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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PEPERIKSAAN AKHIR SEMESTER I
FINAL EXAMINATION SEMESTER I
SESI 2021/2022
SESSION 2021/2022
FAKULTI KEJURUTERAAN MEKANIKAL

KOD KURSUS : BMCG 2312

COURSE CODE

KURSUS : PROSES PEMBUATAN

COURSE MANUFACTURING PROCESS

PENYELARAS : PM TS DR MOHD ZULKEFLI

COORDINATOR

PROGRAM : BMCG
PROGRAMME

TARIKH : 06 FEBRUARI 2022

DATE 06 FEBRUARY 2022

MASA : 9.00 AM
TIME

TEMPOH : 3 JAM
DURATION 3 HOURS

TEMPAT : HALL 3

ARAHAN KEPADA CALON

INSTRUCTION TO CANDIDATES
(1) Pelajar mesti menyempurnakan penghantaran (muat-naik) jawapan akhir ke dalam sistem dalam masa
3 jam.
Student must complete submitting (uploading) the final answer into the system within 3 hours.
(2) Terdapat TIGA (3) soalan didalam kertas soalan ini. Jawab semua soalan.
This examination consists of THREE (3) questions.Answer all questions.
(3) Markah keseluruhan bagi peperiksaan ini adalah 75 markah. Setiap soalan membawa 25 markah
Total marks for this examination is 75 marks. Each question has 25 marks.

KERTAS SOALAN INI TERDIRI DARIPADA 10 MUKA SURAT SAHAJA

(TERMASUK MUKA SURAT HADAPAN)
THIS QUESTION PAPER CONTAINS 10 PAGES INCLUSIVE OF FRONT PAGE

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ANSWER ALL THE QUESTIONS

Q1 (a) Why is it not always a good idea to increase the cutting speed in order to increase the
production rate? Use the Taylor equation to explain your answer.
(7 marks)

(b) Why has the wire-EDM process become so popular in industry, particularly in the
production of tools and dies as shown in Figure 1.1?

Figure 1.1: Tool and die

(8 marks)

(c) A cast-steel valve body before (left) and after (right) machining is shown in Figure
1.2. Determine which surfaces will be machined (noting that not all surfaces are to be
machined). Which machine tool would be best for machining this part? What types of
machining operations are involved, and how should these operations be performed in
order?

Figure 1.2: Cast-steel valve body

(10 marks)

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Q2 (a) A prototype is going to be extruded using the Fused Deposition Modeling (FDM)
technique. The extruder head has a dimeter of 1.5 mm and able to produce layers which
are 0.20 mm in thickness. If the extruder head and polymer extrudate velocities are
both 50 mm/s, estimate the production time for the generation of the product shown in
Figure 2.1 (dimensions are in cm). Assume that there is a 10 s delay between layers
as the extruder head is moved over a wire brush for cleaning.

Figure 2.1 A prototype

(12 marks)

(b) State the difference between an electrode, filler metal, and welding rod in joining
process?
(6 marks)

(c) Select one (1) product that can be found in a kitchen and describe how the product was
joined. Explain why the joining process was selected for that product?
(7 marks)

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Q3 (a) It is impossible to produce a part with 100% similar dimension. Discuss the sources of
variation in the dimension of the product during manufacturing processes
(5 marks)

(b) A company producing a kitchen worktop with specified thickness of range as 5±0.5 cm.
The control chart data for the thickness measurement is shown in Table 3.1. A request from
sales team whether the limit could be increased to 5±0.8 cm, so this could result in
significant order from the customers who preferred not to add the thickness of worktop for
fit.
Use the control chart data as shown in Table 3.1 to;
i) Find Cp and Cpk to determine whether the current process is currently capable.
(3 marks)
ii) Use new limits to determine if the new limits are capable to meet customer’s need.
(3 marks)
iii) Based on the calculation above, conclude the result to the company management.
(2 marks)
Table 3.1 Control chart data
x1 x2 x3 x4
5.2 5.1 4.94 4.6
5.1 5.3 5.5 4.95
4.5 5 4.93 4.92
5.03 4.91 5.1 4.98

(c) With reference to a case study available on the literature, write on the following aspects
involved in sustainable manufacturing practice at the company selected:-
i. Type of sustainable manufacturing practice implemented by the company
(2 marks)
ii. TWO (2) main reasons why the company tend to implement sustainable
manufacturing practice in its operations
In your answer, specify the source of reference made and information relating to
the company selected.
(2 marks)

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(d) Based on your discussion in (c), evaluate the impacts of implementing sustainable
manufacturing practice on the company studied in terms of the following:-
i. Manufacturing cost
ii. Waste management
iii. Environmental impact
iv. Energy consumption
(8 marks)

END OF EXAMINATION QUESTIONS

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JAWAB SEMUA SOALAN

S1 (a) Mengapa kaedah meningkatkan kadar pengeluaran dengan meningkatkan kelajuan

pemotongan bukanlah idea yang baik? Gunakan persamaan Taylor untuk menerangkan
jawapan anda
(7 markah)

(b) Kenapa proses wayar-EDM menjadi begitu popular dalam industri, terutamanya
dalam pengeluaran alatan dan acuan seperti yang ditunjukkan dalam Rajah 1.1?
Terangkan.

Rajah 1.1: Alatan and acuan

(8 markah)

(c) Sebuah badan injap besi tuang sebelum (kiri) dan selepas (kanan) pemesinan
ditunjukkan dalam Rajah 1.2. Tentukan permukaan yang akan dimesin (perhatikan
bahawa tidak semua permukaan harus dimesin). Apakah alat pemesinan yang paling
sesuai untuk menghasilkan bahagian ini? Apa jenis operasi pemesinan yang terlibat,
dan bagaimana operasi ini harus dilakukan dengan teratur?

Rajah 1.2: Badan injap besi tuang

(10 markah)

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S2 (a) Satu prototaip akan diekstrusi menggunakan teknik Pemodelan Pemendapan
Terlakur (FDM). Kepala penyemperit mempunyai diameter 1.5 mm dan mampu
menghasilkan lapisan dengan ketebalan 0.20 mm. Jika kepala penyemperit dan
halaju penyemperit polimer adalah 50 mm/s, anggarkan masa penghasilan untuk
penjanaan produk yang ditunjukkan dalam Rajah 3.1 (dimensi dalam cm). Andaikan
terdapat kelewatan 10 s di antara penghasilan lapisan untuk pembersihan apabila
kepala penyemperit digerakkan di atas berus dawai.

Rajah 3.1 Sebuah prototaip

(12 markah)

(b) Nyatakan perbezaan antara elektrod, logam pengisi, dan batang kimpalan di dalam
proses penyambungan?
(6 markah)

(c) Pilih satu (1) produk yang boleh didapati di dapur dan huraikan cara produk itu
disambungkan. Terangkan mengapa proses penyambungan tersebut dipilih untuk
produk tersebut?
(7 markah)

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S3 (a) Adalah mustahil untuk menghasilkan komponen sama yang 100% sama dimensi.
Bincangkan sumber-sumber yang menyebabkan variasi pada dimensi komponen
semasa proses pembuatannya
(5 markah)

(b) Satu syarikat menghasilkan satu permukaan meja kabinet dapur dengan ketebalan
ukurannya adalah 5±0.5 sm. Ukuran produk yang telah siap adalah seperti di dalam
Jadual 3.1. Pasukan jualan meminta agar had ukuran ditinggikan kepada 5±0.8 sm
supaya dapat memenuhi keperluan pemasangan tanpa perlu menambah ketebalan
untuk pemasangan.
Gunakan data carta kawalan di Jadual 3.1 untuk;
i) Cari Cp dan Cpk bagi menentukan sama ada proses semasa adalah mampu.
(3 markah)
ii) Gunakan had baru bagi menentukan jika ia mampu memenuhi keperluan
pelanggan.
(3 markah)
iii) Berdasarkan pengiraan di atas, simpulkan keputusan kepada pengurusan
syarikat.
(2 markah)
Jadual 3.1 Data carta kawalan
x1 x2 x3 x4
5.2 5.1 4.94 4.6
5.1 5.3 5.5 4.95
4.5 5 4.93 4.92
5.03 4.91 5.1 4.98

(c) Dengan merujuk kepada kajian kes yang terdapat pada literatur, tulis aspek berikut
yang terlibat dalam amalan pembuatan lestari (sustainable manufacturing) di
syarikat yang dipilih:-
i. Jenis amalan pembuatan lestari yang dilaksanakan oleh syarikat
(2 markah)
ii. DUA (2) sebab utama mengapa syarikat cenderung untuk melaksanakan
amalan pembuatan lestari dalam operasinya

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Dalam jawapan anda, nyatakan sumber rujukan yang dibuat dan maklumat
berkaitan syarikat yang dipilih.
(2 markah)

(d) Berdasarkan perbincangan anda di (c), buat penilaian tentang kesan pelaksanaan
amalan pembuatan lestari ke atas syarikat yang dikaji dari segi yang berikut:-:-
i. Kos pembuatan
ii. Pengurusan sisa
iii. Kesan alam sekitar
iv. Penggunaan tenaga
(8 markah)

SOALAN PEPERIKSAAN TAMAT

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APPENDIX /LAMPIRAN

N = Rotational speed of the workpiece, rpm

f = Feed, mm/rev or in/rev
v = Feed rate, or linear speed of the tool along workpiece length, mm/min or in/min
=fN
V = Surface speed of workpiece, m/min or ft/min
= πDoN (for maximum speed)
= πDavgN (for average speed)
l = Length of cut, mm or in.
Do = Original diameter of workpiece, mm or in.
Df = Final diameter of workpiece, mm or in.
Davg = Average diameter of workpiece, mm or in.
= (Do +Df ) /2
d = Depth of cut, mm or in.
= ( Do - Df ) /2
t = Cutting time, s or min
=l/f N
3 3
MRR = mm /min or in /min
= πDavg d fN
Torque = Nm or lb ft
= ( Fc )( Davg /2 )
Power = kW or hp
= (Torque) (w , where w=2p radians/min
Note: The units given are those that are commonly used; however, appropriate units must be
used and checked in the formulas.

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