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EM JAN 2013 MEM560

UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE

COURSE CODE

EXAMINATION

TIME

MANUFACTURING PROCESSES

MEM560

JANUARY 2013

3 HOURS

INSTRUCTIONS TO CANDIDATES

1 .

This question paper cons ists of seven (7) questions.

Answer six (6) questions in the Answer Booklet. Start each answer on a new page.

.

3.

Do not bring any material into the examination room unless permission is given by the

invigilator.

Please check to mak e sure that this examination pack consists of :

i) the Qu estion Paper

ii) an Ans wer Booklet - provided by the Faculty

DO NOT TURN T IS P GE UNTIL YOU RE TOLD TO DO SO

This exam ination paper consists of printed page s

© Hak Cipta Universiti Teknologi MARA

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EM JAN 2013 MEM560

QUESTION 1

a) Answer the following questions briefly:

i) W hat is me trology and why it is important in mechanical engineering practices?

ii) How is mea suremen t distinguished from inspection?

iii) Explain briefly the two (2) major universal systems of units in recording the

measurement.

(6 marks)

b) Lalila is a project engineer in a car manufacturing company and the company had

decided to introduce a new model and the new model must be produced at a

competitive price for global distribution. Discuss four (4) possible ways that she should

take in order to achieve that objective.

(4 marks)

QUESTION 2

a) Hot wo rking for me tal involves plastic deform ation above the recrystallization

temperature of the w ork material. Define the recrystallization tempe rature for the metal.

(2 marks)

b) Propose the most suitable metal forming process to manufacture the following

engineering products:

i) Crane hook

ii) Spanner

iii) Alum inium curtain railing for dom estic application

iv) Electric pow er cable

v) Copper tube for air conditioning duct

vi) Steel T-se ction for building

(2 marks)

c) Crankshaft is an important automotive component. There are at least two (2)

manufacturing processes that can be used to manufacture a crankshaft. Suggest the

two (2) processes and which of these processes preferred and why?

(2 marks)

d) One of the comm on metal forming processes is extrusion process. Define extrusion

process and briefly d escribe the types or methods of extrusion.

(4 marks)


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EM JAN 2013 MEM560

QUESTION 3

a) Varieties of ma terials can be used for casting components and there are number of

different casting techniques involved. Explain the advantages and limitation of these

casting techniques.

(3 marks)

b) Gene rally there are two (2) types of casting; expen dable and permanent mould

casting.

D escribe the differences between expendable and permanent m ould casting.

(3 marks)

c) Briefly explain Die casting process and name two (2) com mon products that can be

produced by this process.

(4 marks)

QUESTION 4

Many methods can be used for joining materials and every joining method has particular

design requirements.

a) Soldering is a joining process and various metals can be soldered together. Explain

briefly about soldering process.

(2 marks)

b) Brazing joins two pieces of metal whe n a melted metallic filler called brass flows across

the joint and cools to form a solid bond. Briefly explain the principle of brazing process.

(2 marks)

c) Explain the principle underlying resistance welding process. Give examp les of products

produced by the following resistance welding processes:

i) Spot welding

ii) Seam welding

iii) Upset butt we lding

(6 marks)

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QUESTION 5

a) There are many traditional machine tools available in FKM machine shop. Answer

briefly the following questions w ith regards to machine tools:

i) Nam e at least six (6) machine tools available in FKM machine shop.

(2 marks)

ii) De scribe briefly one (1) of the machines that you had nam ed in part (i) above .

(2 marks)

iii) Wh en the machine tool is used for metal cutting, chips are produced as waste

materials. Name three (3) basic categories of chips in metal cutting. Discuss

briefly one (1) of them .

(2 marks)

b) Two experiments for turning process using HSS cutting tool were carried out based on

different cutting spe eds and the tool lifes were recorded as follows:

Experiment

1

2

Cutting speed; V

(m/min)

478

321

Tool life; T

(min)

10

25

Determine:

i) the constant in the Taylor s equation,

ii) the tool life T, at V = 31 9 m/m in, and

iii) the cutting spee d for tool life of 20 min .

(4 marks)


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EM JAN 2013 MEM560

QUESTION 6

a) As a man ufacturing engineer, you are required to make a mould for a new design of

mobile-phone-casing using a non-traditional machining (NTM) process. What is the

most suitable NTM p rocess that you will recommend? Explain why you select that NTM

process.

(4 marks)

b) In NTM process, Electron Beam Machining (EBM) and Electrical Discharge Machining

(EDM) fall under the category of thermal process.

i) Ske tch the schem atic illustration for both machining methods to show the

differences in the operational principles.

(4 marks)

ii) Determine two (2) design guidelines for each type of the processes.

(2 marks)

QUESTION 7

a) Name four (4) plastic processing methods available currently in industries. Describe

two (2) of the methods that you have named and list at least two (2) advantages and

disadvantages of the methods described.

(6 marks)

b) Powde r me tallurgy (P/M) application enables the manufacturing of sm all, intricate parts

of high precision resulting in high density, net-shape and the elimination of scrap

during the process. Describe some of the characteristics of the metal powders to be

considered in P/M.

(4 marks)

END OF QUESTION PAPER


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