ME 381 HW 6

P5

d) A common process for the assembly of compound cylinders is thermal shrink- fitting. In your own words, Describe briefly how this procedure may be performed. Explain with reference to solid mechanics concepts, how a thermal shrink-fit can generate forces which hold the cylinders together and enable higher pressure bearing capability (in comparison to a single cylinder). Considering the concepts/principles explained above, describe more generally an alternative method for achieving such improved performance and describe advantages/disadvantages, if any, over a thermal shrink-fitting procedure. (200 - 300 words).

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Calculate mould dimension for sprue runner and in-gate, the material using Fluorothermoplastic and using injection molding. Question: 1. If possible, use a simulation of the position where the defect will occur 2. Calculate to make mold male and female, the shape is near net shape product and determine material for dies, the liquid materials is 167°C Guidelines Sprue Gate Guidelines L 50% W1 A1 2-3° W1 20-100% of W2 R1 > 1.5 mm T2 75-100% T1 (part thickness) N D1 125-400% T1 (part thickness) D1 100-300% T1 (part thickness) Part Thickness 1.6 mm R > 1 mm (0.040") % Shrinkage Parallel to Flow 4.0-4.5 % Shrinkage Perpendicular to Flow 4.3-4.8 T3 100-200 % (part thickness)

Powder Metal Question: You are given alumina powder that comes in large bags and shipped a long distance  a. why is it important to sample the powder in the bags ? b. how do you sample the material? c. what might you expect to see in your sampling?  d. how do you deal with the issue if present ?

Based on the table below, which of the statements below is/are correct regarding the 3D printing process shown in the schematic?   a.You can produce a room-temperature non-fragile 225C oven-safe food container with at least one material from the above table using this process and a 280C nozzle b.You can use this process to print plastic or brittle objects but not elastomers and rubbers c.Manufacturing a thermoplastic HDPE hose with an extrusion nozzle heated to 175C is possible with this process d.You can print thermoplastic and thermoset polymers with this process, you only need to make sure that the nozzle specs and the crosslinking conditions match the polymer requirements e.This process is best suited for the low volume production of tubes, bars and beams due to the nature of the extrusion process

A sand mixture was screened through a standard 12 mesh screen. The mass fraction of the oversize material in feed, overflow, and underflow were found to be 0.4, 0.8, and 0.2 respectively. Calculate the screen effectiveness where the oversize material is the product, and the overall screen effectiveness. Please show full solution and use 4 decimal places.

Task 1 The company is interested in expanding its production capability into ceramic based products. You have been asked to identify typical products manufactured using selected ceramic processes and then describe how the properties of the ceramic make this a suitable process for the product. Briefly describe the process and then examine which types of products which can be manufactured using this process. Then describe the properties that make the ceramic and process suitable for that application. · Ceramic Sintering · Ceramic Hot Pressing · Chemical Vapour Deposition · Reaction Bonding process

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Based on the table below, which of the statements below is/are correct regarding the 3D printing process shown in the schematic? Table 15.2 Melting and Glass Transition Temperatures for Some of the More Common Polymeric Materials Z AXIS a. C. Ⓒ e. A X AXIS B Y AXIS LEGEND: A: Extruder B: Nozzle C: Printed part D: Hot plate E: Filament Material Polyethylene (low density) Polytetrafluoroethylene Polyethylene (high density) Polypropylene Nylon 6,6 Polyester (PET) Poly(vinyl chloride) Polystyrene Polycarbonate Glass Transition Temperature [°C (°F)] -110 (-165) -97 (-140) -90 (-130) -18 (0) 57 (135) 69 (155) 87 (190) 100 (212) 150 (300) You can produce a room-temperature non-fragile 225C oven-safe food container with at least one material from the above table using this process and a 280C nozzle b. This process is best suited for the low volume production of tubes, bars and beams due to the nature of the extrusion process Manufacturing a thermoplastic HDPE hose with an extrusion nozzle…

Task 2 The company is also interested in expanding its production capability into composite based products. You have been asked to identify typical products manufactured using selected composite processes and then describe how the properties of the composite make this a suitable process for the product. Briefly describe the process and then identify at least one type of product which can be manufacturing using this process. Then describe the properties that make the composite and process suitable for that application. · Manual and automated layup · Filament winding · Pultrusion · Resin Transfer Moulding

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Question 3 The diameter of an extruder barrel is 65 mm and its length is 1.75 m. The screw rotates at 55 rev/min. The screw channel depth is 5.0 mm, and its flight (helix) angle is 18°. The head pressure at the die end of the barrel is 5x10° Pa. The viscosity of the polymer melt is given as 100 Pa-s. Calculate the volume flow rate of polymer in the barrel. The drag flow is given by the equation: Qa = 0.5 n2 D² N d̟ sinp cosp The back pressure flow is given by the equation: Pn D dễ sin²o Qb 127L The details of the extruder screw are given in figure 3.1 W. Perpendicular channel width Helix angle (O) Pitch Channel depth de Axial |light| width Axial channel width Perpendicular fight -Direction of mass flow- Figure 3.1. Schematic illustration of a typical "Archimedean" extruder screw. width Root diameter diameter

Question 3 The diameter of an extruder barrel is 65 mm and its length is 1.75 m. The screw rotates at 55 rev/min. The screw channel depth is 5.0 mm, and its flight (helix) angle is 18°. The head pressure at the die end of the barrel is 5x10° Pa. The viscosity of the polymer melt is given as 100 Pa-s. Calculate the volume flow rate of polymer in the barrel. The drag flow is given by the equation: Qa = 0.5 n² D² N d̟ sinp cosp The back pressure flow is given by the equation: Pn D dễ sin²4 Qb 127L The details of the extruder screw are given in figure 3.1 W. channel width Perpendicular Pitch Helix ( p angle () D Channel depth de |Axial |light| width Axial channel width Perpendicular flight -Direction of mass flow- Figure 3.1. Schematic illustration of a typical "Archimedean" extruder screw. width Root diameter diameter

TPC Company produces paint in cans. They have found that in 9 samples of 7 cans each, the average can contains 2.05 liters of paint. The average range found over these samples is 0.24 liters. Find the control limits for X-bar and range charts. b. XYZ company produces staplers and other items. The production cost per unit is $8 and the cost of setting up the production line for this is $60. The annual holding cost rate is 30%. The company works 250 days per year. The production rate for this product is 120 per day. If the annual demand is 20,000 units, i. Which batch size should the company use? ii. What is the minimum monthly cost? iii. What is the total production time allocated to this product annually?

Multiple-Choice Questions The lesson presented a futuristic project for printing structures on the face of the moon. What element functions as support material for the printing of these structures? A. Lunar sand sprayed with binding material B. Carbon fiber scaffoldings Inflatable structure C. D. No support material is required What is the part of 3D printing in tissue engineering? A. Printing a live tissue B. Prototyping the tissue C. Simulating the tissue function D. Printing artificial scaffoldings to grow the tissue on Which attribute of 3D printing may become an advantage over other fabrication methods for printing fully functional electronic devices? Select all correct answers. A. The ability to easily interlock different parts B. The ability to print multiple materials C. Printing accuracy D. Printing speed The case study presented "Genie" - an experimental food printer. What are the advantages of "printing" dry edible ingredients over using wet mixtures and pastes? A. Easier…

Consider the red aluminum tool holder shown in Figure 4. Your job shop has been contracted to make 10,000 pieces this year, with possibility of making 20,000 more each year in the future. Consider the process options below, which option is the best? a) using die casting, cast the holder anodizing the holder to red color b) using injection molding, mold the holder without hole using a mill or drill press, cut the hole anodizing the holder to red color c) using sand mold, cast the holder without hole using a mill, cut all planar surfaces (smooth surfaces) using a mill or drill press, cut the hole anodizing the holder to red color d) using a hacksaw, cut a piece of 3"X3" bar stock to length using a mill, cut all planar surfaces using a mill or drill press, cut the hole anodizing the holder to red color