COLLEGE OF ENGINEERING

PUTRAJAYA CAMPUS
FINAL EXAMINATION

INTERIM SEMESTER, 2019 / 2020

PROGRAMME : Bachelor of Mechanical Engineering (Honours)

SUBJECT CODE : MEFB 213 / MEFB 2013

SUBJECT : Manufacturing Processes

DATE : AUGUST 2020

DURATION : 2 HOURS

INSTRUCTIONS TO CANDIDATES:

1. This paper contains SIX (6) questions.

2. Answer ALL questions.

3. Write all answers in the answer booklet provided.

4. Write answer to each question on a new page.

THIS QUESTION PAPER CONSISTS OF NINE (9) PRINTED PAGES INCLUDING

THIS COVER PAGE
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QUESTION 1 [7 MARKS] [CO1 PO1 (a)]

(a) Cookware and bakeware are types of food preparation containers, commonly found in

a kitchen. Cookware comprises cooking vessels, such as saucepans and frying pans,
intended for use on a stove or range cooktop.

Figure 1. Cookware

As an engineer responsible to manufacture cookware, list TWO engineering

properties that is needed for the cooking pot material to have maximum performance.
[2 marks]
(b) Composites are combinations of two materials in which one of the materials, called
the reinforcing phase, is in the form of fibres, sheets, or particles, and is embedded in
the other materials called the matrix phase. In your opinion, why do you think
composites are preferred material in the construction of a most items around us? State
THREE reasons. [3 marks]

(c) What is the TWO major difference between spot welding and projection welding?
Explain. [2 marks]

QUESTION 2 [ 6 MARKS] [CO1 PO1 (a)]

(a) A machinist has machined a prototype for Company A. During machining, his
cutting

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tool broke twice and needed replacement. Due to tool breakage, the duration taken
for
setup time and reconfiguring the machine caused a delay in the process. The cost
involved escalated due to tool replacement. Quality of the product was compromise
to
due the difficulty faced during machining. In your own words, explain the
machinability of the product [4 marks]

(b) Other than mechanical strength, what other factors should be considered in selecting
metals and alloys for high temperature application? [2 marks]

QUESTION 3 [6 MARKS] [CO2 PO1 (b)]

(a) A construction company is requested to produce long, symmetrical pipes, 10m long to
be installed in the current housing projects. As the chief engineer, what manufacturing
process would you recommend and why? Explain your reasons. [3 marks]

(b) Explain the term ‘quality’. Based on your understanding, why do you think quality is
important? [3 marks]

QUESTION 4 [9 MARKS] [CO3 PO2 (a)]

(a) In the drilling operation of a stainless steel plate, a drill of 50 mm in diameter is

employed. The drill is being rotated at 1000rpm and is penetrating into the plate with
the feed equal to 0.005mm/rev. If the thickness of the plate is 35mm, determine:
(i) The metal removal rate, Q
(ii) The time required for this operation [3 marks]

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(b) The CNC lathe was programmed at a constant surface speed of 225mm/min, , n
=1000 rpm, feed rate of 0.2 mm/rev and a depth of cut of 3.0mm to achieve a
diameter of 50mm. Calculate:-
(i) Material removal rate
(ii) Time taken to machine a 175mm length of cut [3 marks]

(c) A face milling operation used to machine 5 mm from the top surface of a rectangular
piece of stainless steel 400 mm long by 100 mm wide. The cutter has four teeth
(cemented carbide inserts) and is 150 mm in diameter. Cutting conditions are: v = 30
mm/min, f = 10 mm / teeth and N = 1000 rpm. Determine:
(i) Time taken to make one pass across the surface in minutes
(ii) Metal removal rate during cutting operation [3 marks]

Table 1 : Typical machining speeds and feeds

    High Speed Steel Carbide

V
Depth of cut, t V f (mm/min f
Material (mm) (mm/min) (mm) ) (mm)
           
Aluminium 0.150 115 0.009 400 0.012
  0.025 155 0.006 450 0.008
 
Stainless steel 0.150 90 0.006 350 0.010
  0.025 120 0.005 465 0.008

QUESTION 5 [6 MARKS] [CO5 PO1 (b)]

(a) A manufacturer is in need to weld a stainless steel, non-ferrous metal that is made of
flat surface for a particular manufacturing operation. He needs a welding process that
has high metal deposition rate in order to obtain a dense metal and at the same time a

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smooth weld. Based on your knowledge on welding, what welding process would you
recommend and why? [3 marks]

(b) In cold working a metal the strength and hardness increase, and the ductility
decreases. Is there a way to restore these properties close to the original values? How?
Explain your reasoning. In your opinion, why does strength increase with decreasing
grain size [3
marks]

QUESTION 6 [16 MARKS] [CO4 PO1 (b)]

(a) Ultrasonic machining (USM) is an abrasive process which can create any material
into hard and brittle form with the help of its vibrating tool and the indirect passage of
abrasive particles towards the work piece. It is a low material removal
rate machining process

(i) Explain and demonstrate with the aid of sketches, the concept and process of
machining work piece using USM. [5 marks]

(ii) Explain type of materials can be machined by USM and give the examples of
that material. [2 marks]

(iii) State and explain the MAIN components of USM [3 marks]

(iv) State the type of abrasive material used in USM process [2 marks]

(b) You are a manufacturing engineer in a manufacturing plant. During production,

statistical checks indicate the presence of process variation in the manufacturing
process. What are the possible causes of variation? State THREE causes of variation
[4 marks]

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-END OF QUESTION PAPER-

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