ME6605

NATIONAL UNIVERSITY OF SINGAPORE FACULTY OF ENGINEERING

EXAMINATION FOR (Semester 1 : 2011-2012) ME6605 ABRASIVE AND NON-CONVENTIOANL PROCESSES

NOV/DEC 2011 - Time Allowed: 2.5 Hours

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INSTRUCTIONS TO CANDIDATES:

1.

This examination paper contains FOUR (4) questions and comprises FOUR (4) printed pages.

2.

Answer FOUR (4) questions.

3.

All questions carry equal marks.

4.

This is a CLOSED BOOK EXAMINATION.

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Question 1 (a) Each of the following manufacturing processes/methods in the table belongs to one of three types of fabrication methods. Tick [] under the column if you think it belongs to that category. You may tick more than one category if you think that is a hybrid method. Use a separate answer sheet. (6 marks) Manufacturing Processes CNC machining Casting/Forging Stamping Welding EDM Rapid Prototyping (b) The following terminology is applied: FDM: Fused Deposition Modelling; LOM: Laminated Object Manufacturing; SLS: Selective Laser Sintering; DMLS; Direct Metal Laser Sintering; SLA: Stereolithography Apparatus; LENS: Laser Engineering Net Shaping; 3DP: 3D Printer. (i) Which of the following rapid prototyping (RP) system(s) can produce solid metal components? A. 3DP (ii) B. LENS C. SLS D. SLA E. DMLS (3 marks) Subtractive Additive Formative

Which RP process has the highest surface finish compared to the rest? A. 3DP B. FDM C. LOM D. SLA E. SLS (3 marks)

(iii) Which RP process(es) can produce multiple material components, e.g. plastic, wax, metal, etc.? A. SLA (c) B. SLS C. 3DP D. FDM E. LOM (3 marks)

For adaptive slicing of a CAD model, we should use A. thicker layer B. thinner layer C. same thickness D. either one

in the smaller curvature of part surface to increase the part building efficiency without loss of any features. (3 marks) Briefly describe any new applications for rapid prototyping (RP) and justify why RP will be advantageous over other processes in this regard. (7 marks) Question 2 (d)

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(a)

Briefly describe how material is removed in the Chemical-Mechanical Polishing (CMP) process using a suitable process model. (7 marks) Briefly describe how material is removed in the Electrochemical Machining (ECM) process? What are the main advantages of ECM compared to conventional machining processes? (6 marks) In order to produce precision components from hard material with nano surface finish, what can be good manufacturing process(es) to use? Please justify your statements accordingly (6 marks) Name any ultra-precision machining processes that can produce mirror surface finish for ductile materials and brittle materials, respectively. (6 marks)

(b)

(c)

(d)

Question 3 (a) Explain the occurrence of open circuit, normal discharge, abnormal discharge and short circuit in Electro Discharge Machining (EDM) using the voltage and its corresponding current profiles. (6 marks) During the EDM process it is important to set certain critical parameters. In particular, explain the effect of the following (i) (ii) (iii) Discharge current Pulse duration Pulse interval

(b)

with respect to the material removal rate and electrode wear. (15 marks) (c) You are required to machine a hole of 5mm diameter on a ceramic block using the ultrasonic machining process. After machining, the hole was observed to have a taper. In your opinion how the conicity on the feature can be minimized or eliminated. (4 marks)

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Question 4 (a) Describe with neat sketches the working principle of a three-stage solid state laser. (8 marks)

(b)

You are required to machine a hole using a laser. In general what are the various hole parameters you will observe to study the quality of a laser machined hole. (4 marks) What are the advantages and disadvantages of Excimer Laser and Nd: YAG laser? (5 marks) The micro-hardness of boron carbide is 42,200 MPa and that of silicon carbide is 31,400 MPa. Which carbide material is expected to perform better when used as an abrasive to machine glass and alloy and what is the major reason? (8 marks)

(c)

(d)

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