FACULTI OF MECHANICAL ENGINEERING UNIVERSITI MALAYSIA PAHANG BMM3643 (Sem I 2013/14)

Assignment #3
1. a) What are the effects of the different shapes and sizes of metal particles in powder metallurgy processing? b) What is the most common method of producing metal powders? What are some of the other techniques that can be employed to produce particulate material? c) What is isostatic compaction? For what product shapes might it be preferred? (8 marks)

2. a) Describe the RP technology called a three-dimensional printing technique. b) What is rapid prototyping? Provide a definition of the term. Identify three types of starting materials in rapid prototyping? c) Explain the significance of rapid tooling in manufacturing. (8 marks)

3. a) Identify FOUR (4) reasons why machining is commercially and technologically important. b) What variables must be considered in understanding a machining process? c) List FOUR (4) are the primary considerations in tool selection? (8 marks) 4. a) Explain the similarities and differences in the design guidelines for turning and for boring. b) How can a tapered part be turned on a lathe? c) Describe FOUR (4) effects of vibration and chatter in turning operations. (8 marks)

5. a) What is the difference between peripheral milling and face milling? b) What is the advantage of a helical-tooth cutter over a straight-tooth cutter for slab milling? c) Explain why speeds are much higher in grinding than in machining operations. (8 marks) 6. a) Estimate the number of particles in a 500-g sample of iron powder if the particle size is 75 m. The density of iron is 7.86 g/cm3. The particle diameter D is 75 m = 0.0075 cm. b) A 30 mm diameter bar of low-alloy steel, pre-heated to HRC 28, is machined with a turning process over a 200 mm length, using the carbide tool insert. Calculate; Rotational speed (r/min) Material removal rate (MRR) Cutting time (sec)

(Given; The cutting speed, v = 2 m/s; Feed, f=0.25 mm/s & Depth of cut = 0.65 mm) (5 marks)

c) Estimate the time required for face milling an 20.32 cm-long, 7.62 cm-wide brass block using a 2032 cm-diameter cutter with 12 HSS teeth. (Given: Using the high-speed-steel tool, lets take a recommended cutting speed for brass (a copper alloy) at 90 m/min = 1.5 m/sand the maximum feed per tooth as 0.5 mm) (5 marks)

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