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Derive the following equations: (1) (2) (3) = e(1 + e) = ln(1 + e) n = ultimate
Proof (1): Due to volume constancy: Ao.Lo = A.L A/Ao = Lo/L By definition e = (L-Lo)/Lo = L/Lo - L/L e = L/Lo - 1 e = Ao/A - 1 Ao/A = e + 1 By definition = ln(L/Lo) = ln(Ao/A) = ln(e + 1) [Eqn 3.8 on page 45 in your textbook] Proof (2): Due to volume constancy: Ao.Lo = A.L A/Ao = Lo/L By definition e = F/Ao = F/A / e = Ao/A = e + 1 = e (e + 1) [Eqn 3.9 on page 45 in your textbook] Proof (3): During a tensile test, the load increases until the ultimate point, where the necking starts. Due to volume constancy: Ao.Lo = A.L A/Ao = Lo/L
Finding E, K, and n on the true stress-strain diagram. Remember And = E. in the elastic range (Hookes Law) = K.n in the plastic range (Power Law)
Then we can write: Log = Log E + Log in the elastic range Log = Log K + n. Log in the plastic range Using the force-length readings after a tensile test, first calculate and values. Then calculate and plot Log and Log values. It should look as follows: Log E Log = Log E + Log Log Log K
Slope=n
Log = 0
Extrapolate Log = Log E + Log and read the Log value for Log = 0. At that point = E. Extrapolate Log = Log K + n. Log and read the Log value for Log = 0. At that point = K. On Log = Log k + n. Log , the slope of the line = n.
ME 3263 Manufacturing Engineering - Chp 1 Supplemental Documents PROBLEMS Problem #1 A tensile test uses a test specimen that has a gage length of 50 mm and an area = 200 mm2. During the test the specimen yields under a load of 98,000 N. The corresponding gage length = 50.23 mm. This is the 0.2 percent yield point. The maximum load = 168,000 N (ultimate) is reached at a gage length = 64.2 mm. Determine: (a) engineering and true yield strength, (b) modulus of elasticity, and (c) engineering and true tensile strength (ultimate point). Problem #2 A certain steel alloy has a yield strength of 372 MPa (54,000 psi) and modulus of elasticity of 207 GPa (30 X 106 psi). A specimen made from this steel has a rectangular cross section of 13 X 13 mm (.5 X .5 in.). A gage length of 100 mm (4 in.) is marked along the length of the specimen. Calculate the following using Engineering Stress-Strain relationship. (a) A 45 kN (10,000 lb) load is applied to the specimen and then removed from it. What is the gage length when the load is applied, and what is it after the load is removed? (b) What load would produce a stress in the specimen equal to the yield strength? (c) Under the yield load, what would be the gage length of the specimen? Assume 0.2% offset yield. (d) After removal of the yield load, what would be the gage length of the specimen? Assume 0.2% offset yield. Problem #3
e = 98,000/200 = 490 MPa (eng) Area at yield = 50*200/50.23 = 199.08 mm2 = 98,000/199.08 = 492.3 MPa (true) Note that e and are very close. e = E.e or = E. Subtracting the 0.2% offset, e = (50.23 - 50.0)/50.0 - 0.002 = 0.0026 E = /e = 490/0.0026 = 188.5 x 103 MPa (eng)
(b)
= ln(1+e) = ln(1 + 0.0026) = 0.00259 = E. 492.3 MPa = E . (0.00259) E = 492.3/0.00259 = 189.6 x 103 MPa (true) Note that Eng stress-strain values are always below the True stress-strain values; therefore, Eng is safer. e-ultimate = F_ult / Ao = 168,000/200 = 840 MPa (eng) Volume constancy: Ao.Lo = Au.Lu Area at ultimate pt = 50*200/64.2 = 155.76 mm2 ultimate = 168,000/155.76 = 1078.58 MPa (true) Note that Eng stress-strain values are always below the True stress-strain values; therefore, Eng is safer. (c)
(b)
(c)
Self Study Questions (Try these questions either as a team or by yourself without looking at the answers first)
Q1. A test specimen in a tensile test has a gage length of 2.0 in and an area = 0.5 in2. During the test the specimen yields under a load of 32,000 lb. The corresponding gage length = 2.0083 in. This is the 0.2 percent yield point. The maximum load = 60,000 lb is reached at a gage length = 2.60 in. Determine: (a) yield strength Y, (b) modulus of elasticity E, (c) tensile strength TS, (d) determine the percent elongation at ultimate point, and (e) If the specimen necked to an area = 0.25 in2, determine the percent reduction in area. Q2. A specimen with a starting gage length = 125.0 mm and cross-sectional area = 62.5 mm2 has been tested on a tensile test machine. Two force-length readings, when the specimen was in the plastic zone before necking, are F=23042 N for L=131.25 mm and F=28913 N for L=147.01 mm. Assuming uniform elongation at these two data points, determine the strength coefficient K and strain hardening exponent n. Q3. A copper wire of diameter 0.80 mm reaches an area reduction of 75% in a uniform manner when the engineering stress = 248.2 MPa. Determine the true stress and true strain at this point.
ME 3263 Manufacturing Engineering - Chp 2 Supplemental Documents Finding the dimensions of a fit (i.e., tolerances and limiting dimensions on a shaft and a hole) ANSI Given: Basic Size and Class of Fit
1- Allowance Equation (Remember d = Holemin_d and Allowance = Holemin_d - Shaftmax_d ) 2- Tolerance on the Hole 3- Tolerance on the Shaft 4- Limiting Dimensions on Hole and Shaft Use the dimensions in the table above as heights of blocks Block H Block a Block S
ISO Given: Basic Size and Application 1- Determine the type of the fit such as H8/f7
Specifying TolerancesISO
(Basic Size)
(Basic Size)
EMgt Fit diagram for SHAFTS ISO 324 Fundamentals of Manufacturing - Dr. C. Saygin
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ME 3263 Manufacturing Engineering - Chp 2 Supplemental Documents 2- Read the tolerance value from the tolerance tables (1/1000 mm)
3- Calculate the limiting dimensions (d_min, d_max) on the shaft and hole
2) Find limiting dimensions (S_min, S_max, H_min, H_max) of the fit for a basic size of 2.0000 inches and a Class of 5 (ANSI). 3) Find limiting dimensions (S_min, S_max, H_min, H_max) of the fit H7/h6 of for a nominal size of 52 mm (ISO). Based on ISO classification, what type of a fit is it?
VERNIER CALIPER
(1)
(2)
(3)
(4)
(5)
MICROMETER
(6)
(7)
(8)
(9)
(10)
(11)
(12)
---- Ref: http://www.phy.uct.ac.za/courses/c1lab/vernier1.html ----
ANSWERS
(1) 121.68 mm (2) 8.10 mm (3) 30.88 mm (4) 34.60 mm (5) 40.00 mm (6) 7.72 mm (7) 0.29 (8) 3.09 mm (9) 3.46 (10) 3.56 mm (11) 5.80 mm (12) 7.38
ME 3263
Manufacturing Engineering Dr. Can Saygin
Chp 4 Manufacturing Processes
Supplement
True Strain = ln
Ao 1 = ln Af 1 r
True Stress = Y f . = Y f . ln
Ao Af
Draw Force:
F = A f d = A f Y f (1 +
= F.v
tan
) ln
Ao Af
Draw Power:
Process Feasibility Maximum true strain max = n + 1 True strain attempted must be less than (or equal to) maximum true strain
a in 2nd Edition In 3rd and 4th Editions instead of a c = Ac.t See Table 20.1 for Ac
8
Ac
10
11
12
Volume of Material To be Removed Material Removal Rate = ___________________________________ Machining Time to Remove the Volume
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14
PERIPHERAL MILLING
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FACE MILLING - 1
16
FACE MILLING 2
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ME 3263 Chp 4 Power Specific Cutting Energy Material Removal Rate: Turning versus Milling
In turning, the uncut chip cross-sectional area stays constant. Therefore, we can calculate the material removal rate at chip level as MRR = d.f.v . Since the chip cross-section f.d stays constant, Specific Cutting Energy for turning can be calculated as U = Fc/f.d . Then: Power = U.MRR = (Fc/f.d).(dfv) Power = Fc. v However in milling, the chip thickness, while the cutter is in contact with the workpiece, varies. Therefore, MRR = dfv is not accurate for milling. We calculate the material removal rate for milling more accurately at the level of projected area of cut as MRR = w.d.fr . Power for milling can then be calculated as P = U.MRR or P = U.(w.d.fr)
Given: blanking part in Figure P22.4 from half-hard stainless steel, t = 5/32 in. Find dimensions of blanking punch and die.
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6/15/2010
= 10/300 = 0.0333
= (0.0333)0.5 = 0.1826 (b) Plate widens by 2%. t0 w0 v0 = tf wf vf wf = 1.02 w0 40 (w0) (16) = 30 (1.02 w0) vf vf = 40 (w0) (16) / 30 (1.02w0) = 640/30.6 = 20.915 m/min (c) s = (vf - vr) / vr = (20.915 - 18.5) / 18.5 = 0.13 Solution 21.23: Indirect Extrusion Given: indirect extrusion, L0 = 3.0 in., D0 = 1.5 in., Df = 0.375 in., = 90o, Johnson equation: a = 0.8 and b = 1.5, flow curve: K = 75,000 lb/in2. and n= 0.25. Find: (a) rx, (b) , (c) x, (d) p, (e) F, (f) P at v = 20 in/min. (a) rx = A0/Af = D02/Df2 = (1.5)2 / (0.375)2 = 16.0 (b) = ln rx = ln 16 = 2.773 (c) x = a + b ln rx = 0.8 + 1.5 (2.773) = 4.959 (d) Yfaverage = 75,000 (2.773)0.25 / 1.25 = 77.423 lb/in2. p= 77,423 (4.959) = 383,934 lb/in2. (e) Ao = Do2/4 = (1.5)2/4 = 1.767 in2 F = (383,934)(1.767) = 678,467 lb. (f) P= 678,467 (20) = 13,569,348 in-lb/min HP = 13,569,348 / 369,000 = 34.3 hp.
Solution 22.4: Blanking
D_die for blanking = Db = Part Dimensions D_punch for blanking = Db 2c From Table 22.1 (page 504), a=0.075 Clearance c = a.t = 0.075 (5/32) = 0.0117 in. Blanking die dimensions are same as for the part in Figure P22.4. Blanking punch: 3.500 inch length dimension = 3.500 - 2 (0.0117) = 3.4766 in. 2.000 inch width dimension = 2.000 - 2 (0.0117) = 1.9766 in. Top and bottom 1.00 inch extension widths = 1.0 - 2 (0.0117) = 0.9766 in. 1 inch inset dimension remains the same.
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ME 3263 Manufacturing Engineering - Chp 4 Supplemental Documents Turning/ A 40.0-in length is to be turned from a diameter of 5.0 in. to 4.75 in. in one pass at a cutting speed of 400 ft/min and a feed rate of 0.012 in/rev. Determine a) Depth of cut b) Machining time c) Material Removal Rate
Solution
Given: L = 40.0 in Do = 5.0 in Df = 4.75 in v = 400 ft/min f = 0.012 in/rev. a) d = (Do Df) / 2 = (5 4.75) / 2 d = 0.125 in b) Tm = L / fr where fr = N.f fr = (v/.Do).f fr = (400*12 in/min / *5 in) * 0.012 in/rev fr = 3.67 in/min Tm = 40 in / 3.67 in/min Tm = 10.90 min c) MRR = d.v.f MRR = 0.125 in * 400*12 in/min * 0.012 in MRR = 7.2 in3/min
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ME 3263 Manufacturing Engineering - Chp 4 Supplemental Documents Drilling/ A 0.75 in. diameter twist drill is used to drill a through hole on a steel workpiece that has a thickness of 1.5 in. The point angle of the drill is 118. The cutting speed is 50 ft/min and the feed is 0.010 in./rev. Determine a) Machining time b) Metal removal rate
Solution
Given: D = 0.75 in Through Hole, t = 1.5 in = 118o v = 50 ft/min f = 0.010 in/rev a) Tm = (t + A) / fr where fr = N.f = (v/.D).f = (50*12 in/min / *0.75 in) * 0.010 in/rev fr = 2.55 in/min A = 0.5*D*tan(90 - /2) = 0.5*0.75 in *tan(90 - 118o/2) A = 0.225 in Tm = (1.5 + 0.225) in / 2.55 in/min Tm = 0.68 min = 40.6 sec b) MRR= Area * fr MRR = (/4).D2 in2 * 2.55 in/min MRR = (/4)*(0.75)2 in2 * 2.55 in/min MRR = 1.126 in3/min fr
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ME 3263 Manufacturing Engineering - Chp 4 Supplemental Documents Face Milling/ In a face milling operation, the depth of cut is 5 mm and the width of the workpiece is 50 mm. The length of the workpiece is 450 mm. The chip load is 0.25 mm/tooth. The cutter has a diameter of 100 mm and has 20 teeth. If the cutting speed is 1 m/s, calculate: a) Material removal rate b) Machining time c) Power consumption if the specific cutting energy of the workpiece is 4.1 N.m/mm3.
Solution
Given: d = 5 mm w = 50 mm L = 450 mm f = 0.25 mm/tooth D = 100 mm nt = 20 teeth/rev v = 1 m/s = 1000 mm/s a) fr = N.nt.f where N = v/.D N = 3.2 rev/sec = 192 rpm w fr d
fr = 192 rev/min * 20 teeth/rev * 0.25 mm/tooth MRR = w.d.fr = 50 mm * 5 mm * 16 mm/s MRR = 4000 mm3/s b) Tm = (L + D) / fr = (450 + 100) mm / 16 mm/s Tm = 34.4 s c) U = Power / MRR U =4.1 N.m/mm3 Power = U * MRR = 4.1 N.m/mm3 * 4000 mm3/s Power = 16,400 Nm/s = 16,400 W (Nm/s Watt)
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ME 3263 Manufacturing Engineering - Chp 4 Supplemental Documents Peripheral Milling/ A plain milling operation is performed on the top surface of a rectangular workpart that is 300 mm long and 100 mm wide. The milling cutter, which is 75 mm in diameter and has four teeth, overhangs the width of the part on both sides. Cutting conditions are: v = 80 m/min, f = 0.2 mm/tooth, and d = 7.0 mm. Determine: a) Machining time for one pass b) Material removal rate
Solution
Given: d = 7 mm w = 100 mm L = 300 mm f = 0.2 mm/tooth D = 75 mm nt = 4 teeth/rev v = 80 m/min a) Tm = (L + 2A) / fr where fr = N.nt.f = (v/.D).nt.f fr = (80000 mm/min / .75mm) * 4 teeth/rev * 0.2 mm/tooth fr = 271.6 mm/min = 4.52 mm/s A = Sqrt{d(D-d)} = Sqrt{7 mm(75 7 mm)} A = 21.8 mm Tm = (300 + 2*21.8)mm / 4.52 mm/s Tm = 76 sec = 1.26 min b) MRR = w.d.fr = 100 mm * 7 mm * 4.52 mm/s MRR = 3164 mm3/s 300 mm Top view Cutter 100 mm
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Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
ME 3263
Manufacturing Engineering Dr. Can Saygin
Chp 5 Production Systems: An Overview on Basics
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 1 of 3 includes 5.1. Production Systems: Materials Flow, Production Volume, and Part Variety and 5.2. Production Concepts and Mathematical Models
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
ME 3263
Manufacturing Engineering Dr. Can Saygin
Chp 5 Production Systems: An Overview on Basics
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
Supplement - Chp 5 2 of 3 includes 5.3. Analysis of Automated Flow Lines (Chp 5- 2 of 3.pdf)
ME 3263
Manufacturing Engineering Dr. Can Saygin
Chp 5 Production Systems: An Overview on Basics
Number of batches (lots) of various part types [____] [____] 1 Part types P1 P2 2
[____] nQ
Pj
Batch (Lot) sizes of part types [..] [..] Q1 Operation plans of part types P1 Oper1,1 Oper2,1 Opernm,1 To1,1 To2,1 Tonm,1 Oper1,2 Oper2,2 Opernm,2 Q2
[..] Qj
P2
nm j
Pj
Toi ,1 To1
i 1
Toi , 2 To 2
i 1
Toi , j To j
i 1
nm1
nm2
nm j
PROBLEM 2.2
PROBLEM 2.3
PROBLEM 2.4
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PROBLEM 5.1
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PROBLEM 5.5
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