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ISyE 350, Spring, 2007
Exam I
Name: ______
Part I: Multiple Choice. 3 points each. Circle the answer which is most correct.
1. Which of the following statements is true about world market prices for metals:
a) Prices are generally at historic lows due to advances in mining technology.
b) Prices are generally stable.
c) Prices are generally volatile.
d) a or b
e) a or c
2. Which of the following is considered a high cost material:
a) 1090 steel
b) nickel
c) 304 stainless steel
d) a or b
e) b or c
3. Which of the following statements is true about design and manufacturing systems?
a) In a “make-buy” decision for a component part, it is almost always best to make it.
b) Prototypes are inexpensive and no longer useful in modern times.
c) It is best to design a product before planning how to manufacture it.
d) A low-volume manufacturing plant is generally less efficient than a high-volume plant.
4. Which of the following is a property of gray cast iron?
a) ductility
b) dampens vibrations
c) poor wear properties
d) very strong in tension
e) the carbon is smoothly dispersed throughout the crystal structure
5. Which of these heat treatments produces the hardest steel:
a) quench
b) temper
c) stress-relief
d) anneal
e) normalize
6. Which of the following materials would be best for a low cost, corrosion-resistant material:
a) W1 tool steel
b) 304 stainless steel
c) 430 stainless steel
d) White cast iron
e) all of the above
7. When quenched, which steel shows the highest hardenability?
a) 4340
b) 1040
c) 1090
d) 304 stainless steel
e) b or c
8. For annealed 1040 steel, which of the following would increase its strength and hardness the most?
a) tempering
b) quenching
c) stress-relieving
d) normalizing
e) none of the above
9. For annealed 6061 aluminum, which of the following would increase its strength and hardness?
a) tempering followed by quenching
b) quenching followed by tempering
c) tempering followed by stress-relieving
d) quenching followed by stress-relieving
e) c or d
10. Which of the following statements is true?
a) Steel is not usually recycled
b) Steel is often plated with zinc to reduce corrosion.
c) Free-machining steel forms longer chips than regular steel
d) Stainless steels generally contain between 2 and 5% chromium
e) 430 is an “Austenitic” stainless steel
11. Which of the following statements is true?
a) Brass is an alloy of copper and tin
b) Bronze is an alloy of copper and zinc
c) 5052-H32 cannot be hardened by heat-treatment
d) 6061-T6 is one of the most expensive aluminum alloys
e) Magnesium is heavier than aluminum
12. Which of the following statements is true?
a) Plastics are unaffected by moisture.
b) Polypropylene is difficult to recycle.
c) Thermosets are easy to recycle
d) Nylon is a strong plastic.
e) Polycarbonate is an inexpensive plastic.
13. When heated, a thermoplastic will
a) melt
b) burn
c) rapidly form cross-links between polymer chains
d) a or c
e) none of the above
14. Which of these plastics is the most resistant to weathering and UV radiation?
a) PMMA / Acrylic
b) PVC / Polyvinyl-chloride
c) PA / Nylon
d) HDPE / High density polyethylene
e) PP / Polypropylene
15. Which of these plastics is often used for its optical transparency?
a) PMMA / Acrylic
b) PS / Polystyrene
c) PA / Nylon
d) a or b
e) b or c
Part II: Short Answer. 4 points each. Succinctly answer these questions.
1. The Confused Casting Company makes hammers out of gray cast iron. They are about to go out of business because their hammers break the first time they are used. What other cast iron might they consider?
2. Why is normalizing often preferred to annealing?
3. What is it about the microstructure that makes gray cast iron brittle?
4. For the stress-strain curve shown below, what strain value is most important to forming and stamping operations?
5. What do Aluminum Oxide, Silicon Carbide, Cubic Boron Nitride have in common?
6. What do High Speed Steel, Tungsten Carbide, and Cermets have in common?
7. Why is Strain Hardening an important behavior in economical manufacturing?
8. The Super-Strong-Steel company makes heat-treated 1090 steel bars and needs to know if each bar is meeting their specified UTS of 120,000psi. How can they verify their specification most economically?
9. What particular hardening effect do these techniques have in common: Flame Hardening, Induction Hardening, Laser-beam Hardening, Electron-beam Hardening, Carburizing, Nitriding?
Part III: Short Answer. 5 points each. Succinctly answer these questions.
1. Why are thermosetting polymers characteristically brittle?
2. How can recrystallization be used to enable large deformations without fracture?
3. The primary goals of any production system are typically cost, quality, timing, and flexibility/agility. What do the last two goals (timing and flexibility/agility) mean?
4. Bent-Bar Inc. has an order to make 6061-T6 aluminum bars with a 90 degree bend. Their plan is to heat them up to 700 deg F, and then bends them 90 degrees. Why is this a poor process design? What process design would you recommend?
5. Why is it best to perform product design, materials selection, and manufacturing process design concurrently/simultaneously rather than sequentially?