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engineering
materials science engineering

Questions and Answers of Materials Science Engineering

Why is the tooling cost for a spinning operation relatively low?
How is shear forming different from spinning?
What is the distinction between shallow drawing and deep drawing?
Explain why thin material may be difficult to draw into a defect-free cup.
What are draw beads and what function do they perform?
Why is a trimming operation often included in a deep-drawing manufacturing sequence?
How might cold forging be used to substantially reduce material waste?
How does the Guerin process reduce the cost of tooling?
How can fluid pressure or rubber tooling be used to perform bulging?
What is sheet hydroforming?
What explanation can be given for the greater formability observed during sheet hydroforming?
What is the purpose of the inward movement of the end plugs during tube hydroforming?
What are some of the basic methods that have been used to achieve the high energy-release rates needed in the HERF processes?
Why is springback rather minimal in high-energy-rate forming?
What material and process conditions are associated with superplastic forming?
What is the major limitation of the superplastic forming of sheet metal? What are some of the more attractive features?
What are some of the attractive properties or characteristics of cold forging or cold-forged products?
How can strain analysis be used to determine locations of possible defects or failure in sheet metal components?
What is a forming limit diagram?
Explain the key difference between the right- and left-hand sections of a forming limit diagram. These sections correspond to stretching and drawing.
Describe two alternative methods of producing complex-shaped thin products without requiring sheet metal deformation techniques.
What are the primary assets and limitations of mechanical press drives? Of hydraulic drives?
Describe how multiple operations are performed simultaneously in a transfer press.
If a product contains a large-diameter head and a small-diameter shank, how can the processes of cold extrusion and cold heading be combined to save metal?
What are some of the unique capabilities and special limitations of hydrostatic extrusion?
Compare the forming processes of wire drawing, conventional extrusion, and continuous extrusion with respect to continuity, reduction in area possible in a single operation, possible materials,
Consider the various means of producing tubular products, such as extrusion, seam welding, butt-welding during forming, piercing, and the various drawing operations. Describe the advantages,
What are some of the techniques for minimizing the amount of springback in sheet forming operations?
Select a cold forming process and investigate the residual stresses that typically accompany or result from that process.
The component pictured in Figure CS-19 is a fuel-metering device for a large diesel engine. The long dimension of the part is approximately 6.3 cm (2 1/2 in.), and the width is 2.2 cm (7/8 in.). The
Why are the fabrication processes applied to plastics, ceramics, and composites often different from those applied to metals? What are some of the key differences?
In what ways is injection molding of plastic similar to the die casting of metal?
What is the benefit of a hot runner distribution system in plastic injection molding?
Why is the cycle time for the injection molding of thermosetting polymers significantly longer than that for the thermoplastics?
How are the individual components mixed in the reaction injection molding process?
What are some of the attractive consequences of the low temperatures and low pressures of the reaction injection molding process?
What are some of the typical production shapes that are produced by the extrusion of plastics?
What are some attractive features of a twin-screw extruder design?
How does the fabrication of a thermoplastic polymer differ from the processing of a thermosetting polymer?
What type of products are produced by the spinning process?
What are some of the general properties of plastics that affect their machinability?
What property of plastics is responsible for making snap-fit assembly a popular alternative for plastic products?
What are some of the attractive properties of plastics that favor their selection? What are some of the common limitations?
Why should adequate fillets be included between adjacent sections of a mold? What is a major benefit of rounding exterior corners?
Why is it most desirable to have uniform wall thickness in plastic products?
Why are product dimensions less precise when they cross a mold parting line?
Why might threaded inserts be preferred over other means of producing threaded holes in a plastic component?
What are some of the ways that plastic sheet, plate, and tubing can be cast?
What are some of the ways in which metal inserts are held in place in a plastic part?
When designing a decorative surface (design or lettering) on a plastic product, why is it desirable that the details be raised on the product rather than depressed?
Why does locating a parting line on a sharp corner make that feature less noticeable?
What is the benefit of countersinking holes that are to be threaded or used for self-tapping screws?
What process or equipment is used to form rubber compounds into sheets?
What are the two basic classes of ceramic materials, and how does their processing differ?
What are some of the special heat treatment operations performed on glass products?
What are glass-ceramics?
What are some of the techniques that can be used to impart some degree of plasticity to crystalline ceramic materials?
Describe the differences between the injection molding of plastics and the injection molding of ceramics.
What is the purpose of the firing or sintering operations in the processing of crystalline ceramic products?
What are the benefits and limitations of machining ceramic materials before firing versus after firing?
Why are joining operations usually avoided when fabricating products from ceramic materials?
Discuss some of the design guidelines that relate to the production of parts from ceramic material.
Why are the processes used to fabricate particulate composites essentially the same as those used for conventional material?
What are some of the forms in which reinforcement fibers can be used in composite materials?
What is a prepreg?
What are sheet-molding compounds (SMC)? Bulk-molding compounds (BMC)?
In what way is pultrusion similar to wire drawing?
What are some typical products that are made by filament winding? Why might this process be attractive for the production of small quantities of large parts?
What are some of the various molding processes that can be used to shape products from laminated sheets of woven fibers?
What type of reinforcing fibers can be incorporated in the spray molding process? Injection molding?
Describe some of the ways in which a metal matrix can be introduced into a fiber-reinforced composite.
Why might it be desirable to weaken the bond between a reinforcing fiber and a ceramic-matrix material?
Discuss some of the techniques used to cut fiber-reinforced composites.
What is the major concern when considering the joining of fiber-reinforced composites?
Why do blow molding molds typically contain a cooling system?
For what types of parts and production volumes would compression molding be an appropriate process?
What are typical mold temperatures for compression molding? What is the most common mold material?
What are some of the attractive features of the transfer molding process?
Consider some of the more prominent sporting goods that are fabricated from composite materials, such as skis, tennis rackets, golf club shafts, and body panels for racing cars. For two products,
Why has the metal-cutting process resisted theoretical solution for so many years?
For orthogonal machining, the cutting edge radius is assumed to be small compared to the uncut chip thickness. Why?
How does the magnitude of the strain and strain rate values of metal cutting compare to tensile testing?
Explain why you get segmented or discontinuous chips when you machine cast iron.
Why is shear stress so important?
Which of the three cutting forces in oblique cutting consumes most of the power?
Where does the energy consumed ultimately go?
State two ways of estimating the primary force Fc.
How is cutting speed related to tool wear?
What variables must be considered in understanding a machining process?
Why doesn't the cutting force Fc increase with increased speed V?
Why does the cutting force increase with increased feed or DOC?
Which of the basic chip formation processes are single point, and which are multiple point?
How is feed related to speed in machining operations such as turning?
Milling has two feeds. What are they, and which one is an input parameter to the machine tool?
What is the fundamental mechanism of chip formation?
What are the implications of Figure 21-13, given that this video graph was made at a very low cutting speed?
What is the difference between oblique machining and orthogonal machining?
The units for the approximate equation for MRR for turning are not correct. When is the approximate equation not very good (yields a large error in MRR values)?
Suppose you have the following data obtained from a metal-cutting experiment (orthogonal machining). Compute the shear angle, the shear stress, the specific energy, the shear strain, and the
For a turning process, the horsepower required was 24 hp. The metal removal rate was 550in3/min. Estimate the specific horsepower and compare to published values for 1020 steel at 200 BHN.

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