Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 17, Problem 24QLP
How different, if any, are the requirements for punch and die materials in powder metallurgy from those for forging and extrusion operations? Explain.
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GKN Sinter Metals Company pressed iron powders using a compaction pressure of 600 MPa to produced a cylindrical bearing which is 70 cm long and has internal and external diameters of 8 cm and 16 cm, respectively. Determine (a) the most appropriate pressing direction, (b) the required press tonnage to perform this operation, and (c) the final weight of the part if the porosity is 12%, given that the density of iron, ρ = 7.87 g/cm3. Assume shrinkage during sintering can be neglected
What are the practical applications of powder metallurgy components? List at least four items produced by powder metallurgy.
QUESTION 1
(a)
Powder Metallurgy (PM) has become competitive with processes such as casting,
forging and machining, particularly for complex parts made of high strength and hard
alloys. Compare the design considerations for products made of powder metallurgy,
casting and forging process. Evaluate your observation.
(b)
Products made of sheet metals can be easily found around us. Identify some of the
products in your automobile which are made from sheet metal, and discuss the process
or combination of processes required to produce such products.
Chapter 17 Solutions
Manufacturing Engineering & Technology
Ch. 17 - Describe briefly the production steps involved in...Ch. 17 - Name the various methods of powder production and...Ch. 17 - Explain why metal powders may be blended.Ch. 17 - Describe the methods used in metal powder...Ch. 17 - What is isostatic pressing? How is it different...Ch. 17 - What hazards are involved in PM processing?...Ch. 17 - Describe what occurs to metal powders during...Ch. 17 - Prob. 8RQCh. 17 - Why might secondary and finishing operations be...Ch. 17 - Prob. 10RQ
Ch. 17 - Prob. 11RQCh. 17 - Prob. 12RQCh. 17 - Prob. 13RQCh. 17 - What is screening of metal powders? Why is it...Ch. 17 - Why are protective atmospheres necessary in...Ch. 17 - Why is there density variation in the compacting...Ch. 17 - What is the magnitude of the stresses and forces...Ch. 17 - List the similarities and differences of forging...Ch. 17 - Give some reasons that powder-injection molding is...Ch. 17 - How does the equipment used for powder compaction...Ch. 17 - Explain why the mechanical and physical properties...Ch. 17 - What are the effects of the different shapes and...Ch. 17 - Describe the relative advantages and limitations...Ch. 17 - How different, if any, are the requirements for...Ch. 17 - The powder metallurgy process can be competitive...Ch. 17 - What are the reasons for the shapes of the shown...Ch. 17 - Should green compacts be brought up to the...Ch. 17 - Because they undergo special processing, metal...Ch. 17 - In Fig. 17.12, it can be seen that the pressure is...Ch. 17 - Why do the compacting pressure and the sintering...Ch. 17 - What will be stronger: a blend of stainless steel...Ch. 17 - Name the various methods of powder production and...Ch. 17 - Estimate the maximum tonnage required to compact a...Ch. 17 - Refer to Fig. 17.11a. What should be the volume of...Ch. 17 - Determine the shape factors for (a) a cylinder...Ch. 17 - Estimate the number of particles in a 500-g sample...Ch. 17 - Prob. 37QTPCh. 17 - A coarse copper powder is compacted in a...Ch. 17 - A gear is to be manufactured from iron powders. It...Ch. 17 - What volume of powder is needed to make the gear...Ch. 17 - The axisymmetric part shown in Fig. P17.41 is to...Ch. 17 - Prepare an illustration similar to Fig. 13.1,...Ch. 17 - Prob. 44SDPCh. 17 - Compare the design considerations for PM products...Ch. 17 - Prob. 46SDPCh. 17 - Prob. 47SDPCh. 17 - Using the Internet, locate suppliers of metal...Ch. 17 - Explain why powder metal parts are commonly used...Ch. 17 - Prob. 50SDPCh. 17 - Describe how the information given in Fig. 17.15...Ch. 17 - It was stated that, in the process shown in Fig....Ch. 17 - Prob. 53SDPCh. 17 - The axisymmetric parts shown in Fig. P17.54 are to...Ch. 17 - Assume you are working in technical sales. What...
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- QUESTION 1 (a) Powder Metallurgy (PM) enables the processing of materials with very high melting points, including refractory metals such as tungsten, molybdenum and tantalum. Such metals are very difficult to produce by melting and casting and are often very brittle in the cast state. As a manufacturing engineer, state and explain at least SIX (6) limitations of powder metallurgy that is not applicable in particular engineering industries. In a case where you were assigned to use powder metallurgy in metal forming, justify at least THREE (3) PM requirements. (b) A coil of sheet metal is placed in a furnace and annealed in order to improve its ductility. Nonetheless, it is found that the sheet metal has a lower limiting drawing (LDR) than it had before the annealing process. Describe the meaning of LDR and explain the reasons for this behaviour by referring to the microstructure and materials' properties point of view for different types of materials. In addition, discuss the process…arrow_forwardGranule strength is very important in pressing powders. The force applied to a granule with a radius of 1 mm is 0.5 Newton. Calculate the breaking strength of the granule. b) It is observed that the pressed granules break easily during pressing. Write down the reasons of this situation and what would you take precations to solve this problem? Why? (please write down 3 precautions with reasons). odluckarrow_forwardIn powder processing, a cylinder with a diameter of 2 inches and a height of 10 inches is to be made from fine copper powders. A single-action press is used for compaction. If the average density of the green product is 7 g/cm3 at the bottom half of the cylinder, estimate the compaction pressure at the punch surface. Assume no friction between the powders. The coefficient of friction between particles and containers is 0.2.arrow_forward
- Explain the process of powder metallurgy in detail.arrow_forwardThe part shown in Figure is to be pressed from fine copper powders using a compaction pressure of 1000 MPa. Dimensions are milimetres. Determine a) the required press tonnage to perform this operation b) the final weight of the part if the porosity is 15%. Assume shrinkage during sintering can be neglected. (the desity of copper =8,97g/cm³ ) 65 30 25 12 20arrow_forward(b) An engineer is assigned a task to select a possible product to be manufactured in their company with high productivity. Currently, powder pressing is the only processing technique available in the company. i. Choose the most suitable product to be suggested to the company from Figure 7. ii. Justify the answer in (i).arrow_forward
- Which law of thermodynamics best apply to compression molding machine? Explain why.arrow_forward1) Give some examples of design of powder metallurgical partsarrow_forward1) How does the ease of tool locating and clamping affects the design efficiency? Give some examples of design of powder metallurgical partsarrow_forward
- Moulds for blow moulding can be made using aluminium whereas moulds for injection moulding are usuallymade out of tool steel, why?arrow_forwardWhat were the main needs to develop colloidal technique for powder processing, explain your arguments clearly?arrow_forwardThe part shown in Figure is to be pressed from fine copper powders using a compaction pressure of 1000 MPa. Dimensions are milimetres. Determinea) the required press tonnage to perform this operationb) the final weight of the part if the porosity is 15%. Assume shrinkage during sintering can be neglected. (the desity of copper =8,97g/cm3 )arrow_forward
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