CONFIDENTIAL EM/OCT 2009/MEM560

UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE MANUFACTURING PROCESSES

COURSE CODE MEM560
EXAMINATION OCTOBER 2009
TIME 3 HOURS

INSTRUCTIONS TO CANDIDATES

1. This question paper consists of seven (7) questions.

2. Answer six (6) questions in the Answer Booklet. Start each answer on a new page.

3. Do not bring any material into the examination room unless permission is given by the
invigilator.

Please check to make sure that this examination pack consists of:

i) the Question Paper

ii) an Answer Booklet - provided by the Faculty

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of 5 printed pages
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CONFIDENTIAL 2 EM/OCT 2009/MEM560

QUESTION 1

a) All the terminologies listed below are related to manufacturing. Give a brief definition or
explanation about the terminologies listed below:

i) World Trade Organisation (WTO)

ii) Design for Manufacture (DFM)
iii) Free Trade Zone (FTZ)
iv) Gross Domestic Product (GDP)
v) Multi-national Corporation (MNC)
vi) Import substitution
(3 marks)

b) In this age of globalisation and a very competitive world, manufacturing organisation needs
to carry out 'value analysis'. Define 'value analysis' and give some of its benefits.
(2 marks)

c) Metrology and instrumentation is a very important domain in manufacturing. All the

terminologies listed below are related to metrology and instrumentation. Explain briefly the
meaning of these terminologies:

i) Calibration
ii) Imperial system
iii) Metric system
iv) Flatness
v) Roundness
vi) Precision
(3 marks)

d) What is surface roughness and briefly explain the method used for measuring surface
roughness?
(2 marks)

QUESTION 2

a) For metal forming operations, some metals are hot worked and some are cold worked. What
are the disadvantages of hot working over cold working of metals?
(2 marks)

b) List three metal forming hot working processes and also three cold working processes
commonly available in the manufacturing sector.
(2 marks)

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c) Give a suitable forming process for each of the following components:

i) Domestic curtain rail

ii) Brass wire for EDM machine
iii) 'Parang'
iv) Rice cooker
v) Spanner
vi) l-section structural steel
(3 marks)

d) An ingot measuring 0.5m by 0.5m and 2 metres long is rolled into a plate of 1.5 metres wide
and 10mm thick. Calculate the finished length of the plate.
(3 marks)

QUESTION 3

a) Explain briefly the following sand casting terminologies:

i) Sprue
ii) Runner
iii) Parting line
iv) Core
v) Riser
vi) Gating system
(3 marks)

b) Explain at least three possible casting defects that may be caused by the improper gating
system design in sand casting? Give at least three defects.
(3 marks)

c) What are the general product types produced from the following casting processes are
used?

i) Precision investment casting

ii) Shell moulding
iii) True centrifugal casting
iv) Pressure die casting
(4 marks)

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QUESTION 4

a) There are many methods used for joining materials such as adhesives, soldering and
brazing, mechanical fasteners, and welding. Distinguish between brazing and soldering from
the point of view of the filler metals used, applications and the strength of the joint obtained.
(4 marks)

b) 'Two plates were welded together and then the strength of the joint was tested. It was found
that the weld was stronger than the plates'. Comment on the statement (give reasons, etc).
(2 marks)

c) Welding process is an important activity in joining or fabrication and there are two common
types of welding processes; fusion welding and solid-state welding. Explain briefly the
following two common types of fusion welding:

i) Shielded Metal Arc Welding (SMAW)

ii) Submerged Arc Welding (SAW)
(4 marks)

QUESTION 5

a) For working with a lathe machine, various work holding devices are necessary for machining
various types of cylindrical parts. Name at least three of those work holding devices and
describe briefly one of them.
(2 marks)

b) For many metal cutting operations, machining using cutting tools of the type 'throw-away
inserts' is common among machining companies today. Discuss at least four possible
reasons why it is so.
(2 marks)

c) F. W. Taylor was a pioneer on the study of tool life using high speed steel (HSS) cutting tool
in early 20th century. From his study, he came out with what is known as the Taylor's tool life
equation, i.e. VT n = C.

i) Explain the meaning of all the alphabets in the equation (V, T, n and C). What are
some of the shortcomings of that equation?

ii) When machining on a lathe using a medium carbon steel workpiece, cutting velocity
of 40 m/min was used and the cutting tool was replaced every 3 hours. Calculate the
tool life of this cutting tool when used under identical conditions but at a cutting
speed of 50 m/min. Assume n = 0.28.
(6 marks)

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CONFIDENTIAL 5 EM/OCT 2009/MEM560

QUESTION 6

Non-Traditional Machining (NTM) processes such as LBM, EBM, USM, EDM, ECM, etc. are new
machining processes that use various forms of energy to remove unwanted material from the
workpiece. They are now widely used in many industries for various applications.

a) Explain why NTM processes become very important for Malaysian industries, today and for
the future.
(2 marks)

b) All the terminologies listed below are related to NTM processes. Briefly explain the
terminologies given below:

i) Slurry
ii) Dielectric
iii) Laser
iv) Electrode
(2 marks)

c) EDM, ECM and USM processes are commonly used Non-traditional Machining (NTM)
processes. Compare and discuss three major differences between EDM, ECM and USM.
(6 marks)

QUESTION 7

a) What are the differences between thermosetting and thermoplastics? List two examples of
thermosetting plastics and thermoplastics.
(2 marks)

b) Explain at least two methods (only the principle) available for blow moulding of thermoplastics
giving their relative applications.
(4 marks)

c) Blending and sintering are two important processes involved in powder metallurgy. What are
blending and sintering processes and the purposes of these two processes?
(4 marks)

END OF QUESTION PAPER

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