O8-MFG-B10-Page 1 of 4 Dec 2011 NOTES: National Exams December 2011 08-MFG-810, Tooling, Jigs and Fixture Design 3 houre duration I doubt exists as to the interpretation of any question, the ‘candidate is urged to submit with the answer paper, a clear ‘statement of any assumptions made. This is a CLOSED BOOK EXAM. A Casio or Sharp approved calculator is permitted. FIVE (5) questions constitute a complete exam paper. The first question is a descriptive type and consists of 10 sub- questions. Along with the first question, FOUR (4) questions in the following combinations constitute a complete exam paper: two from part A and two from part B. Most questions require an answer in essay format. Clarity ‘and organization of the answer are important,08-MFG-B10-Page 2 of 4 Dec 2011 (20) (30) 41. Answer the following TEN (10) sub- questions. Each are of equal value: 1) What is the erucial difference between a Jig and a Fixture? 'b) What is redundant/duplicate locating? ©) As a general rule how the tolerances on.the tool are determined? d) Why must a tool be foolproof? ©) Where are the best locations for clamping the part? f) You have a choice between a 1/2"-13 U.N.C. thread and a 1/2 - 20 UNF. thread for an applicatien where speed is important - which one are you going to use and why? 49) What is the advised clearance range between the underside of a bushing land the top of the workpiece when reaming? h) What are TWO major problems with Welded Tool Bodies? i) Name TWO advantages of a power-workholding system. |) List TWO advantages of using modular workholders. Part A (Answer only 2 out of 3, all questions are of equal value) 2. Fer the part shown assume that the last operation is to mill out the 57 mm counter bore. Sketch a proper locating layout for this operation, In the sketch, include the name of locators, the main dimensions and tolerances. Suggest techniques to ensure that the workpiece Is correctly located and orientated,08-MFG-B10-Page 3 of 4 Dec 2011 3. Identify the workholding, bushing, and locating devices shown below by writing their names and determining their major characteristics and applications. 4, Amachine shop:has received an order for manufacturing of 3000 flange plates which require three holés accurately drilled 120 degrees apart to mate with a connector valve. Calculate the Cost per Part (CP), Total Saving (TS), and Break-even Point (BP), for the following alternatives and explain which one you recommend: a) Use a template Jig, capable of producing 50 parts per hour and costing $200, Assume a $20 shop rate per hour for the operator. b) Use a duplex jig (two stations jig), which costs $300 and can produce a part every 24 seconds. Assume a §20 shop rate per hour for the operator. (60) : Part B (Answer only 2 out of 3, all questions are of equal value) 6. For the part named Feed Rod Bearing shown in Figure 1, design and sketch the assembly drawing of a Jig to drill and ream all the holes as required in the drawing. 6. For the part named Door Bearing shown in Figure 2, design and sketch the assembly drawing of a Fixture to cut the .38 axd .5 inch slots. 7. For the Feed Rod Bearing part, design and sketch the assembly ‘drawing of an inspection Fixture to be used for inspection of positional tolerances of 11 mm holes. Note: In your answers include any assumptions that you made regarding to the production plan of the parts and general tolerance block, explain what is your selection of Jig or Fixture type and why, show main08-MFG-B10-Page 4 of 4 Dec 2011 dimensions and tolerances, use balloons to label parts and provide a bill of materials, state any special surface finishing or heat treatment as required. For question 7, modify the part's drawing by selecting a proper datum and adding positional tolerancing for the features to be inspected using GD&T notation. FILLETS & ROUNDS 3. ag. J 1 onl bap cr Figure 2: Door Bearing08-Mfg/B10/Dee 2011/Appendix 1 of 1