AER 507 Assignment Solutions

Week 2 Problem 2.1 In example 2-1, i) determine EL and AR; ii) estimate G, S; iii) Is it possible to determine K and n? If yes, how? Solution: Using original area = 62.5 mm2, engineering/true stress and strain can be determined as shown in the following table.

Load 0 17793 23042 27579 28913 27578 20462

length 125 125.23 131.25 140.05 147.01 153 160

stress Mpa 0 284.688 368.672 441.264 462.608 441.248 327.392

strain

true stress true strain 0 0 0 0.00184 285.2118 0.001838 0.05 387.1056 0.04879 0.1204 494.3922 0.113686 0.17608 544.064 0.162187 0.224 540.0876 0.202124 0.28 419.0618 0.24686

1) EL =[(Lf Lo)/Lo] x 100 % = [(160-125)/125]x100% = 28% Check Lf = (1 + EL/100%) Lo = (1+0.28) x 125 = 160 AR [1- Lo/Lf] x 100 % = [1 125/160]x100% = 21.875%

2) G = 0.4E x= 0.4 x160000Mpa = 64000 Mpa S = 0.75T = 0.7T = 0.7 x 462.61 = 323.83 Mpa 3) Yes, Picking two points 494.392= K(0.113686)n; 544.064 = K(0.162187)n 494.392/544.064 = (0.113686/0.162187)n; 0.909 = (0.701)n 0.2695 n = 0.2695, then K = 494.392/(0.113686) = 1.797x 494.392 = 888.297 Check: 888.297(0.113686)0.2695 = 494.392; 888.297(0.162187)0.2695 = 544.07

Problem 2-2 In example 2-2, If the diameter is reduced by D/d = 3, check if the material is broken? Solution: = 2 ln (D/d) = 2ln3 = 2.197 In plastic region, = Kn = 240(2.197)0.15 = 270 Mpa < 350 Mpa not broken.

Week 3 Problem 3.1 Follow example 3.2 to design the same shaft with a specific strength (Mpa/(Mg/m3) = 1000/7 under tensile stress. Use the figure in example 3.2 (provided) to indicate a qualified region of the materials. The allowable TS = 1000/7MPa. Solution: Stress: = F/A; Mass: m = AL Hence: m = FL/ (TS/ ) Specific strength: TS/ = 1000/7. Since S=0.7TS, then TS/ = S/0.7 S/ =0.7 TS/ = 100. Allowable limit S = 0.7TS = 0.7 x 1000/7 = 100 Mpa.

Qualified area

S =100

S/ =100

Problem 3.2 Aluminum has a density of 2.70 g/cm3 at room temperature (20 oC). Determine its density at 650 oC, using value given in Table 4.1 of the text. Solution: Since vT = V/V, then V = vT V Note v = 3 (AL) = 24 x 10-6 mm/mm v = 3x24 x10-6 mm3/mm3 = 3x24 x10-6 cm3/cm3 Then V = vT = 3x24x10-6x(650-20)x1 (cm3) = 0.04536 cm3 Density = m/v = 2.7 g / 1 cm3, at room temperature. At 650 oC = 2.7 g / (1 + 0.04536) = 2.58 g/cm3 (decreasing) Problem 3.3 Follow example 3-3 and 3-4, to calculate the temperature increase and energy needed if the material is nickel. Solution: Since = 13.3 x 10-6(Ni) Temperature increase T = L/ L= 0.1x106/(13.3x39.941) = 188.2 OC Energy needed H = CW(T To) C = 0.105x4.186 from Table 4.2 and convert to Joule W = (62 -42)x1x8.92 H = 0.105x4.186(J/goC)x[(62 -42)x1x8.92](g)x188.2 =46.35 KJ=43.93 Btu

Problem 3.4 Follow example 3-5, determine CPR if material is aluminum with the same amount of weight loss. Solution: CPR = 87.6 x 0.2(g)/(2.7 (g/cm3) x 100 cm2 x 1 yr) = 0.065 cm/yr = 0.65 mm/yr > 0.5 mm/yr Not acceptable

Week 4 Problem 4.1 i) Identify the type of each steel and its carbon content; ii) comment on 1040 and 4140 in terms of TS & EL using Table 6.3. 1020, 1040, 2030, 3130, 4140, 4815, 9260 Solution: i) 1020 plain low C = 0.2% 1040 plain medium C = 0.4% ~ 0.2-0.5% 2030 low alloy (Ni) medium C = 0.3% 3130 low alloy (Ni-Cr), medium C = 0.3% 4140 low alloy (Cr-Mo), medium C =0.4% 4815 low alloy (Ni-Mo), low C = 0.15% < 0.2% 9260 low alloy (Si), high C = 0.60% > 0.5% TS EL 1040 Plain C 75-80 Kpsi 10-20 4140 Low alloy 133 Kpsi 16

ii)

Alloying strengthens the steel without scarifying its ductility. Problem 4.2 i) Identify the type of each aluminum, ii) compare 1100 with 2024 in terms of TS & EL using Table 6.8 and comment on their difference. 1100, 2024, 3004, 4043, 5050, 6063, 7075. Solution: i) 1100 Plain Al 2024 Cu 3004 Mn 4043 Si 5050 Mg 6063 Mg/Si 7075 Zinc TS EL 1100 (O)/(H18) 13/24 Kpsi 40/10 2024 (O)/(T3) 27/70 Kpsi 20/18

ii)

Alloying (Cu) strengthens aluminum for O case. Alloying also makes aluminum heat treatable while maintaining ductility, comparing H18 strain hardening for pure Al with T3 heat treated/cold worked for 2024. 5

Problem 4.3 What type of metal is Inconel 600? Compare it with Ni 200 in terms of TS and EL. Solution: Inconel 600 is a Ni-based super alloy. Inconel Ni 200 TS (Mpa) 640 462 EL 48 47

Week 5 Problem 5.1 Consider steel with 1.2% C content being cooled slowly from 1100 oC to room temperature, what is the final microstructure? If C% is 2%, what will be heating temperature in order to obtain the same final microstructure? Solution: i) The final microstructure is pearlite + cementite. ii) The heating temperature should be at least 727 oC in order to obtain austenite.

Problem 5.2 Refer to Table 6.8, TS(Al 2024-T3) = 70Kpsi, TS(Al 2024-0) = 27 Kpsi. Why is the former stronger than the later for the same material using two different heat treatments? Solution: T3 is a hardening process by solution heat treatment, cold working and naturally aging. O is a softening process by annealing.

Week 6 Problem 6.1 A continuous and aligned glass fiber-reinforced composite consists of 50 % volume of glass fibers having a modulus of elasticity of 60GPa and 50 % volume of a polyester resin. When hardened, the composite material displays a modulus of 40 GPa in the longitudinal direction. It is required to determine the following: 1. Calculate the modulus of elasticity of the polyester resin. 2. If a 16 KN force is applied in the longitudinal direction, calculate the magnitude of the load carried by each of the fiber and matrix phases. 3. Determine the strain that is sustained by each phase when the force in (2) is applied, assuming that the cross sectional area is 200 mm2. Solution: 1) Using Ec = Em (1- ff) + Ef ff Em = (Ec Ef ff)/(1-ff) = (40 60 *0.5)/(1-0.5) = 20 GPa 2) Using force relation Ff /Fm = Ef ff / Em fm = 60x0.5/20x0.5 = 3 Since Fc = Fm + Ff Fc = 4 Fm Fm = 16K/4 = 4 KN Ff = Fc Fm = 12 KN 3) Since Am = fm Ac = 0.5 x 200 = 100 mm2; Af = ff Ac = 0.5.x200= 100mm2 Then m = Fm /Am = 4KN/100mm2 = 40 Mpa f = Ff /Af = 12 KN/100mm2 = 120 Mpa em = m /Em = 40 Mpa/2 Gpa = 2 x10-3 ef = f /Ef = 120 Mpa/ 60Gpa = 2 x10-3 = em Ff = 3 Fm

Week 7 Problem 7.1 A bending operation is to be performed on 4.75 mm thick cold-rolled steel. The part drawing is given at the next page. Determine the blank size required. Solution: A = 180 45 = 135o Kba =0.5 as R/t = 9.5/4.74 =2 BA = 2 (A/360)(R+Kbat) = 2 (135/360)(9.5+0.5 x 4.75) = 27.98 mm Dimension: W = 32 mm, L = 50 +37.5 + 27.98 = 115.48 mm Problem 7.2 Determine the bending force required in problem 7.1 if the bend is to be performed in a V-die with a die opening width = 38 mm. The material has a tensile strength = 450 Mpa. Solution: For V-bending, Kbf = 1.33 F = Kbf (TS) wt2/D = 1.33 (450) (32) (4.75)2 / 38 = 11.371 KN Problem 7.3 Determine the minimum bend radius, for K = 600Mpa and n=0.10. Check if the original bend radius could cause cracking. If yes, how to solve this problem. Solution TS = 450 Mpa Rmin = [((K/TS)1/n 1)/2] t = [((600/450)1/0.101)/2] t = 8..48 t > 2t, crack. It must warm/hot bent.

Week 8 Problem 8.1 The figure below shows a part to be turned on a lathe with machining steps given in the table Below Small cylinder Diameter = 10 mm Length = 100 mm

Large cylinder Diameter = 20 mm Length = 100 mm

No 1 2 3 4 5 6 Operation Cut off a rod to size Turn the front face Turn the back face Turn the large cylinder Turn the small cylinder Turn the middle face Machine (lathe or saw or mill or drill) Sawing machine Lathe Lathe Lathe Lathe Lathe Cutting Tool (single or multiple point tool) Saw Single point cutter Same Same Same Same

i) Select machining parameters for each machining operation, assuming that the work material is aluminium, the cutting tools are HSS, and all machining are finish cuts. Please select a middle value if a range is given. ii) Calculate the total cutting time for the last three machining operations. Assuming that all the given diameters are the starting diameters. Solution: i) From the table, speed = 93 m/min, feed = (0.13 + 0.25)/2 = 0.19 mm

ii) Cutting time: Transverse cutting time: Tm =L/fr =L/fN Facing cutting time: Tm = L/fr = L/fN Speed v = DoN N = v/Do Small cylinder N1 = 93 x 1000 / (3.14 x 10) = 2961.78 rpm 10

Middle face and large cylinder: N2 = 93 x 1000 / (3.14 x 20) = 1480.89 rpm Total cutting time = Lsmall /fN1 + [(Dlarge Dsmall )/2 + Llarge ] / fN2 = 100 / (0.19 x 2961.78) + (5 +100) /(0.19x1480.89) = 0.55 min = 33 sec

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