Ministry of Higher Education

Thebes Institutes
Thebes Higher Institute for Engineering
Subject: Production Engineering Subject Code: GSC013
Department: Basic & Supporting Sciences Level: 0
Duration: 2:00 hrs Date: / 1 / 2019

Final-Term Examination - First Semester 2018/2019

Answer the following questions: No. of questions: 4
Illustrate your answers with sketches when necessary Total Mark: 65 Marks

Question 1: [15 points]

(a) A company is planning a new product line and will build a new plant to manufacture the parts for this
purpose. The product line will include the following: (Neglect the effect of assembly time)
▪ 60 different models,
▪ Annual production of each model is expected to be 1500 units,
▪ Each product will be assembled of 200 components,
▪ All processing of parts will be accomplished in one factory.
▪ There are an average of 5 processing steps required to produce each component,
▪ Each processing step takes 2 min (includes an allowance for setup time and part handling).
▪ All processing operations are performed at workstations, each of which includes a production
machine and a human worker and each workstation requires a floor space of 100 m2,
▪ The factory operates one shift (2500 hr/yr),
Determine (a) How many production operations, (2 points)
(b) How many workers will be required in the plant, (2 points)
(c) How much floor space required. (2 points)
(b) Read the following measurements (4 points)

(c) For turning a stainless steel bar, the recommended feed (f) is 0.006 in,
and the recommended surface speed ( v ) is 1400 ft/min. Let the depth of
cut (d) = 0.15 in.
Calculate the Material removal rate MRR, the power requirement for
spindle and the Cutting force / tooth.
Take the power constant Us = 1.5.
Note that 1 [hp] = 3.96 x 105 [in.lb/min] (5 points)

Question 2: [15 points]

(a)-Choose the correct answer for the following sentences (10 points)
1. ……….. is the alloy formed from copper and zinc.
(a) Tin (b) Brass (c) Bronze (d) Lead
2. ……….. is the heating of a piece of metal (e.g. high carbon steel rod) to dull red heat and then plunged
into cold water to cool it rapidly.
(a) Annealing (b) Hot working (c) Warm working (d) Quenching
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 3. ……….. is used to produce complex shapes but small sizes products.
(a) Ceramic mold (b) Sand casting (c) Die casting (d) Permanent mold
4. ……….. is used in the high production rate.
(a) Ceramic mold (b) Sand casting (c) Die casting (d) Permanent mold
5. Horizontal hydraulic presses of capacities between ……….. are generally used for conventional
extrusion.
(a) 250-5500 tonnes (b) 150-500 tonnes (c) 500-1000 tonnes (d) 25-250 tonnes
6. Stainless steel kitchen lavatories are produced by ………….
(a) extrusion (b) drawing (c) deep drawing (d) sheet metal stretching
7. Seamless tubing is produced by ……...
(a) deep drawing (b) extrusion (c) rolling (d) sheet metal stretching
8. Steel structural parts are produced by rolling from …….. stoke.
(a) slab (b) billet (c) bloom (d) hot strip
9. Steel rods are produced by rolling from ………. stoke.
(a) slab (b) billet (c) bloom (d) hot strip
10. Steel strips are commonly produced by ………..
(a) extrusion (b) cold rolling (c) deep drawing (d) sheet metal stretching
(b) Consider number of teeth for the cutter (n) = 5, cutter diameter
(D) = 1.5 in. Let the width of cut (w) = 1 in and the depth of cut
(d) = 0.2 in. Let the feed / tooth (f) = 0.008 in.
Let the surface speed Vs = 3000 ft/min
Calculate the Material removal rate, Power requirement and
Cutting force / tooth. Take specific energy Us = 0.8 Ib-in/in3.
Take 1 hp min/in3 = 3.96 x105 psi.
Consider using a coated tool such as TiN (5 points)

Question 3: [15 points]

(a) The following sentences are true or false ? (10 points)
1. The forgeability of a material is defined as the capacity of a material to undergo deformation under
compression without rupture.
2. The forged parts cannot be easily welded.
3. The close tolerances in forging operations are easy to maintain.
4. The extrusion ratio is defined as the ratio of volume of the billet to that of the extruded section.
5. The weldability is defined as property of a metal which indicates the ease with which it can be welded
with other similar or dissimilar metals.
6. Limited number of metals and alloys both similar and dissimilar can be joined by welding.
7. Brazed joints are useful for high temperature service.
8. Soldering is a method of joining similar or dissimilar metals by heating them to a suitable temperature
and by means of a filler metal, called solder, having liquidus temperature not exceeding 450°C and
below the solidus temperature of the base material.
9. A typical CNC system consists of a Feedback system.
10. CNC Machine Tools are classified according to open and closed loop systems.
(b) A two-flute twist drill is used to drill a hole in a particleboard that is 20 mm thick. The drill diameter is
8 mm, the drill point angle is 90◦, and the spindle speed is 700 rpm and the feed rate is 0.6mm/s. The specific
cutting energy for particleboard is 70 N/mm2. Determine: (5 points)
(a) The cutting speed (b) Material removal rate
(c) The time required for drilling one hole (d) The feed power required for drilling.

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Question 4: [20 points]
(a)- The following sentences are true or false ? (5 points)
1. CNC machine tools of motion type (point-to-point) are used in milling processes.
2. CNC machine tools of motion type (contouring) are used in drilling processes.
3. One of the classifications of CNC machine tools based on the number of axes is 2, 3, 4, 5 axis
4. In CAM systems, component model is produced using linear sweep with taper in sweep direction.
5. The design of CAM systems is based on automatic surface generation for finite element analysis
6. Among the geometric construction methods, sweep or extrusion is most widely used.
7. Cylindrical components are produced in CAM systems by the rotational sweep technique.
8. Advantage of CAM systems is the ease to train people to use more complex equipment.
9. Grindability is measured by using grinding ratio or G ratio, which is the volume of material removed
from the work per unit volume of wheel wear.
10. Welding process limits the freedom in the mechanical design.
(b) A horizontal spindle surface grinder is cutting with t = 6 mm and U = 40 GPa. Estimate the tangential force
on the wheel if the wheel speed is 40 m/s, the cross-feed per stroke is 1.5 mm, the work speed is 0.35 m/s, and
the wheel depth of cut is 0.06 mm. (5 points)
(c)-Write the correct nomenclature for the following tools (5 points)

(d) Illustrate a technological process to manufacture the item shown in the figure below, containing of several
processes steps. Begin the process with a stock of size 200 mm length and 80 mm diameter. (5 points)

Use the following table for the answer ‫استخدم الجدول التالى لالجابة‬

Step no. Step description Step sketch

‫رقم الخطوة‬ ‫وصف العملية‬ ‫رسم العملية‬
1
2

Good luck

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