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BEng (Hons) Mechanical Engineering (3+0) BEng (Hons) Electrical Engineering (3+0) In Collaboration with University of Sunderland Level 2

MAY 2010 EXAMINATION

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MANUFACTURING PROCESS EAT227

TIME ALLOWED: 2 HOURS INSTRUCTIONS TO CANDIDATE


1. 2. 3. 4. 5. 6. This Paper has three sections, A, B, and C. Answer FOUR questions in total, including AT LEAST ONE from each section. This is a closed book examination this means you are not permitted to use any text books or study aids in the examinations All symbols have their usual meanings unless otherwise defined in the text. You are forbidden to use programmable calculators or dictionaries. You must answer the required number of questions only. Any additional answers will not be marked. You should put a cross through any work you do not wish to be marked. Answering in good English contributes to the higher marks.

7.

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SECTION A (METALS)
1. (a) Explain the advantages (three examples) and disadvantages (two examples) of casting processes [5 marks] (b) Explain the process of horizontal centrifugal casting. Complete your answer with sufficient sketch. [8 marks] (c) List three type of chip which can be produced in metal cutting marks] [3
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(d) A mild steel bar is cut with uncoated WC-Co inserts with 60 m/min of cutting speed, results in 40 minutes of tool life. Furthermore, an increase in cutting speed up to 80 m/min, results in a tool life of 35 minutes. Find the constant n for mild steel bar. [9 marks] [TOTAL = 25 MARKS] 2. (a) A steel cylinder (yield strength is 37 kg/mm 2) is forged as shown in Fig 2.a below. If the h0 = 50 mm, d0 = 10 mm, d1 = 15 mm, calculate (coefficient of friction is negligible): i. Final height h1. [5 marks] ii. The load required, P. [5 marks]
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Fig. 2a (b) Sketch and describe the processes of direct extrusion and indirect extrusion [10 marks] (c) With the aid of a sketch, describe the process of oxy-acetylene welding . [5 marks] [TOTAL = 25 MARKS]

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SECTION B (Ceramic and Glass)


3. (a) Give 5 (five) limitations of powder metallurgy processes . [5 marks]

(b) Give 3 (three) examples of powder making processes by mechanical comminuting technique. Complete your answer with a sketch. [9 marks] (c) What is the different between blending and mixing processes? [6 marks]

(d) Describe the procedure to classify and separate the size of powder [5 marks] [TOTAL = 25 MARKS] 4. (a) Sketch and explain the spinning process in glass technology. (b) Sketch and explain the blowing process in glass technology. [5 marks] [8 marks]

(c) Sketch and explain the different between Fourcault and Coulburn processes in making sheet glass. [12 marks] [TOTAL = 25 MARKS]

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SECTION C (Polymers and Composites)


5. (a) What is the main benefit of elastomers compared to other types of polymer? [5 marks] (b) Explain the process of injection molding in polymer manufacturing. Complete your answer with a sketch. [10 marks] (c) Explain the process of extrusion blow molding in polymer manufacturing. Complete your answer with a sketch. [10 marks]

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[TOTAL = 25 MARKS]

6. (a) Explain the process of transfer molding in polymer technology. [6 marks]


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(b) What is the advantage of composite materials compared to non-composite material? [5 marks] (c) Explain and sketch the open mold process of open mold in composite technology. [8 marks] (d) Explain three type of reinforcing materials for composite technology. [6 marks]
Formatted: Outline numbered + Level: 2 + Numbering Style: a, b, c, + Start at: 1 + Alignment: Left + Aligned at: 0.25" + Tab after: 0.5" + Indent at: 0.5" Deleted: <#> Formatted: Outline numbered + Level: 2 + Numbering Style: a, b, c, + Start at: 1 + Alignment: Left + Aligned at: 0.25" + Tab after: 0.5" + Indent at: 0.5"

[TOTAL = 25 MARKS]

End of QUESTIONS

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