Q4

(a) In tool wear, Taylors equation can be used to calculate the tool life. Given that
the value of n is 0.4 and c is 200, what will happen to the tool life expectancy if the
cutting speed was reduced by
(i)
(ii)

20 %
75%
(20 marks/markah)

(b) In orthogonal cutting the parameters were set based on the condition given that the
thickness of the chip is 0.25 mm; the depth of cut is 0.18 mm and width of cut is 0.57
mm at the cutting velocity of 2 m/s. It is observed that the rake angle was at 20 o with
frictional force is at 500 N and tangential force is at 200 N. Calculate the percentage
of total energy dissipated in overcoming friction at the tool-chip interface.
(30 marks/markah)

(c) A stainless steel rod, 175 mm length with diameter of 25 mm was turned using a lathe
machine in order to reduce its diameter to 10 mm. The spindle was rotated at N=400
rpm with the axial speed of the tool travelling at 200 mm/min. With the help from
Table Q3[c], calculate:
(i).
the cutting speed
(ii). material removal rate
(iii). cutting period
(iv).
cutting force
(v).
power dissipated
Table Q3[c] Approximation range of energy required for cutting processes at
drive motor, corrected at 80% efficiency; (multiply by 1.25 for dull tool)
Jadual S3 [c] Penghampiran julat tenaga yang diperlukan untuk proses-proses
pemotongan pada motor penggerak, disemak pada kecekapan 80%, (darab
dengan 1.25 untuk mata alat tumpul)
Materials/Bahan
Specific energy/Tenaga tentu
(W.s/mm3)
Aluminium alloys/ Aluminium aloi
0.4-1
Cast irons/ Besi tuang
1.1-5.4
Copper alloys/ Paduan Tembaga
1.4-3.2
High-temperature alloys/ Aloi-aloi suhu
3.2-8
tinggi
Magnesium alloys/Aloi-aloi magnesium
0.3-0.6
Nickel alloys/ Aloi-aloi nikel
4.8-6.7

Refractory alloys/ Aloi-aloi tahan

panas
Stainless steels/ Keluli tahan karat
Steels/ Keluli
Titanium alloys/ Aloi-aloi titanium

3-9
2-5
2-9
2-5
(50 marks/markah)

Q5.

(a) (i) State only two types of fusion welding and two types of solid state welding.
(10 marks/markah)
(ii) Use diagrams and explain briefly one type of fusion welding and one type of
solid state welding.
(10 marks/markah)
(iii) State THREE types of defect and explain the reason of each defect in welding.
(10 marks/markah)
(b) (i) Describe and sketch THREE types of finishing operation.
(10 marks/markah)
(ii) Using the Figure Q5[b], justify the finishing operation to evaluate the cost
effective in producing complex part size, shape, surface finish and dimensional
accuracy.

Figure Q5[b] / Rajah S5[b]

(20 marks/markah)
(c) (i) During a milling process, serrated chips and a high frequency noise were produced.
This lead to a high tool wear and the work piece is not precise with low dimensional
accuracy. Plan THREE (3) appropriate activities to reduce the problem encountered.
(20 marks/markah)
(ii) With the help from Figure Q5[c], explain the tolerance relationship with surface
finish and quality based on manufacturing cost in coin making.

Figure Q5[c]/Rajah S5[c]

(20 marks/markah)
Q6. (a) Describe the main procedures that would be involved in designing a large outdoor
bronze arch using a suitable casting method. Explain your choices in terms of economical
point of view.
(40 marks/markah)
(b) A solid copper cylindrical slug is 10 mm in diameter and 150 mm high. It is reduced
in height by 30% at room temperature, using a open-die forging with flat dies. Assuming
that the coefficient of friction is 0.35, determine the flow stress and calculate the forging
force at the end of the stroke. Use the Figure Q3 [c] diagram to get the flow stress.

Figure Q6 [b]/ Rajah S6 [b]

(40 marks/markah)
(c) The constant C in Chvorinovs rule is given as 3 s/mm2, and is used to produce a
cylindrical casting with a diameter of 75 mm and height of 125 mm. Calculate the time
taken for the casting to fully solidified.
(20 marks/markah)
Q7 (a) Name TWO (2) types of casting. Indicate their advantages and disadvantages in the
casting processes. Analyse the feasibility of the casting method chosen to coins
making processes.

(b) Explain why heat transfer and fluid flow are important in metal casting? Sketch the
common internal defects in casting namely blow, scar, blister, scab, misrun, hot tear
and cold shut.
(c) A mold sprue having 20 cm long and the cross sectional area at its base is 2.5 cm2 as
shown in Figure 1[c]. The sprue feeds a horizontal runner leading into a solid
ceramics mold cavity with volume of 1380 cm3. Determine:

(i)

the surface area per volume ratio

(ii)

velocity of the molten metal at the base of the sprue

(iii)

volume rate of the flow

(iv)

time to fill the mold

Figure 1[c] / Rajah 1[c]

It is given that the velocity, v =

Q8.

(a)

and the continuity law is expressed as Q = vA.

(i)

State the differences between orthogonal and oblique cutting.

(ii)

List the types of actual chips formation in cutting process.

(iii)

Why continuous chips is not favourable although theoretically the surface

finish is considered good?

(i)

Analyse Figure 2[a] and explain the phenomenon in temperature zone

during the orthogonal cutting process.

Figure 2[a] / Rajah 2[a]

(b) Machining is also known as material removal process.

(i)

Classify and tabled machining processes into THREE (3) groups

according to the type of tool used, and give ONE (1) example of
machining process for each group.

(ii)

Classify and tabled machining processes into THREE (3) groups

according to the shape of workpiece and give ONE (1) example of
machining process for each group.

(iii)

Give THREE (3) main differences between drilling and boring.

(c) There are many ways to measure quality of machining

(i)

Provide THREE (3) criteria where machinability is commonly assessed

other than surface finish.

(ii)

Other than vibration in machining, list TWO (2) other factors that affect
surface finish and explain how they caused imperfect surfaces.

(iii) Suggest TWO(2) activity to reduce vibration and noice in machining.

Q9. (a) (i) Explain the differences between solid state welding and fusion welding processes.

(ii) In oxyacetylene, arc and laser-beam cutting, the processes basically involve melting
of the workpiece. If 80 mm diameter hole is to be cut from a 250 mm diameter and 12
mm thick plate, sketch a mean temperature rise profile in the blank as a function of kerf.
Assume that one-half of the energy goes into the blank.

(b) A welding operation normally takes place on an aluminium alloy plate. A pipe50 mm in
diameter with 4 mm wall thickness and 60 mm length is butt-welded onto a section of
15x15x5 mm angle iron. The L-shape angle iron has a length of 0.3 m. What would be
the temperature increases of the entire structure due to the heat input from the welding
only if:

(i)

the weld zone in a gas tungsten-arc welding process is approximately 8

mm,

(ii)

an electron-beam welding operation with a bead width of 6 mm.

Assume that the electrode requires 1.5 kJ and the aluminium alloy requires 1.2 kJ to melt 1 g of
the welded material.
(c) Two flat copper sheets each having a thickness of 1.5 mm are being spot welded by the use
of a current of 7000 A and a current flow time of 0.3 s. The electrodes are 5 mm in diameter.
Calculate:

Q10.

(i)

the heat generated in the weld zone. Assume that the resistance is 200

(ii)

the temperature rise.