CONFIDENTIAL UNIVERSITI KUALA LUMPUR INSTITUTE OF PRODUCT DESIGN AND MANUFACTURING Ce ee nn ee eee FINAL EXAMINATION JANUARY 2018 SEMESTER COURSE CODE : PTB 45102 COURSE TITLE : NON-TRADITIONAL MACHINING PROGRAMME LEVEL : DEGREE DATE : 08 JUNE 2018 TIME : 9.00 AM - 11.00 AM DURATION : 2HOURS INSTRUCTIONS TO CANDIDATES Please read CAREFULLY the instructions given in the question paper. This question paper has information printed on both sides of the paper. This question paper consists of TWO (2) sections; Section A and B. . Answer ALL questions in Section A and only ONE (1) question in Section B. e > Please write your answers on the answer booklet provided. THERE ARE 9 PAGES OF QUESTIONS, EXCLUDING THIS PAGE.JANUARY 2018 CONFIDENTIAL SECTION A (Total: 60 marks ) INSTRUCTION: Answer ALL THREE (3) questions. Please use the answer booklet provided. Question 1 a) b) 3) qa) e) Define the term ‘undersize’ as used in EDM Die Sinking. Illustrate your answer with a diagram, (4 marks) Based on ‘rule of thumb’, what will be the electrode dimension for finished hole of diameter 33.3 mm, if only one electrode is used for both roughing and finishing machining? (4 marks) Outline four (4) main characteristics of the material suitable for electrode of EDM process, (4 marks) Describe the term ‘recast’ as used in the EDM process. (3 marks) ‘A copper-based material is to be machined in a die-sinking operation. If discharge current is 25000mAmps, what is the expected metal removal rate? Estimate how much material is removed in 20 hours of operation? (You are expected to show the steps how you reach your answer, no detail calculation is required). Please refer to Table A for necessary data Given Material Removal Rate Where MRR= material removal rate in cubic mm/s or cubic inchimin (constant of proportionality) = 664 for SI unit or 5.08 for imperial unit (5 marks) Page 1 of 9 PTB43102 NON TRADITIONAL MACHININGJANUARY 2018 CONFIDENTIAL Question 2 a) Differentiate the terms ‘Rough Cut’ and ‘Skim Cut’ as used in the EDM Wire Cut process. (4 marks) b) Discuss FOUR main functions of the dielectric fluid used in the EDM process, (4 marks) ©) Elaborate on how taper cut is achieved in the wire EDM (3 marks) d) The surface finish of a part machined by EDM Wire Cut was required to be Ra 0.6 um. The workpiece was steel with thickness of 5mm. The wire used was brass-based of diameter 0.20mm, Based on the machining technology data given in Table B. deduce the following i) The number of cuts required ii) The E pack number for each cut i) The Offset value for each cut (6 marks) ©) Describe two typical applications of the Plasma Arc Cutting (PAC) (4 marks) Question 3 a) Give a brief definition of the term ‘Non-traditional machining (NTM)’ (2 marks) b) Outline three major factors for the development of NTM processes in the context of current manufacturing requirement (6 marks) Page 2 0f9 PTB43102 NON TRADITIONAL MACHINING