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INSTRUCTIONS TO CANDIDATES:
1.
This examination paper contains FOUR (4) questions and comprises EIGHT (8)
printed pages.
2.
3.
4.
5.
Attach the 2 tables for Question 1 together with the answer booklet.
PAGE 2
ME3263
QUESTION 1
Figure 1a shows the components of a Wheel Support assembly assembled according to the
instructions and the exploded view in Figure 1b. The dimensions (in mm) of the components
are shown in Figures 2-5, and their approximate weights are given in the Table 1.
(a)
Determine the Assembly Efficiency in the manual assembly of this product. Clearly
indicate the handling, and insertion and fastening times. Assume the basic assembly
time of a part to be 3 seconds, and tool acquisition time to be 2.9 seconds. Use the
table provided. Determine the Total Assembly Cost per Wheel Support assembly that
the manufacturer will incurr. Assume that the technician rate is $30 per hour.
(14 marks)
(b)
Suggest a few design changes to the current product to enhance the manual assembly
of this product. Determine the modified Assembly Efficiency of the redesigned
product. Use the table provided.
(6 marks)
(c)
Without considering the production volume, comment on whether the current product
is more suited for manual assembly or automatic assembly. List down the possible
bottlenecks in the automatic assembly of the current product.
(5 marks)
Description
Base
Left support
Right support
Wheel
Shoulder screw
Washer
Bushing
Bolt
Nut
Number
1
1
1
1
1
2
2
4
1
PAGE 3
ME3263
(a)
(b)
Assembly Instructions
1.
Place and align the left support on the base.
2.
Insert the 2 bolts into the left support and the base.
3.
Fasten the 2 bolts on the left support using a bolt wrench.
4.
Place and align the bushing on the left support.
5.
Place and align the washer on the bushing on the left support.
6.
Insert the shoulder screw through the washer, bushing and the left support.
7.
Insert the wheel into the shoulder screw.
8.
Place and align the right support and ensure that the shoulder screw passes through the
hole on the right support.
9.
Insert the 2 bolts into the right support and the base.
10.
Fasten the 2 bolts on the right support using a bolt wrench.
11.
Place the bushing on the right support.
12.
Place the washer on the bushing on the right support.
13.
Fasten the nut on the shoulder screw using a bolt wrench.
PAGE 4
Figure 2: Base
ME3263
(a)
(b)
Figure 4: (a) Front view of Wheel, (b) Sectional side view of Wheel
PAGE 5
ME3263
QUESTION 2
A local plastic moulding company has recently secured a contract from an MNC to produce a
batch of bottle caps using ABS plastic material as shown in Figure 6. The bottle cap is to be
moulded using a 32-cavity mould supplied by the MNC.
(a)
Assuming that the maximum cavity pressure is equal to 50% of the processing data
for the selected polymer, select a suitable machine size for moulding the plastic bottle
cap.
(12 marks)
(b)
Assuming that the mould opening is equal to 50% of mould closing speed, a dwell of
3 seconds for the moulded parts to fall between the core and cavity plates and a corecavity clearance of 5 cm, calculate the mould resetting time for moulding the bottle
cap?
(7 marks)
(c)
What is the mould cycle time for moulding the bottle cap?
(6 marks)
(Tables including the details of the runner volumes, injection moulding machines,
processing data for selected polymers are given in Table 2, 3 and 4 respectively.)
(Dimensions are given in mm)
Isometric view
PAGE 6
ME3263
Shot size
(cm3)
22
41
76
146
282
548
1075
2109
Runner
%
37
27
19
14
10
7
5
3
Shot size
(cc)
34
85
201
286
286
2290
3636
Operating
Cost
($/hr)
28
30
33
36
41
74
108
Dry cycle
time
(sec)
1.7
1.9
3.3
3.9
3.6
6.1
8.6
Max. clamp
stroke
(cm)
20
23
32
37
42
70
85
Driving
Power
(kW)
5.5
7.5
18.5
22.0
22.0
63.0
90.0
Specific
Gravity
Thermal
(mm2/s)
0.11
0.09
Injection
Temp.
(0C)
232
218
Mould
Temp.
(0C)
27
27
Ejection
Temp.
(0C)
52
77
Injection
Pressure
(bars)
965
965
High-density polyethylene
High-impact polyethylene
Acrylonitrile-butadienestyrene (ABS)
Acetal (homopolymer)
P{olyamide (6/6 nylon)}
Polycarbonate
Polycarbonate (30% glass)
Modified Polyphenylene
oxide (PPO)
Modified PPO (30% glass)
Polypropylene (40% talc)
Polyester teraphthalate
(30% glass)
0.95
1.59
1.05
1.42
1.13
1.20
1.43
0.13
0.09
0.10
0.13
0.13
260
216
291
302
329
54
93
91
91
102
82
129
129
127
141
1000
1172
1103
1172
1310
1.06
1.27
1.22
0.12
0.14
0.08
232
232
218
82
91
38
102
121
88
1034
1034
965
1.56
0.17
293
104
143
1172
PAGE 7
ME3263
QUESTION 3
In the diagram below, the envelope of the component measures 400mm by 300mm and is
produced from 10mm thick steel. It is utilized in the off road truck industry.
(a)
List the geometric features and attributes of this component, and suggest the process
plan, i.e., the manufacturing processes, that has been used to produce and assemble
this component.
(5 marks)
(b)
Explain the factors that might have been considered in the selection of the
manufacturing processes in this process plan, and suggest an alternative process plan,
i.e., manufacturing processes, to produce this component.
(4 marks)
(c)
(d)
Indicate the plastic material that does not belong to the group.
(a) Acrylonitrile-Butadiene Styrene
(b) Polyvinyl Chloride
(c) Acetal
(d) Urea formaldehyde
PAGE 8
ME3263
(iii) If you are designing a three plate mould, indicate the type of gate you are most
likely to choose?
(a) Fan gate
(b) Submarine gate
(c) Side gate
(d) Pinpoint gate
(iv) Indicate the process that does not belong to the group.
(a) Blow moulding
(b) Compression moulding
(c) Injection moulding
(d) Insert moulding
(8 marks)
QUESTION 4
(a)
(b)
The following 3 approaches are methods of including metal in the AM process chain:
Metal/polymer mixes
Casting
Direct metal laser sintering
For each of these approaches, describe how Additive Manufacturing is involved. Give
one example application, one advantage and one disadvantage for each approach.
(10 marks)
(c)
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