UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

SECOND SEMESTER/YEARLY EXAMINATIONS

MAY 2009

PROGRAMME BEng (Hons) Manufacturing Engineering

BEng (Hons) Mechanical Engineering

Level 3

MODULE NAME Manufacturing Processes and Metrology

DATE Saturday MODULE CODE MECH 3002Y(3)

16 May 2009

TIME 9:30 – 12:30 Hours DURATION 3 Hours

NO. OF 6 NO. OF 6
QUESTIONS SET QUESTIONS TO BE
ATTEMPTED

INSTRUCTIONS TO CANDIDATES

Answer ALL questions.

ISO Tables for Limits & Fits for Hole basis are provided.
 MANUFACTURING PROCESSES & METROLOGY- MECH 3002Y(3)

Answer ALL questions.

Question 1 - [Total 25 marks]

(a) Explain the ‘GO’ and ‘NOT GO’ gauges and how they are used in limits and
fits system. [5 marks]

(b) Explain the problems which may arise in the design and used of these gauges.
[5 marks]

(c) What are the standard practices which are available to minimize the problems
mentioned in part 1(b) above. [5 marks]

(d) A flywheel of 25 mm nominal inner diameter has to be pressed fit onto a shaft
of the same nominal diameter. If the shaft and flywheel assembly would be
subjected to very high speed, using the ISO fits tables, select the most
appropriate class of fit and calculate the maximum and minimum metal limits
of both the shaft and of the flywheel. Determine the greatest and least
differences in the flywheel and shaft dimensions and comment on your
results.
[10 marks]

Question 2 –[Total 25 marks]

(a) XYZ ltd is a company involved in the machining of high precision aluminium
parts for the aerospace industry. The company has recently received an order
to produce 5,000 parts of a component as shown in Figure 2. The critical
dimension of this component is the height H= 250 mm, and the customer has
requested that 100 % of the order should be checked for the variation in H.
The accepted deviation is H ± 0.02mm.

Given the tight schedule between the production and verification of each
component, and also due to the availability of only one quality checker, the
production manager is interested to purchase an instrument which will
enable a quick, and easy verification of the dimension H in the workshop.
The instrument should also enable accurate reading (in the same or alternate
measurement/display unit) of the height H of each component to be
displayed (and noted if required). It is to be noted that the workshop do not
have a compressor.

Explain with the help of clear and labeled diagrams, the most appropriate
instrument which can be used to fulfill the quality check on all the
components. Justify the answer.
[9 marks]

[continued next page]

Page 1 of 4
 MANUFACTURING PROCESSES & METROLOGY- MECH 3002Y(3)

Question 2 [continued]

Figure 2

(b) An engineer is attempting to measure the surface roughness of a highly

polished surface (lustrous finish) which has been obtained through a buffing
process. He is proposing to use the Surtronic 3+ instrument for the surface
roughness measurement, and he will be analyzing the following parameters:
Rsk, Rku, Rt and tp.

(i) Discuss the limitation(s) (if any) associated with the Surtonic 3+.
(ii) Explain the significance of the four surface roughness parameters (Rsk,
Rku, Rt and tp), and what practical information can be gathered from
these parameters.
(iii) Discuss what would be an appropriate value of cut-off to use. Justify
your answer.
[16 marks]

Page 2 of 4
 MANUFACTURING PROCESSES & METROLOGY- MECH 3002Y(3)

Question 3 - [Total 25 marks]

(a) A rectangular sand mould of size 1000 mm (length) × 500 mm (width) × 300
mm (height) is to be filled with molten cast iron.

The height of the pouring basin is 50 mm, and the sprue height is 350 mm.

The diameter of the ingate is 100 mm.

Calculate the mould filling time for the vertical and bottom gating systems.
Comment on the answers. Assume acceleration due to gravity to be 10 m/s2.
State any assumptions.
[10 marks]

(b) The engineer is proposing to have one open riser for the sand casting in part
3(a) above. Explain five (5) methods that can be used to prevent the molten
metal for solidifying too quickly in the riser.
[10 marks]

(c) Explain the use and function of chills in the sand casting process.
[5 marks]

Question 4 - [25 marks]

(a) A plain carbon steel rectangular slab has to be forged so that the final length is
600 mm and final thickness is 300 mm (assume unit width). Assume that the
average yield stress for the steel is 300 N/mm2.

Using Von Mises criterion and a coefficient of friction of 0.35, calculate the
maximum forging force required.
[20 marks]

(b) Explain the difference in the resulting mechanical properties and behaviour
between hot and cold rolling.
[5 marks]

Page 3 of 4
 MANUFACTURING PROCESSES & METROLOGY- MECH 3002Y(3)

Question 5 - [Total 25 marks]

(a) Discuss in details why PTFE is commonly used as a lubricating material as

compared to polyacetals? Support the answer with appropriate diagrams.
[10 marks]

(b) The engineer of a power plant is planning to put in place an oil monitoring
system for the lubricating oil of an internal combustion engine. The
lubricating oil flows in a closed circuit from a reservoir via a pumping system
to the engine and back.

Explain in detail the appropriate sequential methodology and the techniques

that the engineer would use in order to analyse the used lubricating oil. The
answer should include a brief explanation of any specific monitoring testing
procedure(s) required and the related justifications.
[15 marks]

Question 6 - [Total 25 marks]

(a) Explain an appropriate surface preparation technique that can be used prior
to applying a primer coating and a topmost coating on outdoor large carbon
steel structures.
[5 marks]

(b) An engineer is proposing to perform a non destructive testing (NDT) on a

welded joint of two 316 stainless steel plates to check for surface cracks as
well as internal cavity within the weld pool. The plates are 50 mm thickness.
Explain the most appropriate, cost effective and less hazardous types of NDT
tests to reveal the above-mentioned flaws. The candidate is expected to
provide an outline of how to perform the tests.
[7 marks]

(c) (i) Explain the term ‘polarization’ as applied in corrosion phenomena.

(ii) Clearly explain with the help of appropriate diagrams the Tafel
extrapolation method for the determination of the corrosion rate.
[13 marks]

END OF QUESTION PAPER

sg/

Page 4 of 4