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ME3263

NATIONAL UNIVERSITY OF SINGAPORE

ME3263 DESIGN FOR MANUFACTURE AND ASSEMBLY


(Semester I : AY2009/2010)
Time Allowed : 2 Hours

INSTRUCTIONS TO CANDIDATES:

1.

This examination paper contains FOUR (4) questions and comprises EIGHT (8)
printed pages.

2.

Answer ALL FOUR (4) questions.

3.

All questions carry equal marks.

4.

This is an OPEN-BOOK EXAMINATION.

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)

Table 1: Approximate weights of components in Wheel Support Assembly


Part ID
1
2
3
4
5
6
7
8
9
Note:
1.
2.
3.
4.

Description
Base
Left support
Right support
Wheel
Shoulder screw
Washer
Bushing
Bolt
Nut

Number
1
1
1
1
1
2
2
4
1

Weight per component


0.600kg
0.400kg
0.400kg
1.000kg
0.100kg
0.010kg
0.025kg
0.075kg
0.025kg

Assume the basic assembly time of a part to be 3 seconds.


Assume that the technician rate is $30 per hour.
Assume tool acquisition time to be 2.9 seconds.
Use tables provided and attach tables with answer scripts.

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.

Figure 1: Wheel Support Assembly Instructions

PAGE 4

Figure 2: Base

ME3263

Figure 3: Support (left and right)

(a)
(b)
Figure 4: (a) Front view of Wheel, (b) Sectional side view of Wheel

Figure 5: Shoulder Screw, Bolt, Nut, Bushing and Washer

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

Figure 6: Bottle cap

PAGE 6

ME3263

Table 2: Runner Volumes (Du Pont)


Part volume
(cm3)
16
32
64
128
256
512
1024
2048

Shot size
(cm3)
22
41
76
146
282
548
1075
2109

Runner
%
37
27
19
14
10
7
5
3

Table 3: Injection Moulding Machines


Clamping
Force
(kN)
300
500
800
1100
1600
5000
8500

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

Table 4: Processing Data for Selected Polymers


Thermoplastic

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)

Describe 3 different polymer-based Additive Manufacturing technologies. For each


give one advantage, one disadvantage, and one application that suits that technology
better than the others.
(8 marks)

(d)

Multiple choice questions.


(i) Which of the following has the largest influence on the cooling time of a mould?
(a) Recommended mould temperature,
(b) Maximum thickness of the part,
(c) Speed and timing of ejection,
(d) Size of the mould.
(ii)

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)

Additive Manufacturing (AM) technology has been a commercially available process


since the late 1980s, early 1990s. It is only recently however that the AM industrial
community set up an ASTM working group to develop standards for testing parts
made using this technology. With reference to data available from industry reports,
provide a possible explanation as to why the use of standards could be important to
the future development of this technology.
(5 marks)

(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)

A well-known example of Mass Customisation is the in-the-ear hearing aid. Describe


how AM is included in this example and how it enhances the traditionally
manufactured product. Discuss also the software interface for developing the
customised elements and the logistical support.
(10 marks)

- END OF PAPER -

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