EAT 227 May 2015 Exam
EAT 227 May 2015 Exam
Instructions to Candidates:
You should put a cross through any work you do not wish to be
marked
Question 1.
(c) Suggest casting processes which would be used to produce each of the
following components. Justify your process selections.
(a) What is the origin of ductility in metals? Explain this in terms of the
crystalline structure of metals.
(9 marks)
(b)
(i) An aluminium billet with a yield strength (σy) of 100 MPa is to be HOT
EXTRUDED from a diameter of 60mm down to a diameter of 10mm.
Determine the minimum extrusion force (F) required to carry out this
operation. Hence determine whether a 250 tonne (2.5 x 10 6 N) capacity
extruder is capable of carrying out this extrusion. Assume that the volume of
the material stays constant. The appropriate homogeneous work model
equation is:
F = σy A0 ln l1
l0
(ii) What is the pressure exerted by the extruder during this process?
(3 marks)
(a) Glasses are versatile materials with properties that can be controlled by
adjusting their compositions. Discuss the general nature of glass materials in
terms of their composition and properties.
(8 marks)
Your starting materials are silica (SiO2), soda ash (sodium carbonate,
Na2CO3) and limestone (CaCO3). Calculate the batch recipe in terms of the
required weights of starting materials. The following information is given:
(9 marks)
Question 4.
(a) Figure Q4 below shows the different strategies required when shaping
thermoplastic and thermosetting polymers. What are the structural
differences between these 2 types of material which make these different
approaches to processing necessary?
(b) What polymer processing technique would be used for making continuous
UPVC (unplasticised poly vinyl chloride) profile for double-glazed windows?
Justify your choice, describe the main features of the processing equipment
and give an account of the process operation itself.
(15 marks)
Question 5.
(a) The study of the flow behaviour (rheology) of polymer melts is essential to
understand how they behave within processing equipment and for simulating
such processes. All polymer melts are pseudoplastic (to a lesser or greater
extent) in their flow behaviour. Explain what is meant by the term
pseudoplastic.
(5 marks)
(b) A pseudoplastic polymer melt which obeys the power law may also be
described as a power law fluid. If you were given data on the variation of
shear viscosity (η) with shear rate (̇ ), how could you show that a polymer
melt was a power law fluid (i.e. obeyed the power law)?
Power Law: = K ̇ n
(13 marks)
Question 6.
Discuss briefly how the winding angle affects the properties of the final
structure.
(15 marks)