NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

FACULTY OF INDUSTRIAL TECHNOLOGY

INDUSTRIAL AND MANUFACTURING ENGINEERING DEPARTMENT

Master of Engineering in Manufacturing Engineering and Operations Management

MANUFACTURING TECHNOLOGY COURSE CODE: TIE 6122

MAIN ASSIGNMENT BOUQUET

ISSUE DATE: 18 OCTOBER 2019

ASSIGNMENT TWO DUE DATE : 3 NOVEMBER 2019

ASSIGNMENT THREE DUE DATE : 10 NOVEMBER 2019

INSTRUCTIONS AND INFORMATION TO CANDIDATE

Answer ALL questions.

Marks each question is worth are indicated in the brackets [x]
Show all working where relevant
Authenticity of sources cited as literature references will be credited
Clarity and neatness shall be credited

Submission mode: Soft Copy word document, emailed to:

nicholas.tayisepi@nust.ac.zw

Rather submit to both email lines to minimise chances of non-submittal, which shall
NOT be treated as a valid excuse for exemption.

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ASSIGNMENT TWO: ANSWER ALL QUESTIONS DUE DATE: 03/11/2019
Q1. Name and briefly explain the three most common machining processes. [6]
Q2. What are the two basic categories of cutting tools in machining? Give two examples of
machining operations that use each of the tooling types. [8]
Q3. Name and briefly describe the four types of chips that occur in metal cutting. [12]
Q4. Distinguish between generating and forming when machining workpart geometries. [6]
Q5. What is the difference between peripheral milling and face milling? [8]
Q6. In an orthogonal cutting operation, the tool has a rake angle = 15°. The chip thickness before
the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a) the shear
plane angle and (b) the shear strain for the operation. [6]
Q7. In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The feed
and depth of cut are 0.30 mm and 2.6 mm, respectively. The tool rake angle is 8°. After the cut,
the deformed chip thickness is measured to be 0.49 mm. Determine (a) shear plane angle, (b)
shear strain, and (c) material removal rate. Use the orthogonal cutting model as an
approximation of the turning process. [12]
Q8. In an orthogonal cutting operation, the rake angle = -5°, chip thickness before the cut = 0.2
mm and width of cut = 4.0 mm. The chip ratio = 0.4. Determine (a) the chip thickness after the
cut, (b) shear angle, (c) friction angle, (d) coefficient of friction, and (e) shear strain. [15]
Q9. A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an engine
lathe. Cutting speed = 2.30 m/s, feed = 0.32 mm/rev, and depth of cut = 1.80 mm. Determine (a)
cutting time, and (b) metal removal rate. [8]
Q10. In a production turning operation, the production manager has decreed that a single pass
must be completed on the cylindrical workpiece in 5.0 min. The piece is 400 mm long and 150
mm in diameter. Using a feed = 0.30 mm/rev and a depth of cut = 4.0 mm, what cutting speed
must be used to meet this machining time requirement? [5]
Q11. A drilling operation is to be performed with a 12.7 mm diameter twist drill in a steel
workpart. The hole is a blind hole at a depth of 60 mm and the point angle is 118°. The cutting
speed is 25 m/min and the feed is 0.30 mm/rev. Determine (a) the cutting time to complete the
drilling operation, and (b) metal removal rate during the operation, after the drill bit reaches full
diameter. [10]
Q12. A peripheral milling operation is performed on the top surface of a rectangular workpart
which is 400 mm long by 60 mm wide. The milling cutter, which is 80 mm in diameter and has
five teeth, overhangs the width of the part on both sides. Cutting speed = 70 m/min, chip load =

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0.25 mm/tooth, and depth of cut = 5.0 mm. Determine (a) the actual machining time to make
one pass across the surface and (b) the maximum material removal rate during the cut. [12]
Q13. Name the three modes of tool failure in machining and, with the aid of illustrative
sketch(es), identify the two principal locations on a cutting tool where tool wear occurs? [12]
Q14. Identify and write brief notes about the mechanisms by which cutting tools wear during
machining. [20]
Q15. Discuss the desirable properties of a cutting-tool materials. [15]
Q16. Tool life tests in turning yield the following data: (1) when cutting speed is 100 m/min, tool
life is 10 min; (2) when cutting speed is 75 m/min, tool life is 30 min. (a) Determine the n and C
values in the Taylor tool life equation. Based on your equation, compute (b) the tool life for a
speed of 110 m/min, and (c) the speed corresponding to a tool life of 15 min. [15]
Q17. Discuss some of the reasons for the commercial importance of powder metallurgy (PM) as
a manufacturing technology, and explain some of the disadvantages of PM methods. [14]
Q18. Explain the principal methods used to produce metallic powders? [9]
Q19. What is the technical difference between blending and mixing in powder metallurgy? [4]
Q20. What is the difference between physical vapor deposition (PVD) and chemical vapor
deposition (CVD) in manufacturing tools coating? [6]

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ASSIGNMENT THREE: ANSWER ALL QUESTIONS DUE DATE: 10/11/2019

Q21. Present a brief discussion presenting the desirability of Unconventional Machining

Processes in today’s manufacturing environment. [20]

Q23. Write brief notes on ANY FOUR of the following non-conventional manufacturing
technologies and indicate the type of materials for which each method is applied: [40]
(a) Electric-Discharge Machining (EDM)
(b) Electrochemical Machining (ECM)
(c) Ultrasonic Machining (UM)
(d) Chemical Machining (CM)
(e) Laser-Beam Machining (LBM)
(f) Abrasive Water-Jet Machining (AWJM)
(g) Electron-Beam Machining (EBM)
(h) Ion-Beam Machining (IBM)
(j) Plasma-Arc Machining (PAM)

Q24. What precautions should you take when grinding with high precision grinding machines?
Comment on the machine, process parameters, grinding wheel and the cutting fluids. [22]

Q25. A Grinding wheel is inscribed as “A 46 K 5 B 17”. Comprehensively discuss the significance

of this designation with the aid of real life examples. [18]

_______________________eND OF aSSIGNMENTS_________________________________

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