UNIVERSITY OF SOUTHERN QUEENSLAND

Faculty of Health, Engineering, and Sciences

School of Mechanical and Electrical Engineering

MEC 2202: Manufacturing Processes

Semester 1, 2021

Course Examiner: Prof Hao Wang

Associate Examiner: Dr Venkata Chevali

Assignment 1

Total Marks: 200 (20% of Final Grade)

Assignment due on: April 12, 2021 by 11:59 PM through StudyDesk Submission
Portal

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Question 1 150 marks
(Limit your report to 5 pages max. including images, tables and bibliography)

A sports car wheel manufacturer (Ventura) currently produces wheels for German sedans
using sand casting, which requires a mould to be created with sand for each wheel. Ventura
is looking to expand their production in the next 2 years from manufacturing 3000 units
yearly to 10,000 units yearly.

Fig. 1. A generic automotive wheel.

As a Manufacturing Engineer for Ventura, you are required to provide a Report, which should
contain the following:

a) How wheels for automobiles are produced in the industry today, including which
manufacturing processes and the materials are predominantly used.
25 marks

b) Other possible manufacturing processes (and/or materials, if there is a need to

change the materials) available, which can replace the current sand casting process,
with their potential advantages and disadvantages.
25 marks

Based on your research in Points a) and b):

c) Provide details of the three selections that Ventura can consider to replace the sand
casting currently being used. And then the final and best selection with the
consideration of performance, large quantity (volume), and economy. Provide
schematic diagrams of the process, and if there are particular machinery and tooling
involved. Provide the detailed rationale for your decision. [Drawings are mandatory]
100 marks

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Hints/guidance:

• The method of your manufacturing process (and/or materials) selection is important rather than the
report format. Provide details on the reason and rationale.
• Understand the principles of different manufacturing processes and their advantages, disadvantages
and limitations.
• Possible structure for your report:

1. The Current Ventura Wheel and its Casting Processes for Wheel (state your assumption on what
material is currently used for the current wheel)
2. Other Possible Manufacturing Processes for Car Wheels (maybe also other non-metallic materials as
different processes might be for different materials)
3. The Three Possible Candidates (processes and the materials used) for the Increased Production
Volume. With the analysis of advantages and disadvantages of each manufacturing process, and the
economic considerations in your mind.
4. Recommendation of the most suitable manufacturing process (one) for the Ventura Board. Provide
the reasons of your selection and the details of the process.

Question 2 30 marks
Select the most appropriate manufacturing process on the right for the product on the
left. Briefly describe how each of the manufacturing processes works to produce the
corresponding product.

Product Manufacturing Process

1. Aluminium rod a) Powder sintering

2. Ceramic bricks b) Filament winding
3. Aluminium car engine block c) Extrusion
4. FRP pressure vessel d) Forging
e) High pressure die casting
f) Injection moulding

Question 3 20 marks

a) Distinguish between: I) open-die forging, II) impression-die forging, and III)

flashless forging. [Optional drawings may be provided]

b) What are the similar characteristics between forging and compression moulding
used in plastics processing? [Optional drawings may be provided]

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