AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING

i-CREDIT HOURS ENGINEERING PROGRAMS, MANUFACTURING ENGINEERING PROGRAM

Spring, 2020/2021 Course Code: MDP 282 Time Allowed: 2 Hrs.
Non-Conventional Processing
The Exam Consists of Five Questions in Three Pages. 2/3

3.2 Plot a relation between D/d (x-a is and he in ensifier ra io i for al es of D d ranging from o
with increments of 2. Present your calculations in a Table form. (6 marks)

Question 4: [6 marks]
The pho o sho s a Cal in s P le L-Cube, where each small cube is 25x25x25 mm.
The part is required to be built by SLS under the following conditions:
Layer thickness = 0.15 mm Building speed = 700 mm/s
Diameter of Laser beam = 0.5 mm
The Laser beam builds the layer by moving forwards and backwards in the
y-direction.

y
4.1 Calculate the Volume of the powder needed for building the part. (1 mark)

4.2 Find the time required to build the part. (5 marks)

Question 5: [11 marks]

5.1 Draw a drilling operation performed by the Electro Stream Machining Process. (2 marks)

5.2 Show by a neat sketch the effect of the stand-off distance on the kerf during slitting a steel plate by
WJM. (2 marks)

5.3 State three differences between the SLA and the SLS processes. (2 marks)

5.4 Choose the correct answer: (5 marks)

1 ECM could be useful in:
A Addition of recast layers from parts machined by USM
B Etching of recast layers from parts machined by EDM
C Removal of deep cavities from parts machined by LBM
2 In a LASER cutting process:
A the power lost by conduction is equal to the radiated power.
B the power lost by conduction is greater than the radiated power.
C the power lost by conduction is smaller than the radiated power.
D there is no relation between the two powers.
3 In ECM drilling, we have
A DWP = DTool + 2 Side Gap B DWP = DTool - 2 Side Gap C DWP = DTool
4 In EDM, the dielectric strength is expressed in:
m ol ol m ol m ol m 3 5 vol m2
5 In LBM slitting, we have:
A Width of slit = Dlaser + 2 Kerf B Width of slit = Kerf C Width of slit = Dlaser
6 In USM he ool imposes press re on he WP
1 alternating 2 dynamic 3 constant 4 variable 5 magnetic
7 Magnetostriction is a proper ha co ld be sef l for ma erials
A ferromagnetic B plastic C non-metallic D rubber E Nylon
8 Newspaper could be cut with Laser at speeds up to:
6 m/min or 20 m/s or 1 m/s or 10 m/s.
9 Normal ECM processes se a ol age aro nd imes ha sed i h he Elec ro-stream
process.
A 0.3 B 0.1 C 0.01 D 10 E 100
 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
i-CREDIT HOURS ENGINEERING PROGRAMS, MANUFACTURING ENGINEERING PROGRAM
Spring, 2020/2021 Course Code: MDP 282 Time Allowed: 2 Hrs.
Non-Conventional Processing
The Exam Consists of Five Questions in Three Pages. 3/3

10 Sof ma erials hen c b USM absorb energ and make he process less efficien
A no B too little C too much D zero
11 The depth of the HAZ in ECM is nearly equal to:
A 40 mm B zero C 4 µm D 4 V/µm
12 The engraving of a picture on a piece of wood is best done by:
1 ECM 2 EDM 3 WJM 4 LBM 5 AWJM
13 The intensifier in WJM is used to:
A raise the oil pressure B minimize losses in the nozzle
C raise the water pressure D add additives to the water
E filter the water from impurities
14 The machining process that produces surfaces with dull and matt appearance is termed:
A ECM B WJM C AWJM D LBM E EDM
15 The process that uses repetitive impact between the tool and workpiece to remove
material is:
A EDM B ECM C USM D WEDM E WJM F STEM
16 The specific removal rate in ECM is expressed by:
A As/cm3 B cm3/As C cm2s/A D cm2/As E cm3/As3
17 The transducer in USM transforms:
1 mechanical energy to electrical energy
2 electrical energy to mechanical energy
3 mechanical energy to thermal energy
18 The USM has a solenoid inding of nickel lamina ions
A intensifier B transducer C accumulator D attenuater
19 The velocity of the water jet ejecting from the nozzle in a WJM process is around:
A 0.9 m/s B 9 m/s C 90 m/s D 900 m/s
20 To clean the internal surfaces of large castings, use:
1 LBM 2 EDM 3 ECM 4 WJM 5 WEDM

END of Exam, Good Luck

Examination Committee Exam. Date : 9th of July, 2021

Prof. Samy J. Ebeid
Question (3): [6 Marks]

a) A Hss turning tool o is used for turning of a bar Ø100 x 500 mm2

down to Ø 90 mm in single pass , between centres, on a lathe having :

Motor power at moter terminal
Pm kW ηm =6 ηe =20 % If feed = 0.4 mm/rev.

Can the cutting tool be used without lossing its hardness? If not, Determine
the effective cutting parameter which can be changed to prevent the lossing
of its hardness
if the red hardness = 500 Cο keeping the given moter power
if: Fc = 2500 . a . s0.8 N and Ɵ = 280 v0.3 s0.2 a0.05

Question (4): [12 marks]

A coated carbide insert 12x12 mm2 o
is used for machining of a bar Ø65 x 252 mm2 down to
Ø56 mm, between centres, on a lathe having in roughing and finishing operations where the where
the finishing allawence is 1 mm and the Motor power at motor shaft is Pm kW ηm =70 %
Max. perm. feed force (Fap) = 2000 N, Max. perm. torque (Mdp)= 180.8 Nm, (blim) = 8.3 mm.
Determine:
Max. allowable depth of cut, number of passes, (a) in each pass & (amax)actual [2 Marks]
Max. permissible feed, for: Fc = 2500 . a . s0.8 N & Fa = 1500 . a . s0.8 N [3Marks]
0.25 0.4 0.2
(Topt) & (vopt), for C1= 60 L.E./hr & C2 = 12 L.E./edge, v = 275 /( T . s .a ) [3 Marks]
Check the installed motor power. [2 Marks]
Determine the feed travel & m/cg time in roughing for lw =252 mm. [2 Marks]

Prof. Mohamed Abdel Salam

Dr. Mahmoud Zakaria
2
 Final exam ILO Matrix
Assessment method a1 a2 a3 a4 b1 b2 b3 c1 c2 c3 c4 d1 d2 d3
Final term examination • • • • • • • • •
AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
CREDIT HOURS ENGINEERING PROGRAMS
MANUFACTURING ENGINEERING PROGRAM

Spring 2021
Date 5/7/2021 Final Term Exam Time 2 Hours

Metal Removal Processes MDP 273

Total Marks: 40 Marks 1/2
‫الرصاص‬ ‫ال ل ال اف ل‬ ‫ا‬ ‫ا‬ ‫را‬ ‫أ ل‬4 ‫ار‬ ‫ا‬
‫ا‬ ‫ال‬ ‫ال‬ ‫ا دد‬ ‫ا‬ ‫ال ال ا ل‬ ‫ را إ ا ال‬: ‫دا‬ ‫ا‬
‫ا ر ا ا‬

Answer the following :

Question (1): [12 Marks]

a) What is the chatter ? How can be avoided [2 Marks]

b) List down the conditions for obtaining good surface finish. [2 Marks]
c) What is meant by machinability.,List down its criteria. [2 Marks]
d) Draw a RH tool in its sectional views showing angles & reference planes. [3 Marks]
e) What is meant by tool life and optimum tool life Explain by sketch the relatioship between
Tool weat time (B-T relationship) [3 Marks]
____________________________________________________________________________

Question (2): [10 Marks]

o
In orthogonal cutting using a HSS tool α o o
λ o), width of cut (b) = 5 mm,
feed (s) = 0.2 mm/rev, cutting speed (v) = 45 m/min, the obtained measured results are:
Chip thickness ( h2) = 0.6 mm, Cutting force components: (Fc) = 3000 N, (Ft) = 1500 N.
Calculate λc Ø then determine(Ø) graphically using a proper scale for (h1,h2). [2 Marks]
Draw Merchant s circle get Fs), (Fn) (F),(N) graphically determine β As),(Ss) [6 marks]
Determine (vs),(vf) graphically. Check whether Ws+Wf = Wc . [2 Marks]

1
Question (3): [6 Marks]

a) A Hss turning tool o is used for turning of a bar Ø100 x 500 mm2

down to Ø 90 mm in single pass , between centres, on a lathe having :

Motor power at moter terminal
Pm kW ηm =6 ηe =20 % If feed = 0.4 mm/rev.

Can the cutting tool be used without lossing its hardness? If not, Determine
the effective cutting parameter which can be changed to prevent the lossing
of its hardness
if the red hardness = 500 Cο keeping the given moter power
if: Fc = 2500 . a . s0.8 N and Ɵ = 280 v0.3 s0.2 a0.05

Question (4): [12 marks]

A coated carbide insert 12x12 mm2 o
is used for machining of a bar Ø65 x 252 mm2 down to
Ø56 mm, between centres, on a lathe having in roughing and finishing operations where the where
the finishing allawence is 1 mm and the Motor power at motor shaft is Pm kW ηm =70 %
Max. perm. feed force (Fap) = 2000 N, Max. perm. torque (Mdp)= 180.8 Nm, (blim) = 8.3 mm.
Determine:
Max. allowable depth of cut, number of passes, (a) in each pass & (amax)actual [2 Marks]
Max. permissible feed, for: Fc = 2500 . a . s0.8 N & Fa = 1500 . a . s0.8 N [3Marks]
0.25 0.4 0.2
(Topt) & (vopt), for C1= 60 L.E./hr & C2 = 12 L.E./edge, v = 275 /( T . s .a ) [3 Marks]
Check the installed motor power. [2 Marks]
Determine the feed travel & m/cg time in roughing for lw =252 mm. [2 Marks]

Prof. Mohamed Abdel Salam

Dr. Mahmoud Zakaria
2
AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
CREDIT HOURS ENGINEERING PROGRAMS
MANUFACTURING ENGINEERING PROGRAM

Spring Semester 2021 Course Code: MDP 340 Time allowed: 2 Hrs.
METROLOGY LAB II
The Exam Consists of Five Questions in Four Pages. Maximum Marks: 40 Marks 1/4
‫ت ليمات امة‬
.‫م لق ى ا قا ب‬ ‫ت تو ب ال قاب و ذا ان رورى الد ول با مول يو‬ ‫يازة التلي ون ا مول م تو ا دا ل نة األمت ان ي ت الة‬
.‫ال ي م بد ول ما ة األذن أو البلوتوث‬
. ‫الي م بد ول أي تب أو مالزم أو أوراق دا ل ال نة وا ال ة ت ت الة‬
(Answer all the following five questions )

Question (1): [10 marks]

a- Using neat sketches; explain an experiment to measure the thread effective diameter. (3 Marks)
b- The reading over three wires placed over thread of M20X2.5 is 21.160 mm. The wires having 1.65
mm diameter, the right and left flank angles of the thread were 30o 15/ and 29o 45/, and the pitch in
mm of the thread when checked along the teeth were:
Tooth No. 1 2 3 4 5 6
P (mm) 2.500 2.498 2.502 2.503 2.500 2.498
★Calculate the virtual effective diameter (4 Marks)
c- If the previous screw will fit a nut having an effective diameter equals 18.375±0.020 mm and its height
is 15 mm.
★ Check whether the screw will fit fully, partially or will not fit at all. (2 Marks)
★ If partial fit exists; mention the last engaged tooth number. (1 Mark)

Question (2): [9 marks]

a) A Rochdale arm tester having 100 mm leg distance was calibrated on three points x, y, z on a line.
Its readings at point Z was 0.15 mm. The reading of a sensitive level on the same line needs to divide
the line into parts as shown. The readings were 1 and 4 m respectively on the line xy and were -2 and
-3 m respectively on the line yz (3 Marks)
x_____x1______y______y1______z

b) If the calibrated Arm is used to measure the flatness of a surface and the calibration give deviation
value + 0.1 mm
Line abc afe edc bdh ehk bcl hjl cjk
Readings( m) 10 -4 5 -10 -3 86 16 -23

See Next Page 2/4

 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
CREDIT HOURS ENGINEERING PROGRAMS, MANUFACTURING ENGINEERING PROGRAM
Spring Semester 2021 Course Code: MDP 340 Time Allowed: 2 Hrs.
METROLOGY LAB II
The Exam Consists of five Questions in Four Pages. 2 /4

Find the height of each point refereed to plane (abf) (6 Marks)

Question (3): [6 marks]

The following readings were taken at equal steps on a cam shaft tester around a bar

80.186 80.177 80.182 80.180

80.176 80.184 80.175 80.173

check the out of roundness and eccentricity of the bar.

Question (4): [10 marks]

a) Describe how can the following roughness parameters be evaluated: (4 marks)
a. Swedish height H
b. Arithmetic average Ra
c. Rz
d. High spot count
b) In the measurement of surface roughness, heights of 26 successive peaks and valleys were measured
from a datum and as shown in table were: (in microns).
25.5 X 1 37 22 40 19 24 5 42 17 31 11

91 25.5 36 17 32 7 37 2 15 6 25.5 9 25.5

The measurements were obtained over a surface having 0.025 mm sampling length.
If the max peak to valley height (Rt) equals 61 find the value of X (2 marks)
If the value of X is 49, draw the bearing area curve then calculate the H value of the surface (4 marks)

See Next Page 3/4

 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
CREDIT HOURS ENGINEERING PROGRAMS, MANUFACTURING ENGINEERING PROGRAM
Spring Semester 2021 Course Code: MDP 340 Time Allowed: 2 Hrs.
METROLOGY LAB II
The Exam Consists of five Questions in Four Pages. 3 /4
Question (5): Choose the best correct answer [5 marks]
1- Which of the following is not true about effective diameter?
a- Also known as pitch diameter
b- It decides quality of fit between nut and screw
c- This is the diameter of minor cylinder
d- It is a very important dimension for screw threads
2- Flanks of the threads connect the crest with the roots.
a- True
b- False
3- A metric thread M16X2 was measured using three wires method. The best wire
diameter is:
a- 1.15 mm.
b- 2.00 mm.
c- 9.24 mm.
d- 16.00 mm.
4- The major diameter of an external thread is checked by:
a- Abbe vertical metroscope
b- Thread micrometer
c- T Make Mic c e
d- All of the above
5- Three wires technique can be used to measure:
a- The thread major diameter.
b- The thread minor diameter.
c- The thread pitch diameter.
d- The thread flank angle.
6- The pitch diameter of an external thread is checked by:
a- T Make Mic c e
b- Abbe Vertical Metroscope.
c- Thread Micrometer.
d- All of the above.
7- The flank angle of an external thread is checked by:
a- T Make Mic c e
b- Abbe Vertical Metroscope.
c- Thread Micrometer.
d- All of the above.
8- The minor diameter of an external thread is checked by:
a- T Make Microscope
b- Abbe Vertical Metroscope.
c- Thread Micrometer.
d- a and c.
9- The major diameter of an external thread is checked by:
a- T Make Mic c e
b- Abbe Vertical Metroscope.
c- External Micrometer.
d- All of the above.
10- Which type of errors show linear relation between cumulative pitch error and length
of thread?
a- Periodic errors
b- Progressive errors
c- Both a. and b.
See Next Page 4/4
d- None of the above
 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
CREDIT HOURS ENGINEERING PROGRAMS, MANUFACTURING ENGINEERING PROGRAM
Spring Semester 2021 Course Code: MDP 340 Time Allowed: 2 Hrs.
METROLOGY LAB II
The Exam Consists of five Questions in Four Pages. 4 /4

Formula Sheet

P = Mea ed Th ead Pi ch Th ead S a da d Pi ch

ϴ = Ha f he i c ded a g e (Deg ee ), d= Wi e dia e e ( ), P = S a da d Th ead
Pi ch ( ), De = Th ead Si e Effec i e Dia e e ( ), Pacc. = Acc a ed Pi ch
E ( )
P
Reading over wires = S = De + d (1+cosecθ) cotθ
De1 = P a * c
P a = Ma . (+ e) Pacc. Ma . (- e) Pacc.
∆D 0.0131 ∗ P ∗ δθ δθ , F ISO e ic h ead,
δθ in degrees and P nominal pitch mm ∆D i
Vi a Effec i e Dia e e = De + De1 + ∆D

Least square line

y=ax+b

Least square plane

Z = ax + by

END of Exam, Good Luck

Examiners Exam. Date : 19th.of June, 2021

Dr. Mohamed Ahmed Awad
Dr. Tamer Hassan

End of Exam 4/4

AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
Program of Manufacturing

2nd Semester, 2021 Course Code: MDP 350 Time allowed: 2 Hrs.
Industrial Robots
The Exam Consists of Three Questions in Two Pages. Maximum Marks: 40 Marks 1 /2
‫ح ل ماث امت‬
.‫م لق ا قا ب‬ ‫وإذا ان من ال رور الد ل با حم ل‬ ‫حالت‬ ‫ح ازة ال ل ن ا حم ل م حا دا ل نت م حان‬
.‫مح بد ل ما ت ذن أو البل ث‬
Open Book ‫ح‬ ‫م حاناث ذاث ال اب ا‬ ‫دث من ذل‬ . ‫حالت‬ ‫مح بد ل أ ب أو م زم أو أوراق دا ل ال نت وا ال ت ح‬

Answer all questions and assume any missing data

Question (1): [20 marks]

a) For Stanford robot shown in figure (1) bellows
i. Define the Joint Coordinates frames
ii. Write and identify the table of DH Parameters
iii. Write the transformation matrices
iv. Find Total transformation matrix

b) In a robotic set-up, a camera is attached to the fifth link of a 6-DOF robot. It

observes an object and determines its frame rela i e o he camera s frame. Using
the following information, determine the necessary motion the end effector must
make to get to the object:
 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
Program of Manufacturing
nd
2 Semester, 2021 Course Code: MDP 350 Time Allowed: 2 Hrs.
Industrial Robots
The Exam Consists of Three Questions in Two Pages. 2 /2

Question (2): [10 marks]

Solve the inverse position kinematics using geometrical method for the manipulator shown in
figure 2 given

Fig. 2

Question 3: (10 Marks)

The second joint of a 6-axis robot is to go from an initial angle of 20° to an
intermediate angle of 80° in 5 seconds and continue to its destination of 25° in
another 5 seconds. Calculate the coefficients for third-order polynomials in joint-
space. Assume the joint stops at intermediate points.

Formula Sheet

END of Exam, Good Luck

Examination Committee Exam. Date : 28th of June, 2021

Dr. shady Ahmed
 AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
Credit Hours Engineering Programs - CHEP
Manufacturing Program - MANF
Final Examination

Spring 2021- Semester Exam Date : 20.6.2021 Exam Time 02:00 H.

Mechatronics-MDP459
Th Three questions in two pages Total Marks: 40

Answer all Questions and assume any missing data

Question: 1 (15 Marks)

a. Sketch the procedure for designing mechatronics system according to the VDI 2206 and
explain them briefly

b. A bottling plant uses an automated mechanism for filling the containers and transporting
them from one point to another as shown in Fig 1. The sensors monitor the amount of solid
or liquid filled. A conveyor mechanism transports the containers. Under the concept of VDI
2206, design a mechatronic system for the case described. Identify the types and features of
sensors you use, describe how the system works and explain how you are going to interface
and control the system. Make suitable sketches if needed.

Feed
Motor
Control

Fig. 1

Question: 2 (10 Marks)

Pump P1: is driven at 1440 rpm as shown in Fig.2, and having a displacement of 12.5 ml/rev and a
volumetric efficiency of 87%, and power of 3 kw
Cylinder CL1: 63 mm bore diameter x 35 mm rod diameter x 250 mm stroke length
i. If P1, CL1 are used in the below circuit, estimate the extension and retraction time
ii. Calculate the max pushed and pulled forces, by the cylinder

1
 CL1

P1

Fig. 2.

Question 3: (15 Marks)

1. Briefly describe with sketches the principal of operation and construction of the optical binary
absolute encoder.
2. A linear actuator with maximum travel 8 cm, A slider potentiometer with 10 cm range is used to
measure the actuator position. The potentiometer is fixed to the actuator such that the zero
position of the actuator is located to 5% of the potentiometer travel.
It is required to plot the signal voltage versus actuator travel, knowing that the supply
voltage is 5V
Propose a reason for using LVDT instead of slider potentiometer.
3. The linear velocity of a conveyor belt is to be controlled to achieve a target speed 0.3m/s, with
tolerance of 0.1 m/s. An incremental optical shaft encoder has been selected to measure the
angular speed of the Idler Drum

( cm diameter, 75 cm length).

The measurement system MUST be able to measure the variation in speed within 0.01 m/s.
Calculate the suitable resolution.
Calculate the output signal frequency for 0.3 m/s.
Calculate the minimum no. of bits for an absolute encoder with gray coding to
replace the mentioned incremental encoder.

Idler Drum

‫اح‬ ‫ق ا‬ ‫ات با ت‬ ‫أط ب أ‬

Examination Committee:

Dr. Shady A. Maged

2
AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
Program of Manufacturing Engineering – Senior 2
Covid 19-Spring, 2020/2021 Course Code: MDP 472 Time allowed: 2 Hrs.
Non-Conventional Material Fabrication and Heat-Treatment Processes
The Exam Consists of Five Questions in Two Pages. Maximum Marks: 40 Marks 1/2
Important Rules: ‫ت ل ات ا ة‬
Having a mobile, Smart Watch, or earphones inside the examination ‫ة‬ ‫) دا‬ ‫ ا ة ا ذ‬- ‫ ا ا ات ا ذ ة‬- ‫ازة (ا‬
hall is forbidden and is considered as a cheating behavior.
. ‫ت ت ب ا اب‬ ‫ا ت ا ت اة‬
It is forbidden to have any references, notes, books, or any other
materials even if it is not related to the exam content with you in the ‫ة‬ ‫ا‬ ‫دا‬ ‫ز أ أ را‬ ‫أ تب أ‬ ‫بد‬
examination hall. . ‫ا ا ةت ت ا ة‬
Only one A4 paper, two faces, own student handwriting, and contains ‫ت ة‬ A4 ‫لا ت ا رة ا ة‬ ‫لل ال‬
whatever he/she wants is permitted
‫رر‬ ‫ا‬ ‫ا ا ل لل ال‬ ‫ال‬ ‫ال‬

Please, keep your answer for each question in consecutive papers. Use tables as possible as you
can. Improve your handwriting and be neat and precise

Question (1): [8 points]

Define diffusion, its types and factors affecting it

Question (2): [8 points]

Using neat sketch of iron-carbon phase diagram, discuss the differences between normalizing and
annealing

Are they considered softening or hardening processes?

List three of softening and hardening processes

What is the SAE designation of Nickel steel with 0.31% Mn and 0.4 % carbon using SAE designation
What is the meaning of 3340 steel?
1xxx Carbon steels
2xxx Nickel steels
3xxx Nickel-chromium steels
4xxx Molybdenum steels
5xxx Chromium steels
6xxx Chromium-vanadium steels
7xxx Tungsten steels
8xxx Nickel-chromium-vanadium steels
9xxx Silicon-manganese steels

Question (3): [8 points]

Redraw the following diagram and answer the following:

What is this diagram called? What are the phases found in (1) up to (7)? What is the process of (8)
called? What happens if the transformation occurs in non-equilibrium cooling status? And what
will be its name in this case?

If this diagram was for a 1080 steel? What will be the expected diagram for 1040 steel
 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
Program of Materials Engineering – Senior I
Covid 19-Spring, 2020/2021 Course Code: MDP 472 Time Allowed: 2 Hrs.
Non-Conventional Material Fabrication and Heat-Treatment Processes
The Exam Consists of Five Questions in Three Pages. 2/2
e ( C)
Tem e a

Time (s)
Question (4): [8 points]

To which class of heat treatment cycles belong the following: Isothermal annealing/
Austempering/ Martempering/ Ausforming

Draw the heat treatment treatment cycle. Define the expected output structure for 0.8% carbon
steel after these treatment cycles. Which alloys are applicable for Ausforming?

Question (5): [8 points]

What is the difference between hardness and hardenability

What factors affect hardening by quenching?

END of Exam, Good Luck

Examination Committee Exam. Date : 30 June, 2021

Prof. Dr. Ahmed Elsabbagh, Dr. Ramadan Elgamsy
AIN SHAMS UNIVERSITY
FACULTY OF ENGINEERING
Program of Manufacturing Engineering

Spring, 2020/2021 Course Code: MDP 252 Time allowed: 2 Hrs.

Casting and welding 2
The Exam Consists of Four Questions in two pages Maximum Marks: 40 Marks 1/2
Important Rules: ‫ت‬ ‫ت‬
Having a )mobile -Smart Watch- earphones) inside the examination ‫ ا ة ا ذ ) دا‬- ‫ ا ا ات ا ذ ة‬- ‫ازة (ا‬
hall is forbidden and is considered as a cheating behavior. . ‫ت ت ب ا اب‬ ‫ت اة‬ ‫ةا ت ا‬
It is forbidden to have any references, notes, books, or any other
‫أ تب أ ز أ أ را دا ا ة‬ ‫بد‬
materials even if it is not related to the exam content with you in the
examination hall. . ‫ا ا ةت ت ا ة‬

Question (1): [10 marks]

Choose the correct answer

No. Sentence
Electrode with code E7013 is used in
(1)
a) Arc welding b) Gas Welding c) TIG welding
E7013, E refers to
(2)
a) Extrusion b) Electrode c) Electric
(3) Electrode with code E7013 is used in welding in
a) all directions b) flat horizontal only c) vertical only.
(4) DCEN is elding using polarit
a) straight b) revered c) AC
(5) Welding insulating materials b using carbon arc elding b using electrodes
a) single b) Twin c) three
(6) Welding the cracks in Crucible of casting furnace is b using flame
a) Oxidizing b) neutral c) carburizing
(7) Is used as shielded gas in elding o erhead elding
a) Ar b) CO2 c) He
(8) In gas elding the thermal energ is energy
a) chemical b) mechanical c) electrical
(9) O ide cleaning is more in
a) DCEN b) DCEP c) Gas welding
(10) Has deeper penetration for the arc
a) DCEN b) DCEP c) AC arc
(11) In TIG The electrode is Electrode
a) non consumed b) consumed c) no electrode
(12) CAC is used in
a) steel cutting b) steel welding c) steel casting
(13) In TIG e use polarit
a) straight b) reversed c) none
(14) No flux is used in elding
a) CAC b) CAW c) GTAW
(15) Gas Metal Arc elding is elding
a) TIG b) SMAW c) MIG
(16) CO2 Gas is used in As shielded gas
a) GMAW b) GTAW c) SMAW
 AIN SHAMS UNIVERSITY, FACULTY OF ENGINEERING
Program of Manufacturing Engineering
Spring, 2020/2021 Course Code: MDP 252 Time Allowed: 2 Hrs.
Casting and welding 2
The Exam Consists of Four Questions in two pages 2/2

(17) Zig- Zag pattern is used in welding thickness

a) small b) big c) medium
(18) AC is never used in
a) GMAW b) SMAW c) GTAW
(19) In GMAW e use
a) DCEP b) DCEN c) AC
(20) The highest flame in gas elding is flame
a) oxidizing b) neutral c) carburizing
Question (2): [10 marks]

a-Explain in detail the modes of GMAW Transferee [ 4 marks]

b-Compare between TIG and MIG [ 3 marks]
C-Show by neat sketches the TIG torch. [ 3 marks]

Question (3): [10 marks]

a- What are the advantages and disadvantages of CAW?

b- What are the advantages and disadvantages of GTAW?
c- Explain in detail the gas welding process showing the chemical reactions.
d- Explain by using sketches the types of oxyacetylene flame.
e- What is flux its function and its types.

Question (4): [10 marks]

Put in your answer sheet the following table

No Product Welding process

1 Restaurant chimney
2 Gas bottle
3 Copper bars
4 Aluminum sections
5 Titanium products
6 Oil pipeline
7 Pressure vessel
8 Structure steel
9 Stainless steel rings
10 Steel doors

END of Exam, Good Luck

Examination Committee Exam. Date : 22nd of June, 2021

Dr. Ramadan elgamsy
 Final exam ILOS MDP 252 Casting and welding

Question a1 a2 a3 a4 b1 b2 b3 b4 c1 c2 c3 c4 d1 d2 d3 d4
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4 * * *