UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

SECOND SEMESTER/YEARLY EXAMINATIONS

MAY/JUNE 2013
PROGRAMME

BEng (Hons) Manufacturing Engineering

BEng (Hons) Mechanical Engineering

MODULE NAME

Manufacturing Processes & Metrology

Tuesday

DATE

MODULE CODE

MECH 3002Y(3)

07 May 2013

TIME

9:30 12:30 Hrs

NO. OF
QUESTIONS SET

DURATION
NO. OF QUESTIONS
TO BE ATTEMPTED

3 hours
5

INSTRUCTIONS TO CANDIDATES
Answer ALL questions.
The Tables for ISO Limits and Fits are attached.
An extract of the table for standard reduction potentials (25 C) is attached.

MANUFACTURING PROCESSES & METROLOGY MECH 3002Y(3)

Question 1 [Total 10 marks]

A 45 mm nominal diameter shaft and roller bearing assembly is to be used at a speed of
800 rpm for a relatively low inertia loading operation, with moderate positional accuracy
of the bearing with respect to the shaft. The assembly is subjected to a fluid lubrication
regime leading to a hydrodynamic film, and the bearing housing is fitted with a nozzle
for regular replenishment of the lubricant oil. Using the ISO tables for fits, limits and
tolerances, find the most appropriate value for the minimum and maximum shaft and
bearing dimensions, and justify the answer. Calculate the allowance and clearance of the
assembly system.
[10 marks]
Question 2 [Total 20 marks]
(a)

(b)

Clearly explain with appropriate justifications (and with appropriate graphs

and/or schematic diagrams) the most appropriate 2D surface roughness
parameter which can be used in each of the following situations:
(i)

To differentiate between an electro discharge machined surface and a

honed surface.

(ii)

To investigate the impact of the process parameters of electrochemically

machined surfaces on the friction properties and wear rate under the
following different process conditions: current: 1 A, 3 A, 5 A; and electrode
gap: 0.25 mm, 0.5 mm and 0.75 mm.

(iii)

To investigate the efficiency and performance of two (2) processes, namely,

disk polishing and electropolishing.
[5 + 5 + 4 = 14 marks]

A student is investigating the impact of two (2) turning process parameters,

namely, tool material (High Speed Steel, Tungsten Carbide and Alumina), and
feed rate (0.1 mm/rev, 0.5 mm/rev and 1.0 mm/rev) on the extent of out-ofroundness of a cylindrical carbon steel (0.5 % C) steel rod of 25 mm nominal
diameter. The student has performed a design of experiments in order to test the
above-mentioned conditions for the two factors. He has then measured the out-ofroundness by using a Talyrond 31C apparatus with a capacitive- resistive type
filter.
Clearly explain why the student has used a capacitive- resistive type filter, and
discuss what range of filter the student should use.
[6 marks]

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MANUFACTURING PROCESSES & METROLOGY MECH 3002Y(3)

Question 3 [Total 20 marks]

A copper wire of 3 mm nominal diameter is being extruded. Assuming that the yield
stress of copper is 70 MN/m2, using first principle, derive the equation for the extrusion
direct stress, and calculate the maximum permissible (in percentage) reduction that can
be achieved in the wire. Show all detailed steps for the derivation (and support with
appropriate diagrams), and state any assumption used.
[20 marks]
Question 4 [Total 25 marks]
(a)

Explain the use and importance of the following items/features in a sand casting
process:
(i)
(ii)
(iii)

Chills.
Chaplets.
Core.
[9 marks]

(b)

Investigate, using an appropriate methodology the dominant/main wear

mechanism(s) which are likely to occur in each of the following situations:
(i)

A gearbox with two carbon steel (0.7 % C) gears flooded in a lubricating oil
of kinematic viscosity (at 40 C) of 56 mm2/s. The maximum runout of the
shaft of the driving gear is 80 m.

(ii)

A 0.8 % carbon steel impeller of a dye house effluent pump. The 2D

roughness parameters of the impeller surface are as follows: Rq =0.1 m
and R5z =1 m.

(iii)

A roller bearing of 100 mm nominal internal diameter pressed fit onto a

shaft, and the assembly rotating at 3000 rpm. The 2D surface roughness
parameters of the shaft are as follows: Rz= 45 m, and Rku= 3.5. The bearing
ratio at different normalized heights is shown in the table 4 below.
Table 4: Bearing ratio at different normalized heights
Normalised 100
height (%)
Bearing
0.5
ratio (%)

95

90

85

80

75

70

65

60

55

50

0.8

1.0

1.9

2.2

2.6

3.5

5.0 5.5 6.1 8.0

In each case, propose a proper remedial solution to mitigate the problem.

Full marks will be awarded for properly justified answer.
[16 marks]
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MANUFACTURING PROCESSES & METROLOGY MECH 3002Y(3)

Question 5 [Total 25 marks]

(a)

Using appropriate well labeled graphs, discuss the corrosion behavior of iron and
aluminium in a 0.5 M sodium carbonate salt solution. State any assumption(s).
[10 marks]

(b)

Calculate the cell potential for a zinc electrode in contact with a 0.1 M ZnCl2
solution at 70 C. Assume that the activity coefficient for ZnCl2 is 0.5.
The candidate is expected to properly explain the method used and to show all
calculations. State any assumptions.
[6 marks]

(c)

An engineer has to evaluate the integrity of a sleeve, which is made of two metals,
namely a bronze outer layer of 75 mm thickness and a tin inner layer of 45 mm
thickness in order to detect the presence of surface, subsurface and internal
defects, and eventually assess the size and exact position of any defects. The
internal diameter of the sleeve is 300 mm. The engineer is trying to identify the
minimum set of less hazardous tests that would be used to detect any of the above
defects in order to minimize the total testing costs.
Given the above, clearly explain the most appropriate inspection technique(s) that
can be used to detect any surface, subsurface and internal defects in the sleeve.
Justify the answer. Also explain any specific issue which needs to be addressed
when testing the sleeve.
[9 marks]

END OF QUESTION PAPER

/sg

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