Alexandria University ‘Thermal Engineering Science Faculty of Engineering Date: June, 2010 Production Engineering Department Final Term Exam, Time: 3 hours Answer All Questions ee ———— at 20°C, The convection heat transfer coetticient between the base surface and the surrounding air is 33 Wim? °C. if the base has an emissivity of 0.6 and a surface area of 0.02 m*, determine the temperature of the base of the iron. (10, Marks) 2 The compression ratio of an air-standard Otto gyele is 9.5. Prior 10 th eee arena at 100) Pes: Caran t400 fern gine earacecin Pare id of the isentropic derapesne Broeess 1s 800 K. Using specific heat valucs at room temperature, detormiine (a) the highest creature and Pressure in the eycle: (b) the amount of heat tansienred in 4 Ks (¢) the thermal efficiency: and (d) the mean effective pressure. (eV I there iva vehicle working on this cycle, consists Of four eylinders running at 3000 RPM (design cruise speed) calcula in thevcetical driving power for this vehicte. (12 Marks) isentropic compression 2 Consider a steam power plant operating on the simple ideal Rankine ‘c, Steam enters the turbine ania and 450°C and is eondensed in the condenser ata pressure of 10 kw Determine the thermal efficiency of this cycle, (8 Marks) + A reftigerator uses reffigerant-134a as the working fluid and operates on an ideal vapor-compression relfigeration cycle between 0.14 and 0.8 MPa, If the mass ow rate of the refrigerant ts 0.05 ke’s, determine (ay the rate of heat removal frum the reftigersted Space and the power input to the Co essen: (b) the rate of heat rejection to the environment, and (¢) the COP of the reftigerator (10 Marks) ~ Air enters a window air conditioner at 27°C. 19°C wet bulb temperatare and at a rate of 20 mein, nd it leaves as 16°C dry bulb temperature and 90 percent relative humidity, Part of the moisture in the air that condenses during the process is also removed at 16°C. Determine a= the rates of heat and Hark e pemewal trom the air. b)- ifthe electricity power cost is 0.2 L-LKW br. and the g conditioner ‘works 5 hours per day weekly. Calculate the monthly elecric bill for house anne this conditioner, assume the other appliances consunies around 20% of the ait-conditioner energy consumption, (10 Marks) 6- A piston-cylinder device contains 0.05 m' of a gas initially at 200 KPa, AC this scate, a finear spring that has a spring constent of 150 kN/m is touching the piston but exerting no force on it. Now heat is transferred to the gas, causing the piston to rise and to compress the spring until the volume inside the xlinder doubles. If the cross-sectional area of the piston is 0.25 m2 determine {a} the final pressure inside the cylinder, (b) the total work done by the gas, and (c) the fraction of thie wack done against the spring to compress it. (10 Marks) Best wishes Dr. Mohamed Khamis6 ee University of Alexandria Faculty of Engineering Dept. of Production Engineering June 2010 Third from Second Year Time: 3 Hours THEORY OF MACHINES 1- A four-bar mechanism with lengths r= 70 mm, r2= 20 mm, r5= 60 mm, te = 40 mm; 1 is fixed, r2 makes an angle 60°. Combine the mechanism with 2 pantograph to copy the motion of a point on the middle of the coupler with ratio 2: 1. Minimum number of links should be considered. 2 For the mechanism shown in figure, the position of point D is given Determine the position of point C. DB= 30, BC= 30 5- For the same mechanism, if the velocity of point D is 10 ms to the right and its acceleration is 100 m/s* to the left. Find the velocity and acceleration of point C. Consider pure solling between points R and F 4- A.cam with translating roller follower has the following data ~ The rise angle is 120° with cycloid motion. ~ The upper dwell angle is 30° ~ The return angle is 90° with simple harmonic motion. - The rise is 40 mm. ~ The base circle radius is 30 mm. The roller radius is 20 mm ~ The amount of offset of the follower is 15 mm. Find the coordinates of the cam contour at angles 30°, 120°, and 210°. Text book is allowedAlexandria University Faculty of Engi Production Engineering Department May 2010 Engineering Metrology (PE 342) Third year Time allowed: Three hours Number of pages of this examination are two only No external material is permitted Total Exam Marks = 100 (10 Extra} Question (1) A. Show by neat sketches how to measure the following screw thread parameters’ i, Simple effective diameter using three-wires method. ji, Individual and accumulative pitch errors using optical method B.A mating serew and nut have the following same basic dimensions: # Simple Effective diameter (D3 © Pitch ¢p) © Included angle (0+ Ifthe error in the screws inctuded angle is (> AO}: Find the necessary coreeetion in the serews’s simple ctive diameter 10 compensate for the serew included ar serew and nut ror and insure the assembis of thy 20 Marks? Question ( A. Using neat sketches illustrate each of the following i, Main geometrical tolerances assoe ted with the design ot dial gavy at ertor The feature control frame and draving callout for a coneentricity tolerance referred few pve feature datum, ix. Example of a datum target area and corresponding datums target symbol vy. Measurement and evaluation of profile error using profile template. B. Differentiate between straightness tolerance of a feature of size when applied on ate Size (RFS) basis and when applied on Maximum Material Condition (MMC) basis, how the dravsing callout and (b) Measurement and / or gauging method C. Design a functional Go-Gage to check the conformity of the part shown in shown in fig ii, The relationship between vecentrivity error. roundness error, and sectional ru less of Feature Bor each ease, (a) ure are in micrometers. G0 Marks) Dims. in MMS Page 1 of 2 Examiners: Pup MN. Damir, Prof. Mf. a. Younes, Dr 4 Mf, Nhalil and connieQuestion (3) A i, ii B. i ii c i ii », i ii Page 2 of 2 WY Prove that for u spur gear the tooth height at constant chord can be calculated using the following equation: Moo WF cosy of 14". the In a gear train a driver gear has a module of 5 mm and a pressure following data were obtained when measuring the tool) height af constant chord cr No. oftecth | Calculate the error in tooth thickne gear (C) is meshing with gear (B). Illustrate using neat sketches the principle of gear tooth profile in Show the tooth profile inspection graphs for a correct tooth profile aud for wet with bvo different types of ervors. What are the main dim journal bearing? MMustrate how (o evaluate the run-out error in a roller bearing. sional und geometrical features that affect the funicticn of a p's Ilustrate the principle of two different methods for roughness profile measurement Show the concept of bearing area curve and illustrate its functional in:portaace, tHustate with sketches ONLY how the bearing area curve will change when grinding is lapped. surface produced wit! (50 Marks» Examiners: Prof. MN. Damir, Prof. M.A. Younes, DAlexandria University Jysiay) Lely, Faculty of Engineering anh Sus Production Engineering Department ant Lia ad June 2010 2010 win PRODUCTION PLANNING & CONTROL EMAL yy habeas Code : PEI34 PES34:) soll Time allowed: 3 Hours Sela te Attempt the following questions 1. Acrop pesticide conto! manufacturer has experienced the following monthly demand for an environmentally improved pesticide poison | Month ~ | Apa | May Sine | say Alu Demand (Boxes) | 7601 920 “ 30 | 990 | 1720 @. Use a three month simple moving average to make possibie forecasts ». Use simple exponential smoothing with a smoothing coefficient 0.6 to make corresponding forecasts c, Use MAD and Bias to compare and comment on forecasting results of the above two cases 2. A manufacturer of small electric domestic fans has estimated its production requirements forthe ‘coming 6-month pianning horizon as follows: “Month stuly” August "| September | October 7 November ” December | | Productive days [22a at eo eet Demand (Units) x10" "26 16 | 48 joa 9 Currently there are 100 empioyaes with normal produ dally per employee. Baily capacity can be increased by up to 30 percent by working overtime at an additional cost of LE12 per Unit. Regular time salaries average LE30 daily per employee. Costs of storing units in inventory are LE2 per unit each month. Inventory shortages cost LE10 per unit short. Cost of hiring and training a new employee is LE300, and a layoff of an employee costs LE200. Currently, the company has 5,000 units in inventory. Compare the cost of a chase plan when hiring and firing are allowed, with the cost of a corresponding plan when backorders are not allowed. 3. A bakery that supplies a large number f retail outlets uses an ingredient at the rate of 2.000 kilograms a day, 260 days a year, Delivery is virtually constant and requires five days. A three-day Usage of safety stock is set by management and cannot be changed. Ordering costs are LESO per order, and the cost of carrying inventory charge is LEO.001 per kilogram per day Determine a. the economic order quantity, b. the reorder point . the maximum inventory level4. the total annual carrying costs €. cost per inventory cycle 4, A manufacturer is attempting to set the production lot size to use for a particular ite that is manufactured only periodically. The incremental cost of writing manufacturing orders is approximately $10. The aggregate cost of setting up machines for the production run is $40, The inventory holding cost is $1 per unit per year ‘The annual requirements for the item are 12,000, and the production rate is 5000 units per week. a, What is the most economical manufacturing lot size? b. How many production runs are needed per year to salisfy requirements? , What is the corresponding cost per cycle 5. Consider the following MRP situation for Part # PBZ-701, given lead time is 2 weeks and avatleble (stock on hand) is 20 units {Week number Gross requirements, units ‘Scheduled Receipts, units | 10 = b. Ifan economic order quantity of 70 units is being established for PBZ-701. What impact oes this have on the product flow table? 6. Compare FCFS, SPT, EDD dispatching rules for scheduling the jobs shown beiow. 7 4 api tape war as | 92 |e Fob Processing Time (hours) Bue Date : Choose the optimum from the point of view of each of the following perform 1e measures a, average flow time; ». average lateness; ¢. average earliness 4. number of tardy jobs ‘Assume any missing dataAlexandria University Faculty of Engineering Production Engineering Department June, 2010 ‘Nontraditional Machining Processes-PE336_ PE336 Gaou Jaca cle 3 Year sy Samy ia Time allowed: 3 Hours [ _ Dis orbs SSeS ge ] nswer all questions using neat sketches whenever po: 0-120 marks) 1. What are the limitations of the traditional machining methods? 2. Show four functions for the electrolytes used in ECM 3. Mention typical applications for WIM 4. Show the surface roughness ~ current density relation for annealed, and hardened parts 5. Show how printed circuit boards are made? Q-2 20 marks Show using simple sketches @ suitable method for each of the following operations (select 5 different operations): Finishing of balls © Machining complicated shape (3-D) die in hard alloy # Protection of a steel ship body «Finishing of crankshafts, © AFMof spur gears 93 0 marks) 1. Compare using sketches between the honing and MAF of internal bores. 2. Show the main components of the abrasive jet machining (AJM) system 3. Differentiate using sketches between electrolytic plating and anodizing processes 4, Show using sketches how external spur gears are cut by broaching. 5. During abrasive jet machining, the mixing ratio was 0.3. Calculate the mass ratio if the ratio of the density of carrier and density of abrasives is 5 %. 6. Calculate the machining particulars for milling the helical gear. Z=60teeth, B,=45 deg, mg=5mm ‘The lead screw pitch of the milling machine table = 6 mm and the indexing head is equipped by the change gears of 24, 24, 28. 32, 40, 44, 48, 56, 64, 72, 86, and 100 teeth. B-Cuter Se foe Spur Cees Gate Newb > 3 4 8 6 7 8 sa & YF ei nett oot 3S 8 £ BP 8 HE 1-cater el fo Accurate Spur Gans CatrNewter yo? 7 . 8 gs 2 8 BB eee ee CouerNemmber PB 6 Og 8 0 tech © of 8 won oe neoterotens 3 no ho e Good Luck, Exam Committee: H, El-Hofs, H. Youssef. M. Younes, and 6. SolimanAlexandria University Faculty of Engineering Haga Production Engineering Dept. & csv aa June, 2010 2010 ss Machine tool Design PE..... Final Exam PE ...... CU GY! aauas 3” Year ay Time allowed: 3 Hours ele 3 Ga Best of wishes and good luck Wines Glaba F digpu S Gl Gal Attempt to Answer the Following Questions: (105 marks} (25 marks) 4 machine tool spindie, 840mr-long, 60 mm-diameter. supported on two bearings so that the span length between bearings is = 620 mm and the overhang length =220 mm. The modulus of elasticity of the spindle material = 210 GPa.. The nose deflection = 16 jim for 1000 rpm and 4 ym for 1600 rpm. If the bearings are assumed to be infinitely rigid and the system damping is neglected. determine a. The natural frequency of the spindle-bearing system b. The static nose deflection due cutting force c. The value of the cutting force Q-2 (20 marks! For the above spindle, a workpiece is fixed at the nose, and there is a gear at mid of Spindle span, its diameter = 400 mm. The gear is designed to exert a tangential horizontal force of 1 KN and 500 N radial vertical forces. The spindle speed in this case = 1000 rpm and a design life of 25 000 hours is desired. Use an application factor of 12. Use the same size bearings at both locations and a combined reliability of at least 0.92. You are required to calculate the dynamic load rating for each bearing. A cutting force is acting tangentially to the workpiece in the horizontal direction (opposite to gear force 1KN) Q- 3 (25 marks! An 8-speed gear box which has a minimum rotational speed 180 rpm and maximum of 900 rpm is driven by a pole-changing motor, has two speeds of 355 rpm and 900 rpm. (Given that the optimum smallest gear to be used has 18 teeth), a. Draw the optimum speed charts. 5. Sketch the kinematic diagram of the optimum tayout showing the transmission ratio for each two meshing gears. ¢. Find the number of teeth of each transmission group and of the whole gearbox d. Assume a gear module=4mm and calculate the center distance between shafts. Q- 4 (20 marks) A lathe is subjected to a 1.5 KN cutting force, and a 500 N tool frictional force, at the Cutting point on the 240 mm diameter. Design a cast iron Vee and Flat combination guideways. the distance between them = 600 mm, and the recommended working Pressure = 1.2 N/mm’, if the steel saddle length = 120 mm. Height of the spindle center above the flat guideway equals 200 mm, Saddle wt. = 350 N. Also, check that the selected height of the spindle center above the flat guideway is safe Q- 5 (7.5 marks) Explain the effect of each of the following parameters on the machine tool structures:- Apertures ~ Joining elements ~ Flange design Q- 6 (7.5 marks) Explain shortly the design steps for machine tool foundations and how you can check out these design results? Exam Commitice: a. EI Khatik, Mi. Helale. E Saat