Universiti

Malaysia
PAHANG
V

Enginee'iflg . Technclogy Cra1Iv1y

FACULTY OF MANUFACTURING ENGINEERING &

TECHNOLOGY MANAGEMENT
FINAL EXAMINATION
COURSE

MANUFACTURING PROCESSES 1

COURSE CODE

BFF/BFM 2403

LECTURER

NAFRIZUAN MAT YAHYA

DATE

9 NOVEMBER 2010

DURATION

3 HOURS

SESSION/SEMESTER :

SESSION 2010/2011 SEMESTER I

PROGRAMME CODE :

BFFIBFM

INSTRUCTIONS TO CANDIDATE:
(a) This examination paper is divided into TWO sections.
(b) SECTION A: Answer ALL questions.
(c) SECTION B: Answer TWO (2) questions only.
(d) All answers to a new question should start on new page.
(e) All the calculations and assumptions must be clearly stated.
(f) Candidates are allowed to bring one piece of A4 size paper with hand written
note on both sides.
DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO
This examination paper consists of NINE (9) printed pages including front page

BFFIBFMI1O1 1IIBFF/BFM2403

CONFIDENTIAL

SECTION A
ANSWER ALL THREE (3) QUESTIONS
QUESTION 1 (20 marks)
(a) Figure A below shows the connecting rod for an internal combustion engine. This
product can be produced using closed-die forging process.

Figure A: Connecting Rod

i.

Elaborate the steps to make the product starting from bar stock.
(10 marks)

ii.

State the difference between fullering and edging during preforming

operations of this product.
(2 marks)

(b) Extrusion and drawing have numerous applications in the manufacture of

continuous as well as discrete products from a wide variety of metals and alloys.
i.

Define the main difference between the metal extrusion and metal
drawing process.
(2 marks)

ii.

Point out the differences between direct and indirect extrusion

providing a neat sketch.
(6 marks)

CONFIDENTIAL

BFFIBFMJ101 1IIBFF/BFM2403

QUESTION 2 (20 marks)

(a) During metal cutting process, several types of metal chips is produced. Classify
four (4) types of chips during chip formation and sketch any two of them.
(4 marks)
(b) An orthogonal cutting operation is being carried out under the following
conditions: t0 = 0.15 mm, t = 0.3 mm, width of cut = 5 mm, V = 2.5 m/s, rake
angle (a) =80, F = 268 N, F = 500 N and F1 = 200 N.
i.

Calculate the total power dissipated.

(2 marks)

ii.

Determine the power of shearing.

(10 marks)

iii.

Calculate the percentage of total energy dissipated in the shear plane.

(2 marks)

(c) Grinding operation is a chip-removal processes that used an individual abrasive

grain as the cutting tool. Define how is centerless grinding different from
cylindrical grinding?
(2 marks)

CONFIDENTIAL

BFFIBFM!1O11IIBFFIBFM2403

QUESTION 3 (20 marks)

(a) In casting process, the fluid flow of the molten metal is important. The molten
metal is poured through a pouring basin or cup and then flows through the gating
system to fill up the mold cavity.
i.

Sketch and label gating system of casting including pouring cup

(2 marks)

ii.

List and explain the functions of elements consist in the gating system
(8 marks)

(b) Welding process is one of the joining operation that can be classified into two
major categories; fusion welding and solid-state welding. Compare between these
two categories of welding process.
(6 marks)

(c) A wide variety of metalworking fluids including oils, emulsions, synthetic

solutions and solid lubrications are available for specific application in
manufacturing operations. From your point of view, what are the functions of these
metalworking fluids in manufacturing processes?
(4 marks)

BFFJBFMJ101 1IIBFF/BFM2403

CONFIDENTIAL

SECTION B
ANSWER TWO (2) QUESTIONS ONLY
QUESTION 4 (20 marks)
(a) An ANSI 1020 carbon-steel strip will undergoes flat-rolling process in order to
reduce the thickness of the material. The specification of material are: 200mm
wide, 10mm thick and rolled to a thickness of 7mm. The roll radius is 200mm and
rotates at 200rpm. (Assume for ANSI 1020 carbon-steel; K530 MPa and n0.26).
Calculate:
i.

Roll-strip contact length (L)

(2 marks)

ii.

The true strain ( c)

(2 marks)

iii.

Average flow stress (

(2 marks)

iv.

The roll force (F)

(2 marks)

V.

The torque ( T)
(2 marks)

(b) Shearing is one of the common Sheet-metal forming processes. Shearing can be
classify into two types which are punching and blanking.
i.

Comment the differences between these two operations.

(2 marks)

ii.

Ilustrate with appropriate sketching to justify the difference.

(2 marks)

CONFIDENTIAL

BFFIBFM/101 1III3FFIBFM24O3

(c) Extrusion and injection molding are widely used in manufacturing area to produce
variety of plastic products.
i.

Which one of these two processes require the use of mold?

(1 marks)

ii.

Show the main operations in injection molding process to produce

name-tag enclosure as Figure B below.
(5 marks)
Retractabie Clip

Name tag enclosure

/

Nanitag
Figure B: Name-tag Enclosure

CONFIDENTIAL

BFFIBFM/101 1IIBFF/BFM2403

QUESTION 5(20 marks)

(a) Friction stir welding is one of the common methods under solid-state welding
process. Explain the process briefly with the help of neat sketch.
(8 marks)
(b) Brazing, soldering, adhesive-bonding and mechanical fastening process were the
joining processes that can be used to join dissimilar metals of intricate shapes and
various thickness. Figure C below shows an example of combination joint for sheet
metal.
Adhesive
______ - \
_____
Rwet

Figure C: An example of combination joint

Substitute the combination joint other than those stated in the figure.
(4 marks)
(c) Figure D below illustrated a muffler before and after coated using electroplating
process.

llu

Figure D: Muffler before and after electroplating

Recommend appropriate process of electroplating for the muffler.
(8 marks)

CONFIDENTIAL

BFF/BFMI101 lI/BFF/BFM2403

QUESTION 6 (20 marks)

(a) During machining operation, wear and failure often occur in the cutting tools. Why
optimum cutting speed is an important consideration to determine cutting tool life?
(2 marks)
(b) A 15mm diameter bar of low-alloy steel, pre-heated to FMC 28, is finish turned to
14.5mm over a 200 mm length, using the carbide tool insert. Under the roughing
cutting process, calculate; (Given; Spindle rotates, N = 400rpm & Feed rate, v =
200mmlmin)
i. Average cutting speed, V
(3 marks)
ii. Material removal rate (MRR)
(5 marks)
iii.

The total cutting time, t

(2 marks)

(c) Milling is a machining process in which a rotating cutter removes material while
traveling along various axes with respect to the workpiece. Draw a simple sketch
of up milling and down milling and elaborate the differences between them.
(8 marks)

CONFIDENTIAL

BFFIBFMJ101 1IIBFF/BFM2403

QUESTION 7 (20 marks)

(a) In metal casting processes, there are two categories of mold used.
i.

Differentiate between expendable mold and permanent mold.

(2 marks)

ii.

Sand casting is one of the process that classify under the expendable
mold. Describe the steps in a typical sand-casting operation.
(6 marks)

iii.

Choose and explain the best casting process that can be used to produce
hard disk casing as shown on Figure E below. What is the major
advantages of suggested manufacturing process?
(8 marks)
Hard disk casing

Ha rd disk
Figure E: Hard Disk Casing

(b) For successful casting operation, the product with large flat surface is not favorable
design.
i.
ii.

Why?
Propose a technique to reduce the observation stated in (b) i?
(4 marks)

END OF EXAMINATION PAPER