CONFIDENTIAL UNIVERSITI KUALA LUMPUR Institute of Product Design and Manufacturing FINAL EXAMINATION JANUARY 2015 SESSION SUBJECT CODE : PPB15104 SUBJECT TITLE : MANUFACTURING TECHNOLOGY LEVEL : DEGREE TIME | DURATION : 2,00 pm— 4.30 pm (2% HOURS ) DATE : 3 JUNE 2015 INSTRUCTIONS TO CANDIDATES |. Please read the instructions given in the question paper CAREFULLY. x . This question paper consists of ONE (1) section only; Section A e . Answer ANY FOUR (4) of FIVE (5) questions in Section A. 2 . Please write your answers on the answer booklet provided. 6. The usage of calculator is recommended. n Formulae are attached. THERE ARE 4 PAGES OF QUESTIONS, EXCLUDING THIS PAGE.JANUARY 2015, CONFIDENTIAL SECTION A (Total: 100 marks) INSTRUCTION: Answer any four (4) questions. Please use the answer booklet provided. Question 1 (a) Using an input-process-output diagram (IPO), describe: i. Manufacturing as a technical process and ii’ Manufacturing as an economic process (adds value) (10 marks) (0) Figure 1 shows the Die casting part of an automotive. As the manufacturing engineer, you are required to explain the production sequence of the above part from preparation unti finished casting. Figure 1 Die-casting part (10 marks) (c) _ Inthe casting of steel under certain mold conditions, the mold constant in Chvorinov's Rule is known to be Cm = 4.0 min/m2, based on previous experience. The casting is a flat plate whose length = 300 om, width = 10 cm, and thickness = 20 mm. Determine how long it will take for the casting to solidify (5 marks) PPB 15104 MANUFACTURING TECHNOLOGY Page 1 of 4JANUARY 2015 CONFIDENTIAL Question 2 (a) (b) ©) In casting experiments performed using a certain alloy and type of sand mould; it took 190 sec (TST) for a square-shaped casting to solidify. The square (4 sides) was 50 mm on a side. Determine the value of the mould constant B in Chvorinov's Rule. (answer in simm?) (6 marks) Based on Chvorinov's rules calculate the following problem: 1. In the casting of steel under certain mould conditions, based on previous experiment, is known to be B = 2.0 min/om?. The casting is a flat plate with length of 400 cm, width of 200 cm, and thickness of 30 mm. Determine how Jong it will take for the casting fo solidify. (answer in minute) (7 marks) ji, A disk-shaped part is to be cast out of aluminum. The diameter of the disk = 5000 mm and its thickness = 20 mm. If B = 4.0 secimm? in Chvorinov's Rule, how long will it take the casting to solidify? (answer in minute) (7 marks) Describe a difference between: i. Permanent moulds and Expendable ji. Vacuum permanent-mold casting and vacuum molding ( marks) Question 3 @) Sketch the stress-strain relationship of high carbon steel, medium carbon steel and low carbon steel. Based on the relationship, explain the behavior of these materials. (10 marks) PPB 15104 MANUFACTURING TECHNOLOGY Page 2 of 4JANUARY 2015, ‘CONFIDENTIAL, (6) Clamping Unit in injection molding machine consist of toggle, hydraulic and hydromechanical. Explain the mechanical advantage in term of movement and tonnage clamping, ( marks) () The injection unit of injection moulding consists of a barrel and a screw containing a supply of plastic pellets. Sketch the injection unit and explain the function of the unit. Based on the Table 1, calculate the following problems based on shrinkage in injection moulding: i. Compute the corresponding dimension to which the mold cavity should be machined for polyethylene and the mold cavity dimension is 450 mm (2 decimal points). ii, The part dimension for a certain injection molded part made of polycarbonate is specified to 2.75 inches. Compute the corresponding dimension to which the mold cavity should be machined (2 decimal points). Table 4: Typical values of shrinkage for molding of selected thermoplastic Plastic ‘Shrinkage, mralmm ABS 0.006 Nylon 65 ‘0.020 Polycarbonale “0.007 Polyethylene 0.025 Polystyrene 0.004 PVC 0005 (10 marks) Question 4 (2) Compare and differentiate between hot and cold working processes and explain the main objective of hot and cold working process. Provide five (5) advantages of hot working process relative to cold working process of a metal. (10 marks) PPB 15104 MANUPACTURING TECHNOLOGY Page 3 of 4JANUARY 2015 (CONFIDENTIAL, (b) Compare net shape and near net shape forging. Discuss a possible objective of near net shape forging? (© marks) (©) Tool life tests on a lathe have resulted in the following data: (1) v = 350 filmin, T= 7 min; (2) v = 250 ft/min, T= 50 min. i. Determine the parameters 1 and C in the Taylor too! life equation. i, Compute the tool life that corresponds to a cutting speed v = 300 ft/min. ii, Compute the cutting speed that corresponds to a tool life T= 10 min. (10 marks) Question § (2) Briefly describe the term boring and parting in lathe related operation and briefly describe three (3) types of chips that resulted in metal cutting. (© marks) (b) A nnole of 40 mm (D) diameter and 50 mm (d) depth is to be drilled in to a mild steel component. The cutting speed (v) can be taken as v= 2.5 mis and the feed rate (f) as 0.25 mmirev. Assumed that the constant C for mild steel is 616 and K = 84.7. Calculate drilling torque (Nm) and thrust (kN) (10 marks) (©) Acylindrical workpart with diameter of @ 0.250 m and 900 mm tong is to be tumed in an engine lathe. Cutting conditions are: v = 2.5 mis, f = 0.3 mvrev, and d= 4.0 mm, Determine: (i) cutting time (min), and (i) metal removal rate (mm*/s), (10 marks) END OF QUESTION PPB 15104 MANUFACTURING TECHNOLOGY Page 4 f4Formulae: a 142xA 1000 f-2N A=W B-W) for =2 4-2 for =2up tod L+L, _D IN tana L ” TN MRR = M=CD” f° Nam T=KDf TT’ = t= BV/ Ay" P,=2bh& ae P=bldy Ts = BOY Tn = =n fr=Nfmmis pT" =C yr ph dmc MRR = vf D, =D, +D,S+D,S? Work require to shear hole = Fy Xt%C Max load on punch (without shear hole) = qxbx xxt Fox ® Xt Angle of shear tan = a Angle of shear tan@ = ‘punch diameter ingle of shear Pa ‘punch diameter