ME3633 Exam 1 S23 v2

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Louisiana State University *

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3633

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Mechanical Engineering

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Feb 20, 2024

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Exam 1vB – ME3633 Spring 2023 Page 1 of 7 ME 3633 Exam 1 – Version B This exam is an individual assessment. You are only allowed pencils, a calculator, and a single HAND WRITTEN “help sheet” (both sides, to be turned in with your exam); no outside assistance in the form of books, notes, or another student’s work is permitted. Use this document directly as your worksheet. Please work neatly in the spaces provided for your answers to assist in grading. Answers provided outside of the designated spaces may not be graded. You are not allowed any communication with other individuals during the exam. Sign this Academic Integrity Pledge below: I pledge on my honor that I have not given or received any unauthorized assistance on this examination, as defined in section 10.1 of the LSU Code of Student Conduct Signature:___________________________Date:_____________ Instructions 1. Answer all questions, questions carry unequal point values 2. Time allowed – 70 minutes 3. Work all problems symbolically , as far as possible, before numerical values are input. 4. Report answers with appropriate significant figures. Complete the Title Block provided with the following information: a. Your First & Last Name b. Today’s Date c. Section Number a) b) c)
Exam 1vB – ME3633 Spring 2023 Page 2 of 7 True/False, Multiple Choice – Clearly circle the most correct answer 1. Crystalline ceramics include aluminum oxide, tungsten carbide, and other glasses: TRUE FALSE 2. A manufacturing process can be defined as a transformation of materials into items of greater value by one or more processing and/or assembly operations: TRUE FALSE 3. Which one of the following is a type of machine used to perform extrusion: (A) forge hammer, (B) milling machine, (C) rolling mill, (D) lathe, (E) press, (F) torch. 4. Which of the following types of stress-strain relationship best describes the behavior of metals at temperatures above their respective recrystallization points: (A) perfectly elastic, (B) elastic and strain hardening, (C) elastic and perfectly plastic, (D) none of these 5. The plastic region of the stress-strain curve for a metal is characterized by a linear relationship between stress and strain: TRUE FALSE 6. A finishing operation generally involves which one of the following combinations of cutting conditions: (A) high v, f, and d (B) high v, low f and d (C) low v, high f and d (D) low v, f, and d 7. When using the orthogonal cutting model to approximate a turning operation, the width of cut corresponds to which one of the following cutting conditions in turning: (A) depth of cut (B) feed (C) speed 8. Which three of the following operations are classified as peripheral milling rather than peripheral milling: (A) plain milling, (B) end milling, (C) slab milling, (D) pocket milling, (E) surface contouring, (F) straddle milling. 9. In a straight turning operation, the cutting speed of the workpiece is equal to 𝝅𝝅 times the final diameter times rotational speed; True or False? TRUE FALSE 10. With which one of the following tool materials would a single-point tool be designed with the highest positive rake angle: (A) cemented carbide (B) ceramic (C) cermet (D) high speed steel
Exam 1vB – ME3633 Spring 2023 Page 3 of 7 11. What are the two principal locations on a cutting tool where tool wear occurs? 12. What is the physical interpretation of the parameter C in the Taylor tool life equation? 13. Is thread turning classified as generating, forming, neither, or both? Why? 14. What is the difference between threading and tapping?
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Exam 1vB – ME3633 Spring 2023 Page 4 of 7 15. Identify the seven elements of tool geometry for a single-point cutting tool shown below. 16. For a specific work material, identify at least three of the factors that will reduce the unit power in a given machining operation. 17. What is the primary mechanism of chip formation in machining?
Exam 1vB – ME3633 Spring 2023 Page 5 of 7 18. According to the Merchant equation, an increase in rake angle has which two effects, all other factors being the same? 19. How is a material’s measured value of shear modulus of elasticity G related to its tensile modulus of elasticity E , on average? How is shear strength S related to tensile strength TS , on average? 20. What are the differences between primary, secondary, and tertiary industries? Give an example of each category.
Exam 1vB – ME3633 Spring 2023 Page 6 of 7 21. Tool life tests in turning yielded the following data: (1) at v = 350 ft/min, T =5.2 min; (2) at v = 250 ft/min, T = 55 min. (a) Determine the parameters n and C in the Taylor tool life equation. (b) Based on these values, what is the likely tool material used in this operation? (See included table.) Tool material n C (m/min) C (ft/min) High speed steel: Non-steel work 0.125 120 350 Steel work 0.125 70 200 Cemented carbide Non-steel work 0.25 900 2700 Steel work 0.25 500 1500 Ceramic Steel work 0.6 3000 10000 (c) Using your equation, compute the tool life for a cutting speed of 300 ft/min and a cutting speed for a tool life = 10 min.
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Exam 1vB – ME3633 Spring 2023 Page 7 of 7 Low-carbon steel with tensile strength = 300 MPa and shear strength = 220 MPa is turned at a cutting speed = 2.5 m/s, feed = 0.20 mm/rev and depth of cut = 3.0 mm. The rake angle = 5 ° in the direction of chip flow. The resulting chip ratio = 0.45. Using the orthogonal model to approximate turning, determine (a) the cutting force, (b) the feed force, (c) and the friction coefficient for this turning operation THE END. PLEASE TURN IN YOUR “HELP SHEET” (WITH YOUR NAME ON IT) ALONG WITH YOUR EXAM.