UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

SPECIAL RETAKE EXAMINATIONS

JULY 2017

PROGRAMME BEng (Hons) Mechanical Engineering

BEng (Hons) Manufacturing Engineering

MODULE Manufacturing Processes and Metrology

NAME

DATE Tuesday 15 August MODULE MECH3002Y(3)

2017 CODE

TIME DURATION 3 Hrs

09:30 – 11:30 Hrs

NO. OF 5 NO. OF 5
QUESTIONS QUESTIONS
SET TO BE
ATTEMPTED

INSTRUCTIONS TO CANDIDATES

This paper consists of FIVE Questions

Answer ALL questions.

All questions carry equal marks.

 MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y

Answer ALL questions

Question 1 – [Total 20 marks]

(a) Explain the following systematic errors:

(i) Calibration error;
(ii) Stylus Pressure error;
(iii) Avoidable error.
[3x1 marks]
(b) State 5 advantages of light standards.
[5 marks]

(c) Using a suitable diagram, explain the principle of collimation of a beam of light as
used in an optical instrument for angular measurement.
[5 marks]
(d) Label the following parts in a diagram of an external micrometer:
(i) Anvil;
(ii) Spindle;
(iii) Frame;
(iv) Sleeve;
(v) Thimble;
(vi) Ratchet.
[3 marks]

(e) Draw the set-up and state the equation for determining the taper angle of a taper
plug gauge using a sine bar.
[4 marks]

Question 2 – [Total 20 marks]

(a) Briefly explain the use and show a diagram of the following gages:
(i) Snap Gage;
(ii) Plug Gage.
[4 marks]

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 MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y

Question 2 – [Continued]

(b) The limits (in mm) shown on a drawing for a mating hole and shaft are:

.
For the hole 50.000 .

.
For the shaft 50.000 .

State the type of fit and find the allowance . What is the greatest possible amount of
clearance or interference?

[4 marks]

(c) Specify three (3) industrial requirements of surface measurements.

[3 marks]

(d) Using suitable diagrams, explain the significance of the following surface texture
parameters:

(i) Arithmetic Average Roughness, Ra;

(ii) Maximum Individual Peak-to-Valley Height, Ry;
(iii) Profile Bearing Length Ratio, tp.

[3+3+3 marks]

Question 3 – [Total 20 marks]

(a) Using suitable diagrams, show how the grain structure of a metal changes under
the successive actions of the following processes:
(i) Cold Working;
(ii) Heating;
(iii) Prolonged Heating.
[6 marks]

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 MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y

Question 3 – [Continued]

(b) Give three (3) reasons why hot extrusion is preferred for many metals instead of
cold extrusion.
[3 marks]

(c) A metal obeys the Hollomon relationship and has a UTS of 300 MPa. To reach
maximum load, an elongation of 35% is required. Find K and n.
[7 marks]
(d) Explain the occurrence of the following types of sliding wear:
(i) Abrasive wear;
(ii) Adhesive wear.
[2+2 marks]

Question 4 – [Total 20 marks]

(a) Explain the role of the following additives in improving the characteristics of
lubricating oil:
(i) Anti-oxidants;
(ii) Anti-foam;
(iii) Extreme pressure.
[6 marks]

(b) Explain how the ‘four ball’ apparatus is used to test lubricants under extreme
contact stresses.
[5 marks]

(c) Figure 1 shows a combined diagram of an anodic reaction and a cathodic reaction
with activation polarization. Using three (3) separate schematic diagrams, explain
the following forms of activation polarization control:
(i) Mixed control;
(ii) Cathodic control;
(iii) Anodic control.

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 MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y

Question 4 – [Continued]

Figure 1
[6 marks]

(d) Suggest any three (3) rational design principles which can be applied to eliminate
corrosion problems and reduce the time and cost associated with corrosion
maintenance and repair.
[3 marks]

Question 5 – [Total 20 marks]

(a) Outline the three (3) disadvantages of the Vacuum Deposition technique.
[3 marks]

(b) Explain why it is necessary to control the rate of mold filling to avoid formation of
casting defects?
[4 marks]

(c) Referring to Figure 2, do you think it is necessary to weigh down or clamp the 2
halves of the mold? Explain your reasons.

Do you think that the kind of metal cast, such as gray iron vs. aluminium, should
make a difference in the clamping force? Explain.

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 MANUFACTURING PROCESSES AND METROLOGY – MECH3002Y

Question 5 – [Continued]

Figure 2

[4 marks]

(d) List the differences which you would expect in the properties of castings made by
permanent mold vs. sand casting.
[6 marks]

(e) Which of the casting processes would be most suitable for making small toys? Why?
[3 marks]

END OF QUESTION PAPER