Benha University Forming of Non-Metallic materials

Shoubra Faculty of Engineering .Bsc. Production

.Mechanical Engineering Dept May, 21, 2016
Production Section Time Allowed: 3 hours
Total marks:80 No. of pages:2 No. of question: 7

Please answer 6 questions only

1)- (15 marks) (a1, b1, c1, d1, a3, b3, c3)
a- Summarize the important mechanical and physical properties of plastics. (3)
b- What additives are used in plastic ? Why? (3)
c- Explain why thermoplastics are easier to recycle than thermosets. (3)
d- With the aid of sketches, differentiate between injection molding and jet molding. (6)

2)- ( 15 marks ) (a1, b1, c1, d1, a3, b3 )

a- a)- Give an explanation of the following terms;
- Calendering (2)
- Monomer. (2)
- Refractory materials. (2)
- Glass. (2)
b- List the characteristics required of polymer for : golf ball - an automobile dashboared -
clothing - fishing nets. (5)
c- Can polymers be made to conduct electricity? (2)

3)- ( 10 marks ) (a1, b1, c1, d1, a3, b3, c3)

An acetal flanged bushing made in different ways is subject to the following costs. Assume
that only one lot is to be made. For what quantities should each method be used ? (7)

Factors Injection mold Conventional Automatic

machining machining
Die or special tools $ 4500 - $90
Setup - - $22
Material / piece ,cent 0.03 0.21 0.18
Labor/piece, cent 0.033 1.05 0.04

b)- An aluminum sheet has a 2-in diameter hole at 70 oF . The hole is insulated with ABS. The
assembly is heated to 300 oF . what is happening to the assembly. Redesign the assembly if
necessary.
-6
- ά al = 12.2 x 10 in / in oF
- άABS = 1.7 x10-5 in/ in oF
- Working thickness of ABS 0.045 to 0.14.
(ABS thermoplastic compound from acrylonitrile, butadiene and styrene.) (3)
4)- (15 marks ) (a1, b1, c1, d1, a2, b2, c2,a3, b3, c3)

a- For what types of parts , production volumes and materials would rotational molding be
an appropriate process, ( Illustrate with sketches). (3)

b- What are some ways that plastic sheet and plate made? (4)

c- ( 8 marks )
Sketche the following processes, what materials recommended for each processes, and what
are the main specification of the product.
- Sxtrusion.
- casting.
- Transfer moulding.
- Thermoforming.
5)- ( 10 marks ) (a1, b1, c1, d1, a2, b2, c2,a3, b3, c3)
a- How do the slicones differ from organic materials and what makes them useful? (3)
b- Select a product that can be made from one , two or more of the basic materials families
( metals, polymers, ceramics and composites ). (7)
 Describe briefly the function of the product.
 What properties would be required for this product to perfo`rm its function ?
 What materials groups might provide reasonable candidates for your product?
 With the aid of sketches, what processes do you recommended for producing this
product?

Select one question only from the following questions

6)- (15 marks) ( c1, d1, a2, b2, a3, b3, c3)
a)- How is the higher cost of powder metal products justified? (3)
b)- Why is sintering usually accomplished in a controlled atmosphere? (3)
c)- What is green strength ? (3)
d)- a)- List with a net sketches the basic steps that are usually involved in making products by
powder metallurgy? (6)

7)- (15 marks) (b1, c1, d1, b2, c2,a3, b3, c3)
a- What is the composite materials? (3)
b- With the aid of sketches, For what types of parts , production volumes and materials
would hand lay-up molding be an appropriate process. (3)
c- What are the three primary geometries of composite materials. (3)
d- Which of the three primary composite geometries is most likely to possess isotropic
properties. (3)
e- What are some major limitations to the extensive use of composite materials in engineering
applications. (3)

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Good luck
Dr. Aziza sherif