, Engineering and Technology {Materials and Manufacturing 1}
(c) What is the purpose of using Statistical Process Control (SPC) in a mass production environment?
(1 marks)
(d) What are the three types of noise factors found in a manufacturing environment? (3 marks)
i)
ii)
iii)