Surname and Initials: MABENGO N.D.

Student Number : 48591238

Module Code : MME2601
Assignment NO. : 01


Mabengo N.D. Student#48591238July 2013 Page | 1

QUESTION 1

n
m TS
A
V
C T
|
.
|

\
|
=

( )
3
2 2
3926991
4
20 500
4
mm
t D
V =

= =
t t


( )
2
2
2
424115 20 500
4
500 2

4
2
mm
Dt
D
A
= +

=
+ =
t
t
t
t


2,86min = =
|
.
|

\
|
= s T
TS
5 . 171
424115
3926991
2
2


QUESTION 2

From table 4.1, o = 24 x 10
-6
mm/mm/
o
C

L2 L1 = oL1 (T2 T1)

L2 = 1 + 24 x 10
-6
x 1 x (650 20) = 1.01512 cm

(L2)
3
= (1.01512)
3
= 1.0460493cm
3


at 650
o
C =
3
2.581g/cm =
0460493 . 1
70 . 2
(assuming that the mass does not
change)

QUESTION 3

Length = 25 cm = 250mm

Increase = 12 x 10
-6
mm/mm/
o
C x 250 mm x (260 21) = 0.717 mm

QUESTION 4

Heat = (0.21 cal/g-
o
C) x (103cm
3
) x (2.70g/cm
3
) x (300
o
C 21
o
C) = 158.193 cal

But 1 cal = 4.184 J 158.193 x 4.184J = 661.879 J


Surname and Initials: MABENGO N.D.
Student Number : 48591238
Module Code : MME2601
Assignment NO. : 01


Mabengo N.D. Student#48591238July 2013 Page | 2

QUESTION 5

Pultrusion is a process in which continuous fibber rovings are dipped into a resin
bath and pulled through a shaping die where the impregnated resin cures.

QUESTION 6

From table 18.1, Ac = 0.075 c = 0.075 x 2 = 0.15 mm

Die opening diameter = 75 mm
Punch diameter = 75 (2 x 0.15) = 74.7 mm

QUESTION 7

From table 20.1, Ac = 0.075 c = 0.075 x 4 = 0.3 mm

Blanking punch for 85 mm Length = 85 (2 x 0.3) = 84.4mm

Blanking punch for 50 mm Width = 50 (2 x 0.3) = 49.4mm

Blanking punch for 25mm Top and Bottom = 25 (2 x 0.3) = 24.4mm

QUESTION 8

Problems or reasons for excessive burrs

- Very large clearance between punch and die for the material and stock
thickness.

- Worn cutting edges for punch and die with the same corollary as excessive
clearance.

Correcting the problems

- Check the punch and die cutting edges to see if they are worn and regrind
the face if they really are.

- If the die is not worn, measure the punch and die clearance to see if it equals
the recommended value. If not the die maker must rebuild the punch and
die.


Surname and Initials: MABENGO N.D.
Student Number : 48591238
Module Code : MME2601
Assignment NO. : 01


Mabengo N.D. Student#48591238July 2013 Page | 3

QUESTION 9

Area A = (0.3m)
2
= (30cm)
2
= 900 cm
2


Volume V = (30cm)
3
= 27000 cm
3


Surface Area of a spherical particle of D = 0.01cm is A = t x D
2


A = t x (0.01)2 = 314.159 x 10
-6
cm
2
/ particle

Volume of a spherical particle of D = 0.01cm is
6
3
D
V

=
t


V=
( )
9
3
10 5 . 523
6
01 . 0

=
t
cm
3
/particle

Number of particles in 1cm
3
=
9
10 5 . 523
27000

= 51.576 x 10
9


Total surface area = (51.576 x 10
9
) x (314.159 x 10
-6
) = 16 203 064.58 cm
2


Percent increase = 100
900
900 58 . 16203064

= 1 800 240.51%

QUESTION 10

( ) ( )
N p A F
mm d D A
c P
o o p
062 . 236 207 4 . 1140
4 . 1140 22 44 25 . 0 25 . 0
2 2 2 2 2
= = =
= = = t t


QUESTION 11

a) The tolerance band = 0.36. Wear allowance = 0.03 x 0.36 = 0.0108 mm
GO gage will inspect the minimum hole diameter = 30.00 0.18 = 29.82mm
The dimension will decrease as the gage wears, so the wear allowance is
added to it.

Nominal GO size = 29.82 + 0.0108 = 29.8308mm


b) NO-GO gage will inspect the maximum hole diameter = 30.00 + 0.18 =
30.18mm. In this case, no wear allowance is added because this gage
should not fit in the hole and wear away.

Surname and Initials: MABENGO N.D.
Student Number : 48591238
Module Code : MME2601
Assignment NO. : 01


Mabengo N.D. Student#48591238July 2013 Page | 4

QUESTION 12

a)
2
2
/ 8 . 4644
125 . 3
14515
cm kg
cm
kg
Y = =

b) S = E x e, subtracting the 0.2 offset,
( )
018 . 0 002 . 0
5
0 . 5 1 . 5
=

= e

2
/ 4 . 258044
018 . 0
8 . 4644
cm kg
e
S
E = = =

c) TS =
2
/ 8 . 8708
125 . 3
27215
cm kg =

d) EL =
( )
% 32 32 . 0
5
5 6 . 6
= =

e) AR =
( )
% 50 5008 . 0
125 . 3
56 . 1 125 . 3
= =

QUESTION 13

a)
( )
306.93MPa =


= =
5 . 2 5 . 37 2
1000 6780
2
2 2
t t
t
t R
T


b) 0.0130875 =
|
.
|

\
|

= =
5
360
2 1
75 . 3
t
o

L
R


c) a 23452.14MP = = = =
0130875 . 0
93 . 306
G ,

t
t G

d)
( )
( )
491.187MPa =


=
5 . 2 5 . 37 2
10 10850
2
3
t
S


QUESTION 14

From Fig 6.2, the compositions are as follows:

Liquid phase composition = 65%Ni 35%Cu.

Solid phase composition = 83% - 17%Cu.

Surname and Initials: MABENGO N.D.
Student Number : 48591238
Module Code : MME2601
Assignment NO. : 01


Mabengo N.D. Student#48591238July 2013 Page | 5

QUESTION 15

From Fig 6.2 measured values of CL and CS are: CL = 5mm, CS = 12mm

Liquid phase proportion = 12/(12+5) = 0.71

Solid phase proportion = 5/7 = 0.29

QUESTION 16

From Fig 6.3, the compositions are as follows:

Liquid phase composition = 56% Sn 44%Pb.

o phase composition = 18%Sn 82%Pb.

QUESTION 17

From Fig 6.3 measured values of CL and CS are: CL = 10.5mm, CS = 15mm.

Liquid phase proportion = 15/(15+10.5) = 0.59

o phase proportion = 10.5/25.5 = 0.41

QUESTION 18

From Fig 6.3 the compositions are observed as follows:

Liquid phase composition = 78%Sn 22%Pb.

| phase composition = 98%Sn 2%Pb.

QUESTION 19

From Fig 6.3 measured values of CL and CS are: CL = 7.8mm, CS = 4.2mm

Liquid phase proportion = 4.2/(7.8+4.2) = 0.35

o phase proportion = 7.8/12 = 0.65