1. What are the reasons why the bulk deformation processes are important commercially and technologically? 2. Name the four basic bulk deformation processes. 3. What is rolling in the context of the bulk deformation processes? 4. In rolling of steel, what are the differences between a bloom, a slab, and a billet? 5. List some of the products produced on a rolling mill. 6. What is draft in a rolling operation? 7. What is sticking in a hot rolling operation? 8. Identify some of the ways in which force in flat rolling can be reduced. 9. What is a two-high rolling mill? 10. What is a reversing mill in rolling? 11. Besides flat rolling and shape rolling, identify some additional bulk forming processes that use rolls to effect the deformation.

1. Identify the three basic types of sheet metalworking operations. 2. In blanking of a round sheet metal part, indicate how the clearance should be applied to the punch and die diameters. 3. What is the difference between a cutoff operation and a parting operation? 4. Describe V-bending and edge bending. 5. What is springback in sheet metal bending? 6. What are some of the simple measures used to assess the feasibility of a proposed cup drawing operation? 7. Distinguish between redrawing and reverse drawing. 8. What are some of the possible defects in drawn sheetmetal parts? 9. What is stretch forming? 10. Identify the principal components of a stamping die that performs blanking. 11. What are the two basic categories of structural frames used in stamping presses?

12. What are the relative advantages and disadvantages of mechanical versus hydraulic presses in sheet metalworking?

13. What is the Guerin process?

14. Identify a major technical problem in tube bending.

15. Distinguish between roll bending and roll forming.

1. What are the differences between bulk deformation processes and sheet metal processes? 2. Extrusion is a fundamental shaping process. Describe it. 3. Why is the term press working often used for sheet metal processes? 4. What is the difference between deep drawing and bar drawing? 5. Indicate the mathematical equation for the flow curve. 6. How does increasing temperature affect the parameters in the flow curve equation? 7. Indicate some of the advantages of cold working relative to warm and hot working. 8. What is isothermal forming? 9. Describe the effect of strain rate in metal forming. 10. Why is friction generally undesirable in metal forming operations? 11. What is sticking friction in metalworking?

13. Describe the process steps in sand casting? Compare to die casting, what are some major advantages and disadvantages of sand casting? 14. A large steel sand casting shows the characteristic signs of penetration defect – a surface consisting of a mixture of sand and metal. (a) What steps can be taken to correct the defects? (b) What other possible defects might result from taking each of these steps? 15. Using an explicit sketch to illustrate and describe the process steps in investment casting. What are the advantages and disadvantages of investment casting over sand casting? 16. What are some the operations required in sand casting after the casting is removed from the mould?

17. What are the most common metals used in die casting?

18. Which die-casting machines usually have a higher production rate, hot-chamber or cold-chamber?

19. What is the difference between true centrifugal casting and semicentrifugal casting?  

air is compressed in an adiabatic and isentropic compressor from 14 psia and 60F to 210 psia. Determine the outlet temperature [F] and the work consumed by this compressor per unit mas of air [Btu/lbm]. Assume constant specific heats at T=100F

Please explain table look ups, thank you!

7. Identify the three sources of contraction in a metal casting after pouring. 8. What is directional solidification and what is chill in casting? 9. Total solidification time is defined as (select one): (a) time between pouring and complete solidification, (b) time between pouring and cooling to room temperature, (c) time between solidification and cooling to room temperature, (d) time to give up the heat of fusion? 10. What is the difference between a pattern and a core in making sand casting mould? 11. What is function of riser? 12. What properties determine the quality of a sand mould for sand casting?

1. Identify some of the important advantages of metal casting processes, and also some of the disadvantages and limitations. 2. What is the difference between an open mould and a closed mould? 3. Name the two basic mould types that distinguish casting processes. 4. Why should turbulent flow of molten metal into the mould be avoided? 5. What are some of the factors that affect the fluidity of a molten metal during pouring into a mould cavity? 6. How does solidification of alloys differ from solidification of pure metals?

1. Define the concept of “Machine Learning”.

2. Summarise two applications of machine learning and the value it create.

Tests done on a scale model of a turbine diameter 0.3m gave a max. efficiency of 83% at 900rev/minute with a guide vanes 75% open and pressure head of 20m. The power developed was 28.5KW A geometrically similar turbine has to produce 375kW at 75% vane opening but under a head of 26m Calculate 1) the diameter 2)the rotational speed of the full scale turbine hint assume the efficiencies of both machines to be the same

a pelton wheel is supplied with water from a reservoir situated 270m above the nozzle of the wheel . The frictional head loss in the pipe is 24m of water and the coefficient of velocity of the nozzle is .92. The output power of the pelton wheel is 2600KW when running at 659rpm. The hydraulic efficiency of the wheel is 92%.The water velocity over the blades is reduced by 10% due to friction. The supply pipe from the reservoir has a diameterof 700mm and is 596m long with f=0.01. Calculate 1) the diameter of the wheel;2)the diameter of the jet 3. the deflection angle of the buckets 4. the overall efficiency of the turbine and 5. the mechanical efficiency of the wheel.

A shaft inside the sleeve of a journal bearing is being rotated at 1500 rpm. The shaft is 6.00 cm in diameter and is rotating in a bearing sleeve that is 6.02 cm in diameter and 40 cm long. The clearance is filled with oil having properties of ?=0.003 m2 /s and SG=0.88.

a. Find the torque required to rotate the shaft.

b. Find the power required to rotate the shaft. (Answer: 44.1 kW)

c. Discussion: How do the torque and power change when the clearance is halved? How do the torque and power change when the bearing rotates at twice the speed? Note that this discussion requires that problems should be solved using variables and numbers are substituted as a last step. Doing this allows trends to be easily observed.

This is problem 8-13 from El-Wakil’s Powerplant Technology book – Consider a combined gas-steam turbine cycle with both machines ideal. Air enters the compressor at 1 atm and 500 degree R. 200 percent theoretical air gases enter the gas turbine at 2400 degree R. The pressure ratio for both compressor and turbine is 5.624. No intercooling, reheat, or regeneration are used in the gas-turbine cycle. The turbine exhaust is used directly without supplementary firing and leaves to the stack at 1000 degree R. Steam is produced at 1000 psia and 1000 degree F. The condenser pressure is 1 psia. No feedwater heating is used and the pump work may be ignored, Draw the flow and T-s diagrams labeling points correspondingly , and calculate (a) the heat added, per pound mass of air,(b) the steam flow per pound mass of air, (c) the combined work, in Btus per pound mass of air, (d) the combined plant efficiency, and (e) the plant efficiency if the steam cycle is inoperative.

Describe the pig iron manufacturing process (incl. reaction equations)