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CONFIDENTIAL

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FINAL EXAMINATION
SEMESTER I
SESSION 2014/2015
COURSE NAME

: MANUFACTURING TECHNOLOGY

COURSE CODE

: BDA 30502

PROGRAMME

: 3 BDD

EXAMINATION DATE

: DECEMBER 2014/JANUARY 2015

DURATION

: 2 HOURS

INSTRUCTION

: ANSWER FOUR (4) QUESTIONS ONLY

THIS QUESTION PAPER CONSISTS OF FIVE (5) PAGES

CONFIDENTIAL

BDA30502

Q1

(a)

In turning operation, FIVE (5) basic cutting techniques have been used
widely in industries to perform shape and contour. Illustrate in figure and
label completely.
(5 marks)

(b)

There are FOUR (4) types of chip during machining influences by the
cutting speed, spindle speed, material etc. Draw each of the chip formation
and label with the explanation.
(8 marks)

(c)

A slab milling operation is performed to finish the top surface of a steel


rectangular work piece 250 mm long by 70 mm wide. The helical milling
cutter, which has a 80 in diameter and eight teeth, is set up to overhang the
width of the part on both sides. Cutting conditions are: v = 50 m/min, f =
0.12 mm/tooth, and d = 3.00 mm. Determine:
(a)
(b)

the time to make one pass across the surface.


the metal removal rate during the cut.
(12 marks)

Q2

(a)

Describe what mean by the investment casting and give THREE (3)
examples of products that are normally made by such technique?
(5 marks)

(b)

Discuss the different between the mould for sand casting and die casting dies
(10 marks)

(c)

Explain how the die casting works with the aid of a diagram
(10 marks)

Q3

(a)

Describe what mean by the hot working and cold working than give TWO
(2) examples of products that is normally made by such technique?
(5 marks)

(b)

Discuss the different between the upsetting and heading with the aid of
diagram
(10 marks)

(c)

Explain how the impressive die works with the aid of a diagram
(10 marks)

Q4

(a)

Explain how the blow-molding technique works?


(4 marks)

(b)

Describe what it means by calendaring process and give THREE (3)


examples of products that is normally made by such technique?
(5 marks)
2

BDA30502

Q5

(c)

Explain how the compression molding works with the aid of a diagram?
(8 marks)

(d)

Discuss the difference between the mold for injection molding and the mold
for compression molding process?
(8 marks)

(a)

State FIVE (5) reasons why powder technology is important?


(5 marks)

(b)

List FIVE (5) methods that are normally used to produce metal powders?
(5 marks)

(c)

Explain what it means by sintering in powder metallurgy?


(3 marks)

Q6

(d)

State FIVE (5) advantages and the disadvantages of powder technology?


(12 marks)

(a)

What is the basic principle of fusion welding?


(5 marks)

(b)

Describe in detail a typical Arc Welding Process complete with aid of


diagram
(10 marks)

(c)

Compare the advantages and disadvantages of Solid State Welding (SSW)


and Fusion Welding (FW)
(10 marks)

- END OF QUESTION -

BDA30502

ANSWER
Q1

(a)
Operation type

Characteristic
Facing
-

Remove face of workpiece


Control the workpiece length
etc

Contour turning
-

Instead of feeding tool parallel to axis of rotation,

tool follows a contour that is other than straight,


thus creating a contoured shap

Chamfering
-

Cutting edge cut an angle on the corner of the


cylinder, forming chamfer

Cut off or Parting


-

Tool is radially into rotating work at some location


to cut end of part

Threading
-

Pointed form tool is fed linearly across surface of


rotating workpart parallel to axis of rotation at a
large feed rate, thus creating threads

(4 marks)

BDA30502

(b)
Chip type

Characteristic
Brittle work materials
Low cutting speeds
Large feed and depth of cut
High tool-chip friction

Ductile work materials


High cutting speeds
Small feeds and depths
Sharp cutting edge
Low tool-chip friction

Ductile materials
Low-to-medium cutting speeds
Tool-chip friction causes portions of chip to adhere to rake
face
BUE forms, then breaks off, cyclically

Semicontinuous - saw-tooth appearance


Cyclical chip forms with alternating high shear strain then
low shear strain
Associated with difficult-to-machine metals at high cutting
speeds

(c)

(v)

BDA30502

Q2

(a) A pattern made of wax is coated with a refractory material to make mold, after
which wax is melted away prior to pouring molten metal
-cast rotor, jewelery, knee

(b)
Sand casting
Need the core
Need the pattern
Green sand material
Expandable Mold

Die casting
No need core
No need the pattern (Need the cooling channel)
Tool Steel
Permanent mold

(c)
6

BDA30502

(a) die is closed


(b) plunger is withdrawn
(c) Molten metal flow into the chamber
(d) plunger forced molten metal into the die
(e) maintain pressure during solidification
(f) die is open and the part is ejected

Q3

(a) cold working-the working has perform slightly above at room temperature
blanking, drawing
hot working-the working has deformation at temperatures above the recrystallization
temperature
hot forging, impressive die

(b) upsetting
- wire stock is fed to the stop
- gripping dies close on the stock and the stop is retracted
- punch moves forward
- bottoms to form the head

heading
-heading a nail using open dies
- round head formed by punch
- two common head styles for screws formed by die
- carriage bolt head formed by punch and die

BDA30502

(c)
impression die work process by compression of workpart through the dies with inverse of
desired part shape as following,
-prior to initial contact with raw workpiece
-partial compression
-final die closure, causing flash to form in gap between die plates

Q4

(a)
i)
ii)
iii)
iv)

extrusion of parison (1)


parison is pinched at the top and sealed at the bottom around a metal
blow pin as the two halves of the mold come together (1)
the tube is inflated so that it takes the shape of the mold cavity (1)
mold is opened to remove the solidified part (1)

(b) Calendaring process is a process of pass the feedstock through a series of rolls (1)
to reduce the thickness to desired gage (1). Product examples: PVC floor covering,
shower curtains, vinyl table cloths, pool liners, and inflatable boats and toys (3)
(c)

(3)

i)

Charge (raw material) is loaded (1)


8

BDA30502

ii)
iii)

charge is compressed (pressure) and cured (heat) (2)


part is ejected and removed (2)

(d)
Mold for injection
Pack with cooling system and runner
system
Has sprue and runner system
Simple and complex geometry

No heat involved on the mold

Q5

Mold for compression


Simpler and no cooling system and
runner system
No sprue and runner system
Process itself generally limited to
simpler part geometries due to lower
flow capabilities of TS materials
Mold must be heated, usually by
electric resistance, steam, or hot oil
circulation

(a)
i) PM parts can be mass produced to net shape or near net shape, eliminating
or reducing the need for subsequent machining
ii) PM process wastes very little material - ~ 97% of starting powders are
converted to product
iii) PM parts can be made with a specified level of porosity, to produce porous
metal Parts. Examples: filters, oil-impregnated bearings and gears
iv) Certain metals that are difficult to fabricate by other methods can be
shaped by powder metallurgy
v) Tungsten filaments for incandescent lamp bulbs are made by PM
vi) Certain alloy combinations and cermets made by PM cannot be produced
in other Ways
vii) PM compares favorably to most casting processes in dimensional control
viii) PM production methods can be automated for economical production

(b)
i)
ii)
iii)
iv)
v)

Atomization
Reduction
Electrolytic deposition
Carbonyls
Comminution

(c)
Sintering is the process whereby green compacts are heated in a controlledatmosphere furnace to a temperature below the melting point but sufficiently
high to allow bonding (fusion) of the individual particles

BDA30502

(d)
Advantages
i)
Although the cost of metal powder is high, there is no loss of material.
The parts can be produced clean & bright, ready for use.- Net shape and
near shape products.
ii)
Composition of product can be controlled. No risk of contamination.
iii)
Close dimensional tolerances can be maintained.
iv)
Non-metallic substances can be produced and in any proportion to get
the final product.
v)
A wide range of properties such as density, porosity and particle size
can be obtained for particular applications.
vi)
It is possible to unite materials that cannot be alloyed in the normal
sense or would not yield the desired characteristics
vii) Useful for magnetic core having special desirable properties.
viii) Reduction in the production time.
ix)
No skill labor is required.
x)
Saving material and 97 % is possible.
xi)
Composition, structure and properties can be controlled more easily and
closely than any other fabricating process.
Disadvantages
i)
Pure metal powders are very expensive to produce.
ii)
Size of the products to be produced is limited because of the large
presses are required.
iii)
Lack of metals powder like steels, bronzes, brasses etc.
iv)
Strength properties are lower than those of similar article produced by
conventional methods.
v)
Poor plastic properties impact strength and elongation.
vi)
Die design limit the size of products.
vii)
Dies required are very expensive and needed large quantities of
products. Volume must be justified.

Q6

(a) A fusion welding process in which coalescence of the metals is achieved by the
heat from an electric arc between an electrode and the work

10

BDA30502

(b)

- A pool of molten metal is formed near electrode tip, and as electrode is moved along joint,
molten weld pool solidifies in its wake
- Electric energy from the arc produces temperatures ~ 10,000 F (5500 C), hot enough to
melt any metal
-Most AW processes add filler metal to increase volume and strength of weld joint
-An electric arc is a discharge of electric current across a gap in a circuit
-It is sustained by an ionized column of gas (plasma) through which the current flows
-To initiate the arc in AW, electrode is brought into contact with work and then quickly
separated from it by a short distance

(c)
-If no melting, then no heat affected zone, so metal around joint retains original properties
-Many SSW processes produce welded joints that bond the entire contact interface
between two parts rather than at distinct spots or seams
- Some SSW processes can be used to bond dissimilar metals, without concerns about
relative melting points, thermal expansions, and other problems that arise in FW

11

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I

Ui\WER.SITI TI]I\ HIJSSEII\ OI{N MAI,AYSIA


PEPERIKSAAN AKHIR
SEMESTER II
SESI 2010111

NAMA KI'RSUS

TEKNOLOGI PEMBUATAN

KOD KURSUS

BDA 3052

PROGRAM

3 BDD

TARIKH PEPERIKSAJ${

APRIL/MEI 2011

JANGKA MASA

DUA (2) JAi\4

./'\.RAHA.N

JA\MAB EMPAT (4) DARr LrMA (s)


SOALAN DI BA}IAGIAN A DAN JAWAB
DUA (2) DARr (3) SOALAN Dr BAI{AGTAN
B

ficA PUttII{

(30) r'/rrMT

ITILIYANA KHAIRUNNISA

KAMARDIN

KEIITAS SOALAN INI MENGANDTINGI ENAM (6) MUKA STIRAT BERCETAK

FqNsiltPtrrnu5

SULIT

tr
BDA

3052

PART A (80 MARKS):


This section contains

FI\IE (5) questions. Choose

and answer any

FOIIR (4) questions

ONLY.

Q1

(a)

What is a casting process? State three (3) capabiiities and advantages

of

casting procsss.

(4 marks)
(b)

Briefly explain, what is the function of flask, riser, core and pattern in the sand
casting molds?
(4 marks)

(c)

With the aid of a sketch state the investuient casting process.


(7 marks)

(d)

A mechanical part with the tolerance of *0.075 mm with small thickness will be
produced using a casting process. The product needs to be produced in a high
quantity and good quality of surface finish and dimensional accuracy with less
finishing process. In order to produce this part, select the best casting process
and discuss why it is selected.
(5 rnarks)

Q2

(a)

Draw areatfigure of a force diagam shcwing the geometiic relationship


between all the forces acting on the chips in orthogonal cutting.
(7 marks)

(b)

By using illushations, distinguish and explain two forms of milling in the


peripheral milling. Describe the geometry of the chip formed by this process.
(6 marks)

(c)

List down three (3) processes ttrat can be done by the drill machine other than
making ahole'
(3 marks)

(d)

Explain the important steps implemented in the chemical machining.


(4 marks)

BDA

3052

List all the various rolling process available?


(3 rnarks)

Briefly explain open die forging, impression die forging and flashless forging.
(4 marks)
(c)

Explain forward and backward extrusion assisted with figures.


(5 marks)

(d)

what are blanking, piercing / punching, bending and forming processes. Give
example for each one ofthe procssses.
(4 marks)

(e)

In general, what are all advantages and disadvantages of hot working and cold
working processes?
(4 marks)

Q4

(a)

Explain die swell in plastic processing.


(3 marks)

(b)

Explain angle of repose in plastics


(3 marks)

(c)

wha.lr are the difFerences betvr.een thermoprastics and thermosets plastics?

Give examples for each one of them.

(d)

State about the viscoelasticity, viscosity, calendaring

in plastics

rr""::;;-'
(5 marks)

(e)

Explain wiflr figure the vacuum thermoforming process.


(5 marks)

QS

(a)

In powder metallurgy process, packing factor is a very important charactedstic


to be known. Identifu the relationship between packing factor and porosity

of

compacted parts.

(3 marks)

(b)

welding process can be divided into two major categories. what are the two
major categories and explain their differences from the point of processing
fundamental. Give two examples for each category.
(8 marks)

BDA 3052

(c)

Welding operator found out that tfr. :oirrt result of metal inert gas CMIG)
welded products are not constant. Some of the parts were seriously bumt and
full of porosity. There were welded with inconsistent penetration depth. List
out thiee (3) possible reasoils and explain the countermeasures that can be
taken.
(9 marks)

BDA 3052

PART B (20 MARI(S):


This section contains THREE (3) questions. Choose and answer any TWO (2) questions

ONLY.

Q6

cutting operation, the cutting tool has a rake angle of 5o. The lathe is
set so the chip thickness befcre the cut is 0.25 nam. After the cut, the deformed chip
thickness is measured to be 0.7 mm.

ln

an orthogonal

Calculate:

(a)
(b)
(c)

the chip thickness ratio


the angle of the shear plane
the length of the shear plane

If a cutting tool with

(d)
(e)

a rake angle

of

is used in this cutting process, determine:

the new length of the shear plane


the new angle ofthe shear plane

-----r

By refening to ail of the results, explain the reiation of rake angle with the length and
angle of the shear plane in the orthogonal cutting operation.

(i0 marks)

Q7

(a)

A work piece having 75 mrn diameter and length 300 mm is to be reduced


to diameter of 69 mm as final size. The depth of cut is 1 mm- The work piece is
rotating at 900 RPM. A carbide tool of 8 degree rake angle is used. The chip
thickness is 1.3 mm. The feed rate is 0.25 mm /rev.
rJ s 212,091'f
d

" -li-:--+
N+-

=1f^^
Calculate: o{ .g"
N s 91m

(i)

,,"l$ity,

,[s\-^,,

(ii)

f SThe time taken to machine up to 69 mm diameter to lengfh

(iii)

of 200 mm.
Total Material Removal Rate (MRR)

cutting

lorr6tu'$=7.

hnr+s

w{,=

(b)

t\ l'o

**/qr.

$^ "+
s

lor:(o:ra")

v{;"1

( .tr,r

-td

(5 marks)

x(10y1 .f ( n^)
A slab rnilling operation iJperformed to finish tlie top surface of a steel work
piece rectangular in section. The size of the work material is 350 mm iength
and 7$ mm wide. A helical milling cutter ,'which has a 75 mm diameter and
ten teeth, is set up to machine. The cutting speed is 130 m/min, the chip load
is 0.15 mm/tooth and depth of cut is 3 mm.
Calculate the following:

(i)

Time taken to make one pass across the surface and

r'^-"

E
BDA 3052

(ii)

Material Removal Rate (MRR).


(5 marks)

Q8

Tool life tests in turning yield the following data:

r
:

when cutting speed is 100 m/min, tool life is 10 min:


when cutting speed is 75 m/min, tool tife is 30 min.

(a)

Detemrine the n and C values in the Taylor tool rife equation.

(b)

Based on your equation, compute,


the tool tife for a speed of 110 m/min, and
the speed corresponding to atool life of 1j min.

i)
ii)

(10 marla)

3052 Manu

nal Exam Se

51

(a)

Process in which molten


metal flows by gravit-v or other
force into a inoici
where it solidifies in the shape
of the mold cavity. _

Advantages of casting:
Can create complex paft geometries
Can create both external and
internal shapes
Some casting processes arc
net shope; others t*e near
net shape
Can produce ve{y large parts
Some casting methods are
suited to mass

production
(1 mark each, max. 3 marks)

(b)

Flask - a box containing two parts


mold, cope and drag * I mark
Riser - is a reservoir in the
mold that serves as a source
of liquid metar for flre
casting to compensate for
stirintage

J**

solidification.

I mark

Placed ir''side the mold cavitv to defiae


the interior geomerry

r?:h:-irm
Pattern - is used to
_forrn the mold cavity, made of
other material which has the
rrrup.

"r*r"

of

wood, metal, plastic or


- r mark

part to be cast

(4 marks)

(c)

wax

ffiH

patternffi
\wry
(r)

(2)

ffiffii
(3)

(4)

W
(6)

(1) wax pattems are produc


ed, Q)several patterns are
attached to a sprue to form
pattern tree (3) trre pattem
a
hee is-coat"a *itr, ini*
r"r.r-"r*fractory
the full mord is formed uv .or..i"g"tjrJ
materiar,
(4)
coated "t
,rrmcient refractory materiar
".

*itl

F,r
BDA 3052

to make it rigid (5) the mold is held in an inverted position and heated to melt the
wax
and permit it to drip out of the cavity, (6) the mold is preheated to a high temperature,
t]re molten metal is poured, and it solidifies (7) the rnotA is broken awJy from
the
finished casting and the parts are separated from the sprue

(1 mark for each figure and explanation)

(d) Die casting.

(l)
A)
(3)
(4)
(5)
(6)

- 1 mark

highproductionrate
hrge production quatities
closetolerance possiblo +0.026 for small part
good surface finish

thinsectionpossible
small grain size and and good strength due to rapid
(1 mark for each erl$wsr, max 4 answers)

(a)

F: friction force, N: nonnal force to &iction, F. :


force to

r\"*

force,

shear

Fo: cutting force, Ft: thrust force,

force,

R:

normal
the resultant force

( 1 mark for

Fn =

each answer)

BDA 3052

*---__Trhla
up milling

( l mark)

down

rnilling

(1 mark)

up Milling or conventional miiling


-

the direction of motion of the cutter


cutter teeth is opposite the feed direction when
the teeth cut into the work.
(1 mark)

?oIn Milling or climb milling - the direction of cutter motion is the sarne as
the feed direction when the teettr cut into
the work.
(1 mark)

In up milling the chip formed by each cutting


tooth starts out very thin and
increases the thickness during tlr" ,,r."p of the
cutter.

(t mark)
In down milring the chip formed. by each cutting
tooth starts out very thick and
reduces the thickness tlrroughout the cut.
(1 mark)

(c)

1. Reaming
2. Tapping
3. Counterboring
4. Countersinking
5. Centering
6. Spot

(1 mark each for each answer, maximum


3 answers)
(d)

Cleaning - cleaning operatioti to ensure rnaterial


will be removed uniformly
from the surfaces etched.
Masking - a protective.coating called
laskanl is appiied to certain portions of
the part surface' It appiied to those portions
of the #".t ,*a"e that are not to
be etched.

Etching the part is immersed in an etchant that chemically


attacks those
portions of- the surface that are not masked
Demasftipg - The maskant is removed from the
part.
(1 mark for each answers)

r
i

BDA 3052

S3

(a)

Various rolling process are:

i. Two-High Rolling

Mill

ii. Three-High Roliing Mill


iii. Four-High Rolling Mill
iv. Cluster Mill

v.

Tandem Rolling Mill


iv. Thread Rolling
(3 marks)

(b)

Open-die forging - work is compressed between two flat dies, allowing metal
to flow laterally with minimum constraint

q,!6d.
lYq6.a

tw&(ddq0}l

lmpression-die forging - die coutains cavity or impression that is imparted to


workpart
Metal flow is constained so that flash is created.

Flashless forgrng - workpart is completely constrained in die


No excess flash is created.

(4 marks)

(c)

As rarn approaches die opening, a small portion of billet remains that cannot be forced
through die opening. This extoa portion, called the butt, must be separated from
extrudate by cutting it just beyond the die exit Starting billet cross section usually
round. Final shape of extrudate is determined by die opening.

Also called baclcward extrusion and reverse extrusion


Limitations of indirect extrusion are imposed by
a Lower rigidify of hollow ram
G Difficulty in supporting extruded product as it exits die.

___t'*

ffi--r
d$Pi

Ia)

(e) 'The punched out part from the strip is taken for subsequent
operation, it is
called blanking. The punched out part from strip is sluj
i**t"1ir rcrap. It is
called punching /piercing.

(e)

Q4

Advantages: Hotworking
In hot working process, more deformation is possible. Ductility
of the material is
good' Final product shape is good. Lower forles
and power trran in cold working
More intricate work geometries possible, need for annealing
may be reduced or
eliminated
Disadvantages -Reduce in strength, Scale fonnation,
no dimensional control, no
good surface finish.
CoId Working: Advantage: increased strength that results
from strain hardening.
Surface finish is good. Grain flow during J."formation
can cause desirable
directional properties in product. No heatLg of work required.
Disadvantages- Higher forces and. power requirea in th;
deformation operation,
Su.faces of starting work piece muit be free of scaie and
dirt.

(a)

Flow of polymcr

Extruded polymer "remembers" its previous shape when


in the rarger
to return ta it after leaving the die orifice

sectian of the extruder, tries

RDA

(b)

3052

A common test of interparticle friction is the angle of repose, which is the


angle formed by a pile of powders as they are poured from a nalrow funnel.

\----_---Z
\-/
\,/
\

tr ///,v

Funnet

tt
L-l

Pile of powders

(c)

enste of repose

What are the differences between thermoplastics and thermosets plastics?


Give examples for each one of them.
(4 marks)

Thermoplestics
Chemical structure remains unchanged during heating and shaping
More important commercially, comprising more than 7O9lr of total plastics
tonnage
Can be reused after re-melting
Thermosets
Undergo a curing process during heating and shaping, causing apermanent
change (cr o s s -linking) in molecular structure
Once cured, they carnot be remelted.

(d)

Yiscosity of a polymer melt decreases with shear rate, thus the fluid becornes
thinna at higher shear rates. Viscosity decreases with temperatuxe, t}us the
fluid becomes thinner at highet ternperatures.
Yiscoelasticity
It is the properfy of a material that determines the strain it experiences when
subjected to combination of siless and stain
Possessed by both polymer solids and polymer melts
Example: die swell in exkusion, in whichthe hotplastic expands when exiting
the die opening.

Die swell
I

r"ra*o*

Feedstock is passed through a series of rolls to reduce thiclcress to desired


gage Expensive equipment, high production rates. Process is noted for good
surface finish and high gage accuracy.Typical materials: rubber or rubbery
thermoplastics such as plasticized PVC

BDA 3052

il:iffi"lrl?;ry;X:,8:-,

shower currains, vinyl rable


ctoths, poot riners,

w
*--NN**
/._kEk

re-eB{.*

ffiE{t_

L_lMl*

-N>XNN
fl)
(2t

(a)

(b)

,wob

ffi
M6lddpan

(d)

S5 (a)

/:

(c)

i*

+*

porosity + packing
factor: 1.
packing factor
bulk density divided by true density.
One of the above

relation

Furtherexplaination +

2 marks.

tmart<.
Total Marks: 3 marks

O)

Fusionwelding
(The material is melted

Example: Arc welding, {dog


R*.G*ce

mark
2 marks
welding Oxy-fuel gas welding.
I mark

the process)

Solid state weldins


(coarescence resurlts frgm
application of pressure alone
or a combinuriol

point)

;;e prelr*.)

3::r-fry0":melting
Example:
Diffirsion welding,

filction

wetOing

ll*k
?::F
I MArK

Total Marks: g marks

BDA 3052

(c)

-Torch movement speed.


-Need constant and comect speed.
-Current and voltage setting
-Constant and correct current setting
-Shield gas flow rate.
-Constant and enough gas to shield the welding area until
&e melted area resolidified.
-Shield gas q4pe.
-Some materials are reactive against certain shield gas (titanium
and nitrogen)
2 marks (for each examFle of countermeasure).
I mark (for each correct explaination).

Total marks: 9 marks

BDA 3052

PART B (20 MARKS):


s6

(a)

(b)
(c)
(d)
(e)

r:

:0.357 _ 2 marks
tan : 0.357(cos5)lt-(0.357 sin 5|
A366 :20.1o _ 2 marks
.0
to: ls sin 0 .'. ls :0.2510.343 :0.72g mm _
1.5 mark
tan $ : 0.357(cos1) /t-(0.357 sin l) :
0.359 : 19o _ 2 marks
to= ls sin $ ... is = 0.2510.325 :
0.769 mm - 1.5 mark

Ato:

0.2510.7

Increasing the rake angle, will increase the


shear angle and reduce the length
of shear
plane. - 1 mark
(10 marks)

s7 (a)

1' Cutting

2'

Time

velocity:

rc

xdxN

taken:!.lgm

1000 =

3.142x 75 x g00 /1000 :272mlmin.

of turning i feed rate x

:0.99 mins.
T_

Turning to be done by ttu'ee

z.

RpM:200 / a,5X

g00

tir*J;im"ken :

i.) MRR for 75 mm diameter:

0.88

x d x feed

x3 :2.64minutes.

rate: 2r2 x1 x 0.25

ii) MRR for73mmdiamet., Iti;?of iloi:rH#"boo


iii) MRR for 71 mm diameter : 2A0x 1 x 0.25 :
SO,tiOO
iv) MRR for 69 mm diameter: 195 x I 0.25 : qg,:lSO
Totai IyIRR = 53000 + 5i5000 + 50000 +
4g750: cubic mm /min.

(b)

(5 marks)

cuttingverocity:zuxDxN/r000 =3.r4zx 75 xN:


130
N: 130 x 1000 /3.t4}x 75:551 R.PM
Feed rate : N x number of teeth x chip
load: 551 x 10 x 0.25

826.5

Approach length:75 mm.


Time taken to machine

i)

ii) Mry:.* *
rnm / mln^

x reed ,ut"

: (L + 75) / feed rate


I [t: ii?r8;!

];f;3iffiff:
(5 marks)

BDA 3052

(a)

(t) 100(10)"= C
Yg-.^qy,ions:
100(10)' :75(30)"
n 100 + nla l0 = Ia 75 + n11139
4.61+2.3 n= 4.31+3.4 n
4.61"

and

r!g(1.80

!:= 100(10)0:7 =
Check C:75(30)o'7 = ZSt3Oo.27
=
ll1 f27:

C=

(c)

186

t{,.g

186.0

f'27 = 186.0/ll0= 1.69

T=

4 marks

- 4.31 = (3.4 _2.3) n

n=5.27

(b)

e)75(30).: g.

3 marks

l.6gtn27 :1.693.7 = 6.97 min

u (15)0'27: 186.0
v = 186.0(15,)02? = 186.0/2.07

=g9,g6 m/min

3 marks

":t'

E:

10