bff2403 - manufacturing processes i

7/23/2019 Bff2403 - Manufacturing Processes i

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Universi t i

Malaysia

P A H A N G

Enginee i f lg . Technclogy Cra1Iv1y

FACULTY O F M ANUFACTURING ENG INEERING

T E C HN O L O G Y M A N A G E M E N T

FINAL EXAMINATION

CO URSE

ANUFACTURING PROCE SSES 1

CO URSE CO DE

FF/BFM 2403

L E C T U R E R

A F R IZU A N M A T Y A HY A

DATE

N O V E M B E R

2 0 1 0

DURATIO N

HOURS

SESSION SEMESTER :

ESSION

2 0 1 0 / 2 0 1 1

SEMESTER I

PROGRAMME CODE :

FFIBFM

INSTRUCTIONS TO CANDIDATE:

a)

This examination paper is divided into TWO sections.

(b )

SECTION A:

Answer ALL questions.

(c )

SECTION B:

Answ er TW O 2) questions only.

d )

All answers to a new question should start on new page.

e )

All the calculations and assumptions must be clearly stated.

f)

Candidates are allowed to bring one piece of A4 size paper with hand written

note on both sides.

DO NO T TURN TH IS P AG E UNTIL YO U ARE TO LD TO DO SO

This exam ination paper consists of

NINE (9)

printed pages including front page



CONFIDENTIAL

FFIBFMI1O1 1IIBFF/BFM2403

SECTION A

ANSWER ALL THREE 3) QUESTIONS

QUE STION 1 20 marks)

a) Figure A below shows the connecting rod for an internal combustion engine. This

product can be produced using closed-die forging process.

Figure A: C onnecting Rod

i

Elaborate the steps to make the product starting from bar stock.

10 marks)

ii .

State the difference betw een fullering and ed ging during preform ing

operations of this product.

2 marks)

b) Extrusion and drawing have numerous applications in the manufacture of

continuous as w ell as discrete products from a wide va riety of metals and alloys.

i Define the main difference between the metal extrusion and metal

drawing process.

2

marks)

ii .

Point out the differences between direct and indirect extrusion

providing a neat sketch.

6 marks)

2



CONFIDENTIAL

FFIBFMJ101 1IIBFF/BFM2403

QU STION 2

20 marks)

a) During metal cutting process, several types of metal chips is produced. Classify

four 4) types of chips during chip formation and sketch any two of them.

4 marks)

b) An orthogonal cutting operation is being carried out under the following

conditions: t

= 0.15 mm, t = 0.3 mm, width of cut =

5 mm, V

= 2 5 m/s rake

angle a) =8

F

= 268 N,

= 500 N and = 200 N.

i.

Calculate the total power dissipated.

2 marks)

ii . Determine the power of shearing.

10 marks)

iii.

Calculate the percentage of total energy dissipated in the shear plane.

2

marks)

c) Grinding operation is a chip-removal processes that used an individual abrasive

grain as the cutting tool. Define how is centerless grinding different from

cylindrical grinding?

2

marks)

3



CONFIDENTI L

FFIBFM 1O11IIBFFIBFM2403

QUESTION 3 20 marks)

(a) In casting process, the fluid flow of the molten metal is important. The molten

metal is poured through a pouring basin or cup and then flows through the gating

system to fill up the mold cavity

i

Sketch and label gating system of casting including pouring cup

(2

marks)

ii

ist and explain the functions of elements consist in the gating system

8 marks)

(b) Welding process is one of the joining operation that can be classified into two

major categories; fusion welding and solid-state welding. Compare between these

two categories of welding process.

6 marks)

(c) A wide variety of metalworking fluids including oils, emulsions, synthetic

solutions and solid lubrications are available for specific application in

manufacturing operations. From your point of view, what are the functions of these

metalworking fluids in manufacturing processes?

(4

marks)

4



CONFIDENTIAL

FFJBFMJ101 1IIBFF BFM2403

SEC TION B

A N S W E R T W O

2)

Q U E S T I O N S O N L Y

Q UE STION 4 20 mar ks )

a) A n A NSI 10 20 carbon-steel strip will undergoes flat-rolling process in order to

reduce the thickness of the material. The specification of material are: 200mm

wide, 10mm thick and rolled to a thickness of 7mm. The roll radius is 200mm and

rotates at 200rpm. Assume for AN SI 1020 carbon-steel; K530 M Pa and n0.26).

Calculate:

Roll-strip contact length L

2 marks)

The true strain c)

2

marks)

Average flow stress

2 marks)

iv .

The roll force F

2

marks)

V .

he torque

T

2

marks)

b) Shearing is one of the common Sheet-metal forming processes. Shearing can be

classify into two types which are punching and blanking.

C omment the differences between these two operations.

2

marks)

ii.

Ilustrate with appropriate sketching to justify the difference.

2

marks)

5



CONFIDENTIAL

FFIBFM/101 1III3FFIBFM24O3

c) Extrusion and injection molding are widely used in manufacturing area to produce

variety of plastic products.

i.

Which one of these two processes require the use of mold?

1 marks)

ii .

Show the main operations in injection molding process to produce

name-tag enclosure as Figure B below.

5 marks)

Retractabie Clip

Name tag enclosure

Naniétag

Figure B:

Name tag Enclosure



CONFIDENTIAL

FFIBFM 101 1IIBFF BFM2403


a)

Friction stir welding is one of the comm on methods un der solid-state welding

process. Ex plain the process briefly with the help of neat sketch.

8 marks)

b)

Braz ing, soldering, adhesive-bonding and m echanical fastening process were the

joining processes that can be u sed to join dissimilar metals of intricate shapes and

various thickness. Figure C b elow shows an exam ple of combination joint for sheet

metal.

dhesive

______ \

_____

w e t

Figure C: A n example of combination joint

Substitute the comb ination joint other than those stated in the figure.

4 marks)

c)

Figure D below illustrated a muffler before and after coated using electroplating

process.

u

Figure D:

M uffler before and after electroplating

Recomm end app ropriate process of electroplating for the muffler.

8 marks)

7



CONFIDENTIAL

FF/BFMI101 lI/BFF/BFM2403


(a) During machining operation, wear and failure often occur in the cutting tools. Why

optimum cutting speed is an important consideration to determine cutting tool life?

(2

marks)

(b) A 15mm diameter bar of low-alloy steel, pre-heated to FMC 28, is finish turned to

14.5mm over a 200 mm length, using the carbide tool insert. Under the roughing

cutting process, calculate; (Given; Spindle rotates, N = 400rpm Feed rate,

200mmlmin

i. Average cutting speed,

(3

marks)

ii. Material removal rate (MRR)

5 marks)

iii.

he total cutting time,

(2

marks)

(c) Milling is a machining process in which a rotating cutter removes material while

traveling along various axes with respect to the workpiece. Draw a simple sketch

of up milling and down milling and elaborate the differences between them

8 marks)

8



Ha rd disk

CONFIDENTIAL

FFIBFMJ101 1IIBFF/BFM2403

QU STION 7 20 marks)

a) In metal casting processes, there are two categories of mold used.

i

Differentiate between expendable mold and permanent mold.

2

marks)

ii

Sand casting is one of the process that classify under the expendable

mold. Describe the steps in a typical sand-casting operation.

6 marks)

iii Choose and explain the best casting process that can be used to produce

hard disk casing as shown on Figure E below. What is the major

advantages of suggested manufacturing process?

8 marks)

Hard disk casing

Figure E

Hard Disk Casing

b) For successful casting operation, the product with large flat surface is not favorable

design.

i

Why?

ii

Propose a technique to reduce the observation stated in b) i?

4 marks)

END OF EXAMINATION PAPER

9

bff2403 - manufacturing processes i

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