Mech3002y 3 2017 2

UNIVERSITY OF MAURITIUS
FACULTY OF ENGINEERING
SECOND SEMESTER EXAMINATIONS
MAY 2017
PROGRAMME BEng (Hons) Mechanical Engineering

BEng (Hons) Manufacturing Engineering
MODULE NAME Manufacturing Processes and Metrology
DATE Monday MODULE CODE MECH3002Y(3)

22 May 2017
TIME 9.30 – 12.30 Hrs DURATION 3 hours
NO. OF 5 NO. OF QUESTIONS 5

QUESTIONS SET TO BE ATTEMPTED
INSTRUCTIONS TO CANDIDATES
All questions carry equal marks.

The following are attached at the end of the questionnaire:
Table 1: Standard Electrode Potentials at 25 Celsius and Their Isothermal Temperature
Figure 2: Plot giving multiplying factors for forging as a function of friction coefficient
and geometry
Table 2: Standard gagemakers’ tolerances
Table 3: Properties of steel and aluminium alloys (annealed condition)
Table 4: Typical lubricants and approximate friction coefficients for bulk deformation
processes
MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y(3)
Answer all questions.
Question 1 – [Total 20 marks]
(a) Explain the function of the following grades of standards:
(i) Primary Standard;

(ii) Secondary Standard;
(iii) Tertiary Standard;
(iv) Working Standard.
[4x1 marks]
(b) In a Vernier caliper, the value of the smallest division on the main scale is 0.5 mm and
there are twenty divisions on the vernier scale. Determine the accuracy of the caliper.
If the main scale reads 13mm and the fifth division on the vernier scale coincides with
a division on the main scale, what is the value of the dimension being measured.
[1+1 marks]
(c) Describe briefly with the help of diagrams how an autocollimator is used in the
following situations:
(i) To check the deflection of elastic or springy materials;

(ii) To check the angle of workpieces.
[2+2 marks]
(d) Describe how a pair of Vee blocks and a DTI could be used to measure the out-of-
roundness of a cylindrical component.
You should include in your description any other instruments used and any
precautions taken.
You should also explain how the out-of-roundness value will be computed from the
readings obtained.
[10 marks]
Page 1 of 9
(a) Describe, with the help of properly labelled diagrams, an interference fit and a
clearance fit.
[2x4 marks]
(b) Explain the use of the following types of fits:
(i) Running fit;
(ii) Push fit;
(iii) Drive fit;
(iv) Force fit.
[4x2 marks]
(c) Design a Class Z go/no-go gage to qualify an internal diameter with the following
dimension (in inches). Do not include a wear allowance.
[4 marks]
(a) By using three (3) separate diagrams for the bar stock shown in Figure 1, draw the
grain structure resulting from:
(i) Forging;
(ii) Machining;
(iii) Casting. [3x2 marks]
Figure 1
Figure 1
(b)A 302 stainless steel cylinder of height 12 cm and diameter 7 cm at room temperature
is compressed to a height of 2 cm between large platens. Mineral oil is used as a
lubricant between the cylinder and platens. Calculate the force necessary and stress on
the platens.
[14 marks]
Page 2 of 9
(a) Differentiate between hydrostatic lubrication and hydrodynamic lubrication as

applied to a bearing.
[2+2 marks]
(b) Write down the equations for rusting of steel in air.

[4 marks]
(c) Calculate the tendency for corrosion to occur in the following metal electrolyte
systems:
(i) Silver in cupric acid;
(ii) Nickel in silver nitrate. [4+4 marks]
(d) Outline four (4) causes of crevice corrosion. [4x1 marks]
(a) Explain electrostatic spraying as used in the painting of car bodies.

[4 marks]
(b) Outline the three (3) principal sources of shrinkage during casting.
[3x1 marks]
(c) Explain the role of the following sand additives in Green Sand Casting:
(i) Cellulose
(ii) Iron Oxide
(iii) Polymers & Chemicals
(iv) Carbons [4x1 marks]
(d) Find the weights that need to be kept to compensate for the forces during pouring in
a sand casting process of a cast iron pipe of 12.5 cm external diameter and 10 cm
internal diameter with a length of 180 cm. The metal head is to be about 20 cm, while
the moulding flask used for the purpose is 200x25x20 cm in size. Take the density of
the core sand to be 0.0165 N/cm3 and the liquid metal density to be 0.0771 N/cm3.
[9 marks]
END OF QUESTION PAPER

mm
Page 3 of 9
Table 1: Standard Electrode Potentials at 25 Celsius and Their Isothermal

Temperature
Page 4 of 9
Standard Electrode Potentials at 25 Celsius and Their Isothermal Temperature
Page 5 of 9
Figure 2: Plot giving multiplying factors for forging as a function of friction

coefficient and geometry
Page 6 of 9
Table 2: Standard gagemakers’ tolerances
Page 7 of 9
Page 8 of 9
Page 9 of 9

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UNIVERSITY OF MAURITIUS

SECOND SEMESTER EXAMINATIONS

PROGRAMME BEng (Hons) Mechanical Engineering

MODULE NAME Manufacturing Processes and Metrology

DATE Monday MODULE CODE MECH3002Y(3)

TIME 9.30 – 12.30 Hrs DURATION 3 hours

NO. OF 5 NO. OF QUESTIONS 5

All questions carry equal marks.

Table 1: Standard Electrode Potentials at 25 Celsius and Their Isothermal Temperature

Table 2: Standard gagemakers’ tolerances

Table 3: Properties of steel and aluminium alloys (annealed condition)

Answer all questions.

Question 1 – [Total 20 marks]

(a) Explain the function of the following grades of standards:

(i) Primary Standard;

(i) To check the deflection of elastic or springy materials;

Question 2 – [Total 20 marks]

Question 3 – [Total 20 marks]

Question 4 – [Total 20 marks]

(a) Differentiate between hydrostatic lubrication and hydrodynamic lubrication as

(b) Write down the equations for rusting of steel in air.

(d) Outline four (4) causes of crevice corrosion. [4x1 marks]

Question 5 – [Total 20 marks]

(a) Explain electrostatic spraying as used in the painting of car bodies.

END OF QUESTION PAPER

Table 1: Standard Electrode Potentials at 25 Celsius and Their Isothermal

Standard Electrode Potentials at 25 Celsius and Their Isothermal Temperature

Figure 2: Plot giving multiplying factors for forging as a function of friction

Table 2: Standard gagemakers’ tolerances

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