UNIVERSITY OF MALTA

FACULTY OF ENGINEERING
B.ENG.(HONS.) IN MECHANICAL ENGINEERING
YEAR II SEMESTER II
MAY/JUNE 2014 SESSION OF EXAMINATIONS
MFE2201 Advanced Manufacturing Processes

11th June 2014

09.15-11.15 hours
This paper contains FOUR questions. You are to attempt THREE questions.

Stationary: Calculators allowed

Graph Paper

1.a) What is the difference between direct and indirect Rapid Tooling (RT)? Mention two main
applications for indirect RT.
(6 marks)
b) Describe, with the help of diagrams, the working principle of the following additive
manufacturing (AM) technologies:
(i)
(ii)
(iii)

Selective Laser Sintering (SLS)

Three-Dimensional Printing (3DP)
Electron Beam Melting (EBM)
(12 marks)

c) Imagine a scenario in which an injection moulding tooling company is planning to use AM to

increase the heat transfer efficiency of their moulds, by fabricating cooling channels which are
more conformal to the geometry of a particular part. By taking a case study part, discuss how
you would use AM technology to help the company in this respect. Clearly specify the AM
technology you would use.
(9 marks)
d) Mention two important requirements during the generation of an STL file. Use diagrams as
deemed required.
(6 marks)

Cont/2
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2.a) Explain in detail with the aid of diagrams where necessary, the working principle of the
following manufacturing processes:

Abrasive Water-Jet Machining (AWJM);

Plasma Arc Machining (PAM) ;

(9 marks)
(9 marks)

b) A company in the building industry needs to cut large quantities of different profile shapes in 20
mm thick marble slabs. For this application, justify one non-traditional machining process from
the list in (2a) above that might be used. Assume that either the part geometry or the work
material (or both) rules out the use of conventional machining processes. Justify your answer by
indicating three attractive characteristics of the selected process.
(5 marks)
c) Using diagrams, briefly explain how the following PAM process variants work:
Dual gas plasma, and
(5 marks)
Water-injected plasma.
(5 marks)

3. Non-transparent microfluidic devices containing micro channels and chambers need to be

manufactured with an annual production of 5,000 devices.
a) Select the most suitable manufacturing technique to produce the micro components as described
above using at least three selection criteria.
(6 marks)
b) With regard to polymer materials,
i.

Explain at least three advantages of using polymer materials for manufacturing such
microfluidic devices.
(3 marks)

ii.

From which group of thermoplastic materials would you choose for the micro fluidic
devices as described above? Give reasons for your answer.
(3 marks)

iii.

Why is recyclability of polymer materials very important for microfluidic devices? In

addition, explain the recyclability of the material you selected.
(3 marks)

Cont/3
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c) If the devices are manufactured from polypropylene (PP) with a glass transition temperature
(Tg) of 0C and a melting temperature (Tm) of 165C.
i.

Explain briefly the macromolecules structure below Tg, between Tg and Tm as well
as above Tm.
(9 marks)

ii.

Select and describe the optimum processing temperature window for the
manufacturing technique you selected in (a).
(3 marks)

iii.

Explain the respective manufacturing steps and most important parameters.

(6 marks)

4. A company utilises, a Cincinnati Arrow 500 Vertical Machining Centre (VMC) which is equipped
with an A2100 Siemens controller to machine steel parts.
a) The VMC part program for this product is listed below. Generate plan and section detailed
diagram(s) as deemed necessary, complete with the relevant X, Y and Z dimensions of the
final component that results after the abovementioned VMC utilising this part program,
machines the workpiece in Figure 1. The cutting tools being utilised are a 10 mm endmill
(Tool 1), and a 6 mm endmill (Tool 2). Assume that fixtures for clamping the workpiece to
the machine table do not interfere with the tool path, and that the work piece has been aligned.
Assume also that after workpiece set-up, the datum is located as shown in Figure 1. The as
finished shape of the part fits within a maximum overall rectangular workpiece shape
envelope as shown in Figure 1.
(18 marks)
b) With reference to this part program, explain each of the following
i.
ii.
iii.

M3 in line N10;
M6 in line N70;
L0 and S800 in line 50.
(4 marks)

c) After machining on the Cincinnati Arrow 500 VMC, the part is hardened. Subsequently a
blind cavity with internal splines as shown in Figure 2 needs to be machined in the hardened
workpiece, with the centre of the cavity at co-ordinates X210 Y100. The splines have an
overall depth of 8 mm and thus do not go through the part thickness. What non-traditional
manufacturing process would you recommend to the company in order to machine this cavity
feature?
(2 marks)
d) Explain with the aid of a diagram the principle of operation of the process recommended in
2(c) above.
(9 marks)
Cont/4
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CNC Part Program

:G90 T1 M6
N10 G0 G97 G94 G71 G90 X50 Y50 Z100 S1000 F75 M3 M8
N20 G0 G90 Z50
N30 G23 X90 Y70 U120 V80 Z-8 R0 Q0 K-1 L0 E50 W15 I1 J1 S500 F10
N40 G0 G90 Z50 S1000 F75
N50 G26.1 G90 X90 Y70 U40 Z-4 R-8 Q0 L0 K-1 E50 I0.5 J0.5 W20 S800 F20
N60 G0 G90 Z80
N70 T2 M6
N80 G0 G90 X-10 Y-10
N90 G0 G90 Z0
N100 [@count]=0
N110 [loop]
N120 [@count]=[@count]+1
N130 G1 G91 Z-2 F50
N140 G1 G41 G90 X0 Y0 F75
N150 G1 X0 Y80
N160 G1 X40 Y170
N170 G1 X80 Y170, C2
N180 G1 X80 Y140
N190 G1 X160 Y140
N200 G1 X160 Y170, C2
N210 G1 X260 Y170
N220 G1 X260 Y50
N230 G2 G17 G90 X210 Y0 I210 J50
N240 G1 X0 Y0
N250 G1 G40 G90 X-10 Y-10
N260 (If[@count]<6 goto [loop])
N270 G0 Z200
N280 M30
N290 M2

Cont/5

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Fig 1 Workpiece and Location of Datum.

Fig 2 Cavity with Internal Splines

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