EAT 227 May 2015 Exam

UNIVERSITY OF SUNDERLAND
DEPARTMENT OF COMPUTING, ENGINEERING AND

TECHNOLOGY
YEAR TWO EXAMINATION 2015
EAT227 MANUFACTURING PROCESSES
Date: May 2015 Time:
Instructions to Candidates:
Time Allowed: Two Hours.
There are SIX questions set.
You must attempt any FOUR questions.
This is a closed book examination – this means you are not

permitted to use any text books or study aids in the
examination.
You are allowed to use a non programmable calculator.
You must answer the required number of questions only. Any

additional answers will not be marked.
You should put a cross through any work you do not wish to be
marked
Question 1.
(a) If an engineering alloy is cast into a shape which is then mechanically

formed to the final product, the casting is termed an “ingot”. What typical
grain structure would you expect to find in a steel ingot?
(6 marks)
(b) Casting of engineering alloys to produce a final shaped product may be

carried out via “expendable” moulds and patterns. Give a description of the
particular example of this type of casting process represented in the
schematic diagram below (Figure Q1).
Figure Q1 Schematic of a Casting Process

(7 marks)
(c) Suggest casting processes which would be used to produce each of the
following components. Justify your process selections.
(i) A nickel-based alloy (melting temperature = 1453ºC) turbine blade for

use in a jet engine.
(ii) An aluminium-silicon alloy (melting temperature = 577ºC) pump casing
for use in a domestic central heating system.
(6, 6 marks)
Question 2.
(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
In the above equation:

A0 = Cross-sectional area before extrusion
l1 = Length after drawing
l0 = Length before drawing
(8 marks)
(ii) What is the pressure exerted by the extruder during this process?
The extrusion pressure is given by a rearrangement of the above equation:
Extrusion Pressure (Stress) P = F = σy ln l1

A0 l0
(3 marks)
(iii) If the extrusion is carried out at a speed of 10 cm/s, calculate the

minimum power required for this operation.
(5 marks)
Question 3.
(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)
(b) Glasses may be shaped by a variety of processes which include pressing,

blowing, drawing, casting, rolling and floating. Describe one such shaping
process of your choice.
(8 marks)
(c) A soda-lime glass with the following composition by weight is to be

manufactured:
76% silica (SiO2), 15% soda (Na2O) and 9% lime (CaO)
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:
Na2CO3 → Na2O + CO2  (flue)

CaCO3 → CaO + CO2  (flue)
(Relative Atomic Masses are: C = 12, O = 16, Na = 23, Si = 28, Ca = 40)
(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?
Figure Q4, Contrasting Process Behaviour of Thermoplastics and

Thermosets.
(10 marks)
(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
….where τ is the shear stress and K and n are constants.

(7 marks)
(c) Table Q5 below shows the variation of apparent viscosity of a nylon PA
melt with temperature at a shear rate of 10 s-1. By graphical means,
determine the activation energy for melt flow (E) at this shear rate.
Temperature (C) Apparent viscosity

(Pa.s)
240 2513
250 1576
260 1030
270 698
280 484
Table Q5. Rheological data for PA polymer
 = A e E/RT [or  = A exp (E/RT)]
(Gas constant R = 8.314 J/K/mol)
(13 marks)
Question 6.
(a) Describe the nature of the filament winding process.
In your answer specify what sorts of structures are produced by this

method.
Discuss briefly how the winding angle affects the properties of the final
structure.
(15 marks)
(b) What stages are involved in the laying up of a laminated composite by

hand?
What is the function of the gel coat here?

(10 marks)

EAT 227 May 2015 Exam

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UNIVERSITY OF SUNDERLAND

DEPARTMENT OF COMPUTING, ENGINEERING AND

YEAR TWO EXAMINATION 2015

EAT227 MANUFACTURING PROCESSES

Date: May 2015 Time:

Time Allowed: Two Hours.

There are SIX questions set.

You must attempt any FOUR questions.

This is a closed book examination – this means you are not

You are allowed to use a non programmable calculator.

You must answer the required number of questions only. Any

(a) If an engineering alloy is cast into a shape which is then mechanically

(b) Casting of engineering alloys to produce a final shaped product may be

Figure Q1 Schematic of a Casting Process

(i) A nickel-based alloy (melting temperature = 1453ºC) turbine blade for

In the above equation:

The extrusion pressure is given by a rearrangement of the above equation:

Extrusion Pressure (Stress) P = F = σy ln l1

(iii) If the extrusion is carried out at a speed of 10 cm/s, calculate the

(b) Glasses may be shaped by a variety of processes which include pressing,

(c) A soda-lime glass with the following composition by weight is to be

76% silica (SiO2), 15% soda (Na2O) and 9% lime (CaO)

Na2CO3 → Na2O + CO2  (flue)

(Relative Atomic Masses are: C = 12, O = 16, Na = 23, Si = 28, Ca = 40)

Figure Q4, Contrasting Process Behaviour of Thermoplastics and

….where τ is the shear stress and K and n are constants.

Temperature (C) Apparent viscosity

Table Q5. Rheological data for PA polymer

 = A e E/RT [or  = A exp (E/RT)]

(Gas constant R = 8.314 J/K/mol)

(a) Describe the nature of the filament winding process.

In your answer specify what sorts of structures are produced by this

(b) What stages are involved in the laying up of a laminated composite by

What is the function of the gel coat here?

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