UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

SECOND SEMESTER/YEARLY EXAMINATIONS

MAY 2011

PROGRAMME BEng (Hons) Manufacturing Engineering

BEng (Hons) Mechanical Engineering

MODULE NAME Manufacturing Processes & Metrology

DATE Wednesday
11 May 2011 MODULE CODE MECH3002Y(3)

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

NO. OF 6 NO. OF QUESTIONS 6

QUESTIONS SET TO BE ATTEMPTED

INSTRUCTIONS TO CANDIDATES

Answer ALL Questions.

The ISO Limits and Fits – Hole Basis: Clearance Fits, Transition Fits, Interference
Fits Tables are attached.

Table for the evaluation of viscosity index is attached.

 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y(3)

Answer ALL questions.

Question 1 - [Total 25 marks]

(a) A 55 mm nominal diameter shaft and roller assembly is to be used for a low
speed and low torque precision operation, with very good positional (and
centring) accuracy of the roller with respect to the shaft. The assembly is
subjected to a boundary lubrication regime. Using the ISO tables for fits,
limits and tolerances, find the most appropriate value for the minimum and
maximum shaft and roller dimensions, and justify the answer. Calculate the
allowance and clearance of the assembly system.
[10 marks]

(b) An engineer has to check the effective diameter of a vee thread. Explain in
detail an appropriate method that can be used for the measurement process.
Show all relevant schematic diagrams.
[15 marks]

Question 2 - [Total 25 marks]

(a) A production engineer is proposing to use a set of four (4) 2D surface

roughness parameters in order to compare the surface roughness properties
of the following surfaces: honed, shaped, milled and electrochemical.

Explain with appropriate justifications the set of most appropriate four (4) 2D
surface roughness parameters which the engineer can use. Full marks will be
awarded for the correct interpretation of the information that can be obtained
from the relevant 2D surface roughness parameters in order to differentiate
among the four (4) surfaces.
[18 marks]

(b) Explain the process where densification is achieved during powder

metallurgy (PM). Discuss one alternative densification technique where net
shape can be obtained at lower temperatures.
[7 marks]

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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y(3)

Question 3 - [Total 25 marks]

(a) An engineer is proposing to use conventional sand casting process in order to

manufacture a cast iron part which has the following main outer dimensions:
300 mm (length) × 150 mm (width) × 200 mm (height). The engineer has
chosen a cope and drag assembly box, and the dimensions of each box are as
follows: 600 mm (length) × 450 mm (width) × 300 mm (height). He is
proposing to have half of the moulding cavity in the cope box and the other
half in the drag box. The pouring basin will be designed in the cope box.
Assume that the sprue has a cylindrical cross sectional area throughout its
height, and that the sprue diameter is 30 mm.

Calculate the following:

(i) Height of the pouring basin.

(ii) Draw a proper schematic diagram to show the cope and drag
assembly, and the vertical positioning of the sprue, sprue well, runner,
ingate and mould cavity for a bottom gating system. The engineer is
using the following gating ratio for the sprue-runner-ingate cross-
sectional area; 1:4:4, where the runner has a cylindrical cross sectional
area.

Calculate the mould filling time for the bottom gating system.

(iii) Draw a proper schematic diagram to show the cope and drag
assembly, and the positioning of the sprue and mould cavity for a
vertical gating system assuming that the sprue gate is vertically above
the mould cavity.

Calculate the mould filling time for the vertical gating system.

(iv) Comment on the answers for parts (ii) and (iii) above.

Assume acceleration due to gravity to be 10 m/s2. State any other

relevant assumptions.
[15 marks]

(continued next page)

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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y(3)

(Question 3 continued)

(b) A part as shown in Figure 2 has to be sand casted.

(i) Explain how the design of the four (4) through holes can be realized in
the mould cavity.

(ii) Briefly explain with the help of an appropriate labeled sketch the
resulting microstructure of the casted part, and list the main factors
affecting the formation of the resulting microstructure.
[10 marks]

Figure 2: 3D drawing of the part to be sand casted.

Question 4 – [Total 25 marks]

A cylindrical copper part is being extruded such that the initial diameter of 50 mm is
reduced to a final diameter of 40 mm. The yield stress for copper can be assumed to
be 200 N/mm2.

(a) Using Tresca criterion, calculate the direct stress that is generated at the inlet
part of the process when reducing the diameter from 50 mm to 40 mm. Show
all calculations, and also show the main steps for the derivation of the
equation used for the calculation of the direct stress.

(b) Under what condition would the maximum possible reduction in cross-
sectional area be achieved?

(c) Using the condition as stated in part (b) above, calculate the maximum
possible percentage reduction in cross-sectional area.
[25 marks]

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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y(3)
Question 5 – [Total 25 marks]

(a) An engineer has to select a lubricating oil for a heavy duty gear box. It is
expected that the operating temperature of the gear system would not exceed
50 °C since there are sufficient overheating protection systems. Two
lubricating oils have been short listed, A and B. Lubricating oil A has a
kinematic viscosity at 40 ºC of 40 °C = 120 [cS], and at 100 ºC of  100 °C = 20 [cS].
Lubricating oil B has a kinematic viscosity at 40 ºC of 40 °C = 47.5 [cS], and at
100 ºC of 100 °C = 10 [cS]. Using appropriate data, calculate the Viscosity Index
for the two oils, and comment on your results with respect to the intended
application.
[7 marks]

(b) Carefully analyse the following case studies, and in each case explain the
main wear mechanism(s) which is/are likely to occur:

(i) Pumping of clean lubricating/cooling oil in a galvanized steel pipe

where the internal surface roughness data are as follows: Rsk = 0.68, Rku
= 3.5 and Rq = 15 µm.

(ii) Injection moulding of polycarbonate part in a pair of carbon steel (1.2

% Carbon and 65 HRC) dies, and using an ejector pin mechanism in the
die for the release of the product.

In each of the above two cases, explain the most appropriate technical and
cost effective technique that can be used to mitigate the wear problem, and
justify your answer.
[18 marks]

Question 6 –[Total 25 marks]

(a) (i) Outline the galvanic corrosion phenomenon.

(ii) Explain in detail the four (4) main factors which affect the occurrence
of galvanic corrosion.
(iii) Discuss five (5) main methods for mitigating galvanic corrosion.
[2 + 8 + 10 marks]

(b) Outline the Eddy Current method of non destructive testing, and briefly
explain two (2) NDT testing applications of this method.
[5 marks]

END OF QUESTION PAPER

sg/

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