NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY FACULTY OF ENGINEEERING DEPARTMENT OF INDUSTRIAL AND TECHNOLOGY Bachelor of Engineering (Hons.) Inqystrial and Manufacturing Engineering Advanced Manufacturing Technology (AMT) TH; S216 Main Examination Paper March 2023 This examination paper consists of 5 pages Time Allowed: 3 hours \ Total Marks: 100 Special Requirements: None { fH Examiner's Name: Dr. Eng. Sipiwe Trinity Nyadongo INSTRUCTIONS AND INFORMATION TQ CANDIDATE 1. Answer any five (5) questions J 2, Each question carries 20 marks 3. Use of calculators is permissible | | “ ’ Page|l ofS Copyright: National Universiyfof Science and Technology, 2023 rasa k Scanned with CamScannerPr question) — a) Describe using appropriate diagrams the following Rapid Prototyping technologies: ta i) Fused deposition modelling and é ii) 3D printing. For each describe the process, the application, advantages and disadvantages. b) A cone-shaped part isto be fabricated using stereolithography. The radius of the cone at its base ~35 mm and its height 49 mm, The layer thickness = 0.20 mm. The diameter of the laser beam = 0.22 mm, and the beam is moved across the surface of the photopolymer at a velocity of 500 mm/s. Compite & estimate for the time required to build the part, if ~10 seconds are lost each layer to lower the height ofthe platform that holds th par. Neglect post-curing time. “ fa * QUESTION 2 ¢ a) Define Additive manufacturing. 2) b) Compare and contrast additive manufacturing to subtractive manufacturing. [8] ©) The cup in Figure Q2 is to produced using Additive manufacturing, Use the Generic AM. Process to describe how this cup will be i produced, (Relevant diagrams should be used) [10] © Figure Q2—A cup a Question 3 Figure Q3 shows a mechanical energy nontraditional process. 00' A Bol Page 2 of § Copyright: National University 6f Science and Technology, 2023 Scanned with CamScannera, oe rr Figure Q3 — Noiraditional Mechanical energy process a) Identify the process. ry \ b) _ Distinguish process from the other processes in the mechanical energy category i (6) ©) __ Identify two different products that/can be made using this process for use by NUST students. 22] @ Chemical milting is used than srerat plant to create pockets in wing sections made of an aluminum alloy. The stating thickness of one workpart of interest is 20 mm. A series of rectangular-shaped potkers/12 mm deep are to be formed with dimensions ‘Metal removal rate i mm3/min, ‘Time required to machine to the specified depth, ¢ iip)) required dimensions of the opening ih the cut and peel maSkant to achieve the desired Spocket'size on the part 14] Question a) Describe the following nanoparticles factories in comparison to macro patticles. (make use of examples in your explant ) i) Motion, a 2) res ofS Copyright: National S| Science and Technology, 2023 Scanned with CamScannerii) Appearance, a iil). Surface area. 2) \ (8) ©) Nanotechnology is finding application in day to day products because of their good” b) Explain the characteristics of Fullerines, characteristics. Describe application in two products (one must be an engineering product and another a basic product). (6) Question 5 a) LIGA is an imps i) printers work. (10) Question 6 8) Viole manufacturing company makes use of eleetrochemical machining i) Name the three main types of electrochemical machining. eA B) ii) Explain the two significant dizadvaniages of electrochemical'm Flachiaing. [4] iii) The company has been experiencing a quality challenge of ‘overcuts’. What is meant by the term overcut in electric discharge machining? B) +b) The frontal working area of the electrodejs 2000 mm2 in a certain ECM operation in which 2'volts. The material being cut is nickel the applied current = 1800 amps and the yoltage (valence = 2), whose specific removal rate C = 3.42 x 10-2 mm3/A-s. i) If the process is 90% efficient, determine the rate of metal removal in mm3/min. [5] iii) If the resistivity of the electrolyte = 140 ohm-mm, determine the working gap? [5] te Question® A single crystal boule of silicon is grown by the Czochralski process to an average diameter of 110 mm with length = 1200 mm. The seed and tang ends are removed, which reduces the length to 950 mm. The diameter is ground to 100 mm: 4-30 mm wide flat is ground on the surface which Page 4 of 5 Copyright: National University Of Science and Technology, 2023 Scanned with CamScannerextends from one end to the other. The ingot ig tne sliced into wafers of thickness = 0.50 mm, using an abrasive saw blade whose thickness = 0.33 mm. Assuming that the seed and tang porions cut off the ends of the starting | boule were conical in shape, determine: (20) (6) The original youme bf whe bdse, aad (b) How many wafers are cut from it, assuming the entire 950 mm length can be sliced; and (©) What is the volumetric proportion of silicon in the starting boule that is wasted during processing? Scanned with CamScanner