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B. IND. ENG. (Hons.)

MFE1202 Fundamentals of Manufacturing & Machining

15th June 2009

0915 1115 hours

This paper contains FOUR questions. You are to attempt THREE.

Stationery: Use of calculators allowed.

Graph Paper

1 a. How are product variety and production quantity related when comparing typical
factories? Illustrate your answer graphically.
(6 marks)
b. (i) What is the difference between processing and assembly operations in a
production environment?
(ii) Briefly describe three different types of shaping operations in this context.
(12 marks)
c. When planning a machining operation, in what order would you select the cutting
conditions (cutting speed, depth of cut, and feed), and why?
(5 marks)
d. Illustrate using a sketch graph the cost factors involved in metal cutting, and show
that cutting speed has an optimum value for minimum production cost.
(7 marks)
e. If one wanted to minimise production time rather than production cost, would the
optimum cutting speed be higher or lower? Why?
(3 marks)

2 a. Explain the difference between roughing and finishing operations in machining.

(5 marks)
b. What is an orthogonal cutting operation?
(5 marks)
c. Why is the orthogonal cutting model useful in the analysis of metal machining?
(5 marks)
d. The cutting force and thrust force in an orthogonal cutting operation are 1470 N
and 1589 N, respectively. The rake angle is 5, the depth of cut is 5.0 mm, the feed is
0.6 mm/rev, and the chip thickness ratio is 0.38. Determine using a graphical method:
(i) the shear strength of the work material and
(ii) the coefficient of friction in the operation.
(18 marks)

3 a. What are the differences between rotational parts and prismatic parts in
(6 marks)
b. Distinguish between generating and forming when machining workpart geometries.
(6 marks)
c. What is the difference between peripheral milling and face milling?
(6 marks)
d. How do shaping and planing differ?
(5 marks)
e. A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an
engine lathe. Cutting conditions are as follows: cutting speed is 2.30 m/s, feed is 0.32
mm/rev, and depth of cut is 1.80 mm. Determine
(i) cutting time, and
(ii) metal removal rate.
(10 marks)

4 a. Identify three desirable properties of a cutting tool material.

(3 marks)
b. Tool life tests in turning yield the following data: (1) when cutting speed is 100
m/min, tool life is 10 min; (2) when cutting speed is 75 m/min, tool life is 30 min.
(i) Determine the n and C values in the Taylor tool life equation.
Based on your equation, compute
(ii) the tool life for a speed of 110 m/min, and
(iii) the speed corresponding to a tool life of 15 min.
(14 marks)
c. Describe how you would carry out a ring test on a grinding wheel, to check for
(5 marks)
d. What is centerless grinding? Illustrate your answer using a sketch.
(6 marks)
e. A centerless grinding operation uses a regulating wheel that is 150 mm in diameter
and rotates at 500 rev/min. At what inclination angle should the regulating wheel be
set, if it is desired to feed a workpiece of length 3.5 m and diameter 18 mm through
the operation in exactly 45 sec?
(5 marks)