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AIN SHAMS
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FACULTY
OF ENGINEERING
DESIGN
& PRODUCTION
ENGINEERING
DEPARTMENT
3'd year Protlucrion
Section
2"d Semester,
Mav 2007
Time : 3.00 Hrs
The Exam consi st s of Si x
euest i ons
i n (2)
pages
23/5/2007
t/2
a) Using neat sketches
and brief notes compare between: (put the answer in table)
1- Drop forging
and press forging
2- Hydro-forming
and explosive iorming
b) Draw the diagram illustrating
ihe effect of fiiishing temperature
on grain size during forging
process
of carbon stee1, and compare between fine grains and coarse-grains.
c) I' -or the stepped shaft shonn in figure, made of mild steel.
l - choose t he sui t abre manuf act uri ng
process and machi ne.
2- Make a forming drawing.
3- Expl ai n
t he t echnol ogi cal
seqr_rence of operat i ons.
For mi ng
Ouest i on
(1)
a) Describe in detail using sketches the different methods to produce
an I
_
Beam.
b) Sketch the distribution
of the rolling pressure
in the deformation
zone under the effect of
t he f ol l owi ng.
l - Usi ng Front Tensi on al one.
2- Usi ng Back Tensi on al one.
3- Usi ng Front and Back Tensi on.
4- Di f f erent
I ni t i al Thi ckness (
t b )
c) Expl ai n usi ng sket ches
t he e. rt rusi on
del ect s and horv t o o' ercome t hem.
(17
Mark)
(16
Mark)
a) I l l ust rat e t he advant ages
and di sadvant ages
of porvder met al l urgy f or procl uct i on
of engi neeri ng part s.
b) Describe trvo methods
used for manufacturing
metar por,r,ders.
c) Expl ai n t hree met hods
used f or f ormi ng t he t hl rmopl ast i c
mat eri al s and t hei r appl i cat i ons
uesti on
P. T. O
AIN SHAMS UNIVERSITY, FACULTY OF
DESIGN & PRODUCTION ENGINEERING
ENGINEERING
DEPARTMENT
Time : 3.00 IIrs
The Exam consi st s of Si x
Quest i ons
i n (2) Pages
Machi ni ng
Quest i on(l ) (15
Marks)
a) Classify, using neat sketches, the different types of mandrels used in turning.
b) What are the requirements of use of collets instead of regular lathe chucks in turning?
c) What are the differences betr,veen a conventional center lathe and capstan and turret lathes?
d) Illustrate with on a diagrammatic sketch, how many cr"rtting tools can be installed on a capstan
l at he.
e) What are the difference(s) between universal and horizontal and vertical milling rnachines?
0
Differentiate between the fixed-bed type and colurnn and knce type milling machines.
g) What are the advantages and disadvantages of up and down milling?
Questi on(2)
(20 Marks)
a) What are the functions of a universal dividing head?
b) Determine the procedure for milling an 85 teeth gear on a milling machine. equipped with24,
24, 28, 32, 40, 44, 48, 56, 64, 72, 86. 100 change gears and an i ndex pl at e wi t h 37, 39, 41, 43, 47
and 49 holes circles.
c) What type of indexing can be used in dividing the periphery of a helical gear, and why?
d) Explain, with the aid of neat sketches the generation method used in cutting gear teeth.
e) What i s meant by abrasi ve machi ni ng?
0
Explain in brief the main specifications of a grinding wheel.
g) What is meant by too hard or too soft grinding rvheel?
h) Expl ai n t he mechani sm of sel f sharpeni ng of gri ndi ng r, vheel s. Horv does t hi s hel p i n sel ect i ng a
proper gri ndi ng rvheel rvhen machi ni ng Al umi num and case hardened st eel ?
i) t-or what type of workpieces is centerless grinding tnost efficient?
Quest i on( 3)
(15 Marks)
i
i
t
n \
b)
What i s meant by superf i ni shi ng operat i ons?
Descri be how to generate a compl ex path for the l appi ng operati on, and rvhy do rve need to
generate such a path?
What are the cri ti cal honi ng process parameters?
Can we use a cast i ron l ap, when l appi ng a workpi ece made of brass? And why?
Descri be Wi t h t he ai d of neat sket ches t he superf i ni shi ng operat i on.
What are the di fferences betu,een honi ng and i nternal cyl i ndri cal gri ndi ng?
d)
c)
0
Good
Luck