Faculty of Mechanical Engineering

Universiti Teknologi MARA

Shah Alam
Course Code : MEM5!
Course "ame : MA"UFACTUR#"$ %R&CESSES
Test ' Time : (ui) * ' +5 mins

,ou need to A"S-ER A.. /uestions0
Ans1ering 2onus /uestions 1ill 2e giving you e3tra marks 4if any50
A. Casting
60 Com7are and contrast the 2asic 7rocess 7rinci7les in sand casting, investment casting,
and pressure die casting. $ive sam7le * each0 8&ct9!+: 6! marks
*0 ;iscuss the 7ossi2ility and differences of 7roduct cost and /uality as7ects of sand
casting, investment casting, and pressure die casting0 8&ct9!+: 6! marks
<0 ;escri2e defects in sand casting due to im7ro7er selection and 7re7aration of moulding
materials0 -hat are the 7ossi2le remedies= 8&ct9!+: 6! marks
+0 ;escri2e the function of riser in casting0 Using Caine>s method? calculate the cylindrical
riser 4height and diameter e/ual5 necessary to feed a grey cast iron sla2 casting
!3!3<cm 1ith a side riser? casting 7oured hori)ontally into the mould0 8"ov 9!5:
@ Marks
Freezing Ration X of a mould is defined as a ratio of cooling characteristics of
casting to the riser.
A B SAcasting ' Ccasting
SAriser ' Criser
Caines empirical relationship for the freezing ratio:
A B a D c
,D2
Where ! riser volume"casting volume
a, # and c are constants $hose values for different materials are as follo$s%
a 2 c
Steel !06! !0!< 60!!
Aluminium !06! !0! 60!!
Cast iron? 2rass !0!+ !0!6@ 60!!
$rey cast iron !0<< !0!< 60!!
Aluminium 2ron)e !0*+ !0!6@ 60!!
Silicon 2ron)e !0*+ !0!6@ 60!!
50 #llustrate t1o of the $as ;efects in sand casting0 -hat are the causes for the defects and
ho1 can 1e rectify it= 8"ov 9!5: Marks
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(U#E *
"ame :
#; :
$rou7 : EM;5M66 ' E;M5M5A
;ate :
0 Select a 7roduct of your choice using sand casting 7rocess0 Friefly e37lain the 7rocedure
to 2e follo1ed for making a sand mould for this 7roduct0 8"ov 9!5: @ Marks
@0 ;etailed out maGor disadvantages of sand casting 7rocess and ho1 are they overcome=
8"ov 9!5: @ Marks
H0 Friefly discuss 1hy draft and shrinkage allo1ance is im7ortant for 7atterns= -hat is a
dou2le shrinkage allo1ance= 8"ov 9!5: Marks
I0 ;escri2e the follo1ing 7rocessesJ 8A7r 9!I: Marks
i5 %ressure die casting
ii5 .ost 1a3 casting
iii5 Continuous casting
iv5 #nvestment casting 8A7r 96!:
6!0 E37lain the follo1ingJ 8&ct 9!I: < Marks
i5 S7rue
ii5 Runner
iii5 %arting line
iv5 Core
v5 Riser
vi5 $ating system
660 E37lain < 7ossi2le casting defects due to im7ro7er gating system design in sand casting0
8&ct 9!I: < Marks
6*0 -hat are the general 7roduct ty7es 7roduced from the follo1ing casting 7rocesses are
used=
i5 %recision investment casting
ii5 Shell moulding
iii5 True centrifugal casting
iv5 %ressure die casting 8&ct 9!I: + Marks
6<0 $ive at least + im7ortant 7ro7erties re/uired for moulding materials in sand casting0
8A7r 96!: * Marks
6+0 -hat is $rain Fineness "um2er 4$F"5 and ho1 does it affect the 7ro7erties of the sand
mould= 8A7r 96!: * Marks
650 -hat are the advantages of die casting over sand casting in terms of its mechanical
7ro7erties or design ca7a2ilities= 8A7r 96!: < marks
60 ;iscuss at least < common defects generally encountered in casting 7rocesses0 8A7r 96!:
< Marks
6@0 .ist * casting 7rocesses that are em7loyed and e37lain 1hy these 7rocesses are suita2le
for that 7articular mould or die materialJ
i5 SandJ
ii5 Metal 8A7r 96!: < Marks
6H0 $ear 2eam can 2e made using shell moulding0 E37lain teh 7rocess se/uence and state
each * advantages and limitations of the 7rocess0 8A7r 96!: @ Marks
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6I0 State and e37lain * methods to reduce core shifting in sand casting0 8A7r 96!: < Marks
*!0 Ko1 1ould the end 7roducts of castings made 2y 7ermanent mould differ from sand
casting= 8A7r 96!: + Marks
*60 -hat sort of casting most suita2le forJ 8A7r 9!I: * Marks
i5 Steam tur2ine
ii5 Einc door handle
**0 -hat are the im7ortant considerations involved in choosing a casting method= 8A7r
9!I: * Marks
B. Joining
60 E37lain the 7ossi2le 1elding 7rocess suita2le for a 65mm thick 7late CS 4A#S# 6!555
Goined in flat 7osition0 ;etailed out the Goint and edge 7re7aration? 1elding method?
1elding consuma2les 4if any5 and 7recautions involved0 8&ct9!+: 6! marks
*0 E37lain and descri2e the differences 2et1een mechanical fastener'riveting? adhesive
Goining? soldering? 2ra)ing and 1elding0 8&ct>!+? "ov >!5? A7r >!I? &ct >!I L A7r
96!: <D + marks
<0 ;istinguish 1ith sketches the 1elding setDu7 2et1een M#$ 4$MA-5 and T#$
4$TA-5 1elding 7rocess0 E37lain the differences of 2oth 7rocesses0 8"ov >!5 L
A7r 96!: + Marks

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+0 Suggest suita2le 1elding 7rocess for making a stainless steel gasoline tanks and
e37lain the 1elding 7rocess used in detail0 8"ov 9!5: < Marks
50 -ith the hel7 of schematic sketches? com7are and contrast SMA- and $TA- in
terms of Source of Keat? Electrode and Shielding? Manual'Automatic o7eration?
Current'Keat in7ut and its a77lication0 8"ov 9!5: @ Marks
0 Metal Goining can 2e either 7ermanent or tem7orary Goints0 Com7are costs and the
relative advantages and disadvantages of those t1o methods0 $ive e3am7les to sho1
that factors affect the choice of the method for a 7articular Go20 8A7r 9!I: < Marks
@0 ;escri2e and e37lain the three 1elding classes of com7osition in the 1eld )one
4autogenous? homogeneous and heterogenous5 and name one 7rocess for each grou70
8A7r 9!I: + Marks
H0 9T1o 7lates 1ere 1elded together and then strength of the Goints 1as tested0 #t 1as
found that the 1eld 1as stronger than the 7lates>0 Comment on the statement 41ith
reasons etc50 8&ct 9!I: * Marks
I0 E37lain 2riefly the follo1ing t1o common ty7es of fusion 1eldingJ
i5 SMA-
ii5 SA-
6!0 E37lain the 7rinci7les underlying the resistance 1elding0 $ive * 7roducts that usesJ
i5 S7ot 1elding
ii5 Seam 1elding
C. TM
60 Car2ide tooling
The 2est and economical 7rocess in ma+ing car#ide tooling tools0 E37lain 1hy0
8&ct9!+: H marks
;escri2e the stages involved0 8&ct9!+: * marks
*0 ;efine? descri2e? e37lain the follo1ing terminologiesJ 8&ct>!+: + marks
i5 Slide1ay
ii5 Koning 7rocess
iii5 Ko2
iv5 Conventional machining
v5
Surface finish
Factors in selecting surface finish and surface cleaning. [Oct04] 4 marks
Describe the stages involved in Barrel Finishing and name !roducts suitable for the
!rocess. [Oct04] " marks
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<0 Machine tools M list four o7erations that can 2e 7erformed 2y a lathe machine0
8"ov9!5: * Marks
+0 ;escri2e the terminologies related to C"C metal cutting 7rocessJ
i5 A2solute 7ositioning
ii5 %oint to 7oint 4%T%5
iii5 Machining centre
iv5 Automatic tool changer
50 Continuous chi7 1ith FUE affects the dimensional accuracy? surface finish of the 1ork
7iece and the cutting tool life0 Ko1 can these 7ro2lems 2e im7roved= 8"ov 9!5: <
Marks
0 ;escri2e the e/uation introduced 2y F0- Taylor in metal cutting of tool life e,uation?
CT
n
B C0
i5 -hat are the t1o shortcomings of the e/uation=
ii5 A lathe machine using a medium car2on steel 1ork 7iece? cutting velocity of
+!m'min and a cement cutting tool insert 1as re7laced every hour0 Calculate the
tool life of the tool 1hen used under identical condition 2ut at s7eed of 5!m'min0
Assume the tool inde3 is B !0*H0 8"ov >!5 L &ct 9!I: 5 Marks
iii5 E37lain the meaning of the al7ha2ets in the e/uation C? T?
n
and C0 8&ct >!I L
A7r 96!:
iv5 $ive one im7roved e/uation for 7rediction the tool life0 8A7r 96!:
@0 Nigs and fi3turesJ 8"ov 9!5: + Marks
i5 Com7are and contrast 2et1een a Gig and a fi3ture0
ii5 E37lain the advantages of using Gigs and fi3tures0
H0 Suggest and e37lain a suita2le and economical 7rocess onJ 8"ov 9!5: Marks
i5 Coating Cutting Tools 1ith Titanium "itride 4Ti "5
ii5 Removing 2urr of small com7onents 1ith large /uantity like valve sto7 for
refrigerator com7ressor0
I0 ;escri2e the factors involved in selecting cutting tools0 8"ov 9!5: * Marks
6!0 -hy do some machining com7anies use cutting tools 1ith inserts0 8"ov 9!5: < Marks
660 -ork holding devices M list at least four and 2riefly descri2e them0 8"ov 9!5: <
Marks
6*0 ;efine machine tool0 ;escri2e the 7rocess that can 2e carried out using four identified
machine tools in your Machine Sho70 8&ct >! A7r 9!I: 5 marks
6<0 -hy grinding machine is made availa2le in almost all Machine Sho7= 8&ct>!: +
marks
6+0 A 7o7ular choice and higher utilisation than milling machine? give reasons 1hy grinding
machine is so0 8"ov 9!5: < Marks
650 FUE is common 7ro2lem in metal cutting as it affect dimensional accuracy and surface
finish of a 7roduct as 1ell as FUE reduces the life of a cutting tool0 ;iscuss some
solutions for this 7ro2lem0 8&ct>!: * marks
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60 ;iscuss three factors to consider in selecting a 7articular C"C machine to 2e used in
machining a 7articular 7art0 8&ct>!: < marks
6@0 ;escri2e the follo1ing terminologies involved in C"C machiningJ 8&ct>!: + marks
i5 #ncremental 7ositioning
ii5 %oint to 7oint 4%T%5
iii5 Machining centre
iv5 CAM
6H0 A factor in 7roduct reGection is due to vi2ration in C"C Machining 7rocess0 ;iscuss the
factors 4at least <5 to 2e considered in solving the 7ro2lem0 8&ct>!: < marks
6I0 Machine toolsJ 8A7r 9!I: + marks
i5 .ist < chi7s 7roducing machine tools that can 2e used for machining flat
surfaces0
ii5 .ist < chi7s 7roducing machine tools that can 2e used for machining
cylindrical round 7arts0
iii5 -hy grinding machine is one of the most im7ortant machine in any machine
sho70
*!0 Crater 1ear M e37lain crater 1ear and fundamental factors that influence its formation0
E37lain the ste7s to minimise it0 8A7r 9!I: + Marks
*60 "ame at least < holding devices used 1ith a lathe machine in machining various of
cylindrical 7arts and descri2e 2riefly one of them0 8&ct 9!I: * Marks
**0 ;iscuss at least + reasons 1hy in many metal cutting o7erations? machining using a
9thro1Da1ay inserts> is common0 8&ct 9!I: * Marks
*<0 ;escri2e 2rieflyJ 8A7r 96!: * Marks
i5 Rough machining
ii5 Steady rest
iii5 Magnetic chuck
iv5 Machining centre
*+0 .ist at least + o7erations that can 2e 7erformed on a lathe machine0 8A7r 96!: * Marks
*50 ;escri2e 1hy 7arts 7roduced on a lathe machine encounter many reGect due to 2ad
surface finish0 Friefly e37lain the reasons and action to minimise the 7ro2lem0
8A7r 96!: < Marks
*0 ;escri2e the function of cutting fluid0 8A7r 9!I: * Marks
*@0 ;efine MRR0 8A7r 9!I: < Marks
*H0 ;escri2e the criteria of selection of machine tool0 8A7r 9!I: * Marks
D. NTM
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60 USM M descri2e the 2asic 7rinci7les and give e3am7les of its use0 Use sketches to
su2stantiate your arguments0 8"ov 9!5: Marks
*0 ;iscuss maGor differences 2et1een TM and "TM0 $ive also their relative merits0
8&ct>! L A7r 96!: + marks

<0 Fased on the follo1ingJ 8&ct>! L A7r 96!: marks
i5 "ame the "TM
ii5 "ame the 7roducts that uses this 7rocess
iii5 ;escri2e the 7rocess
+0 ;escri2e the factors involved in the develo7ment of "TM0 8"ov 9!5: + Marks
50 ;iscuss + reasons for the 7urchase'use of "TM in 7reference to TM tools0
8A7r >!I L &ct 9!I: * Marks
0 ;escri2e the 2asic 7rinci7les of EFM and USM and give e3am7les of their use0 Sketches
may 2e used0 8A7r 9!I: H Marks
@0 Com7are and discuss < maGor differences of E;M? ECM and USM0 8&ct 9!I: Marks
H0 E37lain the follo1ingJ 8&ct 9!I: * Marks
i5 Slurry
ii5 ;ielectric
iii5 .aser
iv5 Electrode
I0 ;escri2e the follo1ing "TM0 8A7r 9!I: 5 marks
;escri2e the 7roducts made availa2le from the 7rocess0
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