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EM/JAN 2013/MEM560

UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE

MANUFACTURING PROCESSES

COURSE CODE

MEM560

EXAMINATION

JANUARY 2013

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)
ii)

the Question Paper

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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EM/JAN 2013/MEM560

QUESTION 1
a)

b)

Answer the following questions briefly:

i)

What is metrology and why it is important in mechanical engineering practices?

ii)

How is measurement distinguished from inspection?

iii)

Explain briefly the two (2) major universal systems of units in recording the
measurement.
(6 marks)

Lalila is a project engineer in a car manufacturing company and the company had
decided to introduce a new model and the new model must be produced at a
competitive price for global distribution. Discuss four (4) possible ways that she should
take in order to achieve that objective.
(4 marks)

QUESTION 2
a)

Hot working for metal involves plastic deformation above the recrystallization
temperature of the work material. Define the recrystallization temperature for the metal.
(2 marks)

b)

Propose the most suitable metal forming process to manufacture the following
engineering products:
i)

Crane hook

ii)

Spanner

iii)

Aluminium curtain railing for domestic application

iv)

Electric power cable

v)

Copper tube for air conditioning duct

vi)

Steel T-section for building

(2 marks)

c)

Crankshaft is an important automotive component. There are at least two (2)

manufacturing processes that can be used to manufacture a crankshaft. Suggest the
two (2) processes and which of these processes preferred and why?
(2 marks)

d)

One of the common metal forming processes is extrusion process. Define extrusion
process and briefly describe the types or methods of extrusion.
(4 marks)

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EM/JAN 2013/MEM560

QUESTION 3
a)

Varieties of materials can be used for casting components and there are number of
different casting techniques involved. Explain the advantages and limitation of these
casting techniques.
(3 marks)

b)

Generally there are two (2) types of casting; expendable and permanent mould
casting. Describe the differences between expendable and permanent mould casting.
(3 marks)

c)

Briefly explain Die casting process and name two (2) common products that can be
produced by this process.
(4 marks)

QUESTION 4
Many methods can be used for joining materials and every joining method has particular
design requirements.
a)

Soldering is a joining process and various metals can be soldered together. Explain
briefly about soldering process.
(2 marks)

b)

Brazing joins two pieces of metal when a melted metallic filler called brass flows across
the joint and cools to form a solid bond. Briefly explain the principle of brazing process.
(2 marks)

c)

Explain the principle underlying resistance welding process. Give examples of products
produced by the following resistance welding processes:
i)

Spot welding

ii)

Seam welding

iii)

Upset butt welding

(6 marks)

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QUESTION 5
a)

There are many traditional machine tools available in FKM machine shop. Answer
briefly the following questions with regards to machine tools:
i)

Name at least six (6) machine tools available in FKM machine shop.
(2 marks)

b)

ii)

Describe briefly one (1) of the machines that you had named in part (i) above.
(2 marks)

iii)

When the machine tool is used for metal cutting, chips are produced as waste
materials. Name three (3) basic categories of chips in metal cutting. Discuss
briefly one (1) of them.
(2 marks)

Two experiments for turning process using HSS cutting tool were carried out based on
different cutting speeds and the tool lifes were recorded as follows:
Experiment

Cutting speed; V
(m/min)

Tool life; T
(min)

478

10

321

25

Determine:
i)

the constant in the Taylor's equation,

ii)

the tool life T, at V = 319 m/min, and

iii)

the cutting speed for tool life of 20 min.

(4 marks)

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EM/JAN 2013/MEM560

QUESTION 6
a)

As a manufacturing engineer, you are required to make a mould for a new design of
mobile-phone-casing using a non-traditional machining (NTM) process. What is the
most suitable NTM process that you will recommend? Explain why you select that NTM
process.
(4 marks)

b)

In NTM process, Electron Beam Machining (EBM) and Electrical Discharge Machining
(EDM) fall under the category of thermal process.
i)

Sketch the schematic illustration for both machining methods to show the
differences in the operational principles.
(4 marks)

ii)

Determine two (2) design guidelines for each type of the processes.
(2 marks)

QUESTION 7
a)

Name four (4) plastic processing methods available currently in industries. Describe
two (2) of the methods that you have named and list at least two (2) advantages and
disadvantages of the methods described.
(6 marks)

b)

Powder metallurgy (P/M) application enables the manufacturing of small, intricate parts
of high precision resulting in high density, net-shape and the elimination of scrap
during the process. Describe some of the characteristics of the metal powders to be
considered in P/M.
(4 marks)

END OF QUESTION PAPER

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