EM/JAN 2012/MEM560

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UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE

MANUFACTURING PROCESSES

COURSE CODE

MEM560

EXAMINATION

JANUARY 2012

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 2012/MEM560

QUESTION 1
a)

Describe briefly the following manufacturing terms related to MEM560:

i)

Design for Manufacture

ii)

Multi-national Corporation (MNC)

Hi)
iv)

Import substitution
Value analysis

v)

Mass production

vi)

Just-in-time (JIT)

vii)

Tooling costs

viii)

G8
(4 marks)

b)

Ahmad works as an engineer in a Metrology Department of a manufacturing company

and he found out after measurement that many products did not posses sufficient
quality regarding the actual dimension which has deviation from the nominal value.
State three (3) possible causes of having deviation of measurement results and give
one (1) example for each of the causes.
(3 marks)

c)

Measurement and inspection are related to quality and any manufacturing organisation
must emphasize on quality. Discuss on the above statement.
(3 marks)

QUESTION 2
a)

Hot working process involves plastic deformation above the recrystallization

temperature of the material. Define the recrystallization temperature for a metal.
(2 marks)

b)

Explain the general characteristics of metal forming processes listed below:

i)

Rolling

ii)

Forging

iii)

Extrusion

iv)

Drawing
(4 marks)

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c)

EM/JAN 2012/MEM560

Compare the differences between open die and closed die forging.
(2 marks)

d)

Springback occurs in sheetmetal bending due to elastic recovery of the material when
load is removed in the process. Explain two (2) methods to overcome this springback
problem.
(2 marks)

QUESTION 3
a)

Why the selecting of sand for molds is important at the initial stage of casting?
(2 marks)

b)

In sand casting, generally, further operations are required after the cast part has
solidified and removed from the mould. Discuss at least three of those required
operations.
(3 marks)

c)

Give a step-by-step procedure for Investment casting and list two common products
that can be made using Investment casting.
(5 marks)

QUESTION 4
a)

Compare the differences between adhesive bonding from other joining methods and
give two (2) limitations of adhesive bonding.
(3 marks)

b)

Give four (4) common mechanical fastening methods and discuss why mechanical
fastening may be preferred over other joining methods.
(3 marks)

c)

Differentiate between brazing and welding processes. List three (3) advantages and
applications of brazing as compared to welding.
(4 marks)

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EM/JAN 2012/MEM560

QUESTION 5
a)

One of the most popular machine tool in any machine shop is a grinding machine.
Discuss at least three (3) reasons why it is so.
(3 marks)

b)

You are asked to purchase a new lathe machine to do a machining job for an important
client. Discuss at least three (3) important items that you must state for the lathe
specification.
(3 marks)

c)

In metal cutting, the classical model of a tool life equation is given by a simplified
mathematical model, VTn = C.
i)

Explain the meaning of the alphabets; V, T, n and C.

ii)

Why the simplified model as given above is not accurate and give suggestions
to improve that equation?
(4 marks)

QUESTION 6
a)

Explain what you understand about Non-Traditional Machining processes.

(2 marks)

b)

Many machining industries in Malaysia are now buying non-traditional machine tools
instead of the conventional machine tools. Discuss briefly four (4) reasons for the
purchase (or use) of these machines in preference to the ordinary conventional
machine tools.
(2 marks)

c)

Non -Traditional Machining (NTM) processes can be used to machine various types of
materials; metals or non-metals. Choose one (1) NTM process that can be used to
machine a hard non-cylindrical non-metallic material and briefly describe the basic
principles of the process. Give also examples of its applications.
(6 marks)

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EM/JAN 2012/MEM560

QUESTION 7
a)

Plastics can be grouped into thermoplastics and thermosetting. Describe and

differentiate between thermoplastics and thermosetting plastics.
(3 marks)

b)

Briefly describe the powder metallurgy technology and explain briefly three (3) methods
of production of metallic powder.
(4 marks)

c)

What are the production steps involved in making powder-metallurgy parts and
describe what happened during the sintering process.
(3 marks)

END OF QUESTION PAPER

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