ME4261/ME4261E

NATIONAL UNIVERSITY OF SINGAPORE

ME4261/ME4261E TOOL ENGINEERING

(Semester II : AY2011/2012)

Time Allowed : 2 Hours

INSTRUCTIONS TO CANDIDATES:

1. This examination paper contains FOUR (4) questions and comprises FOUR (4)
printed pages.

2. Answer ALL FOUR (4) questions.

3. All questions carry equal marks.

4. This is an OPEN-BOOK EXAMINATION.

5. Programmable calculators are NOT allowed for this examination.

 PAGE 2 ME4261/ME4261E

QUESTION 1

An Aluminum workpiece of batch size 1000 is to be machined as given in Figure 1. Using

neat sketches, propose a jig and /or fixture which can be used to machine the following

Operation 1: Machine Surface C using vertical machining centre.

Operation 2: Machine hole of diameter 10 mm on surface B using the drilling machine

In your proposed solution clearly indicate the following:

(a) Locating methods

(b) Supporting methods
(c) Clamping methods
(25 marks)

QUESTION 2

(a) You are a process planner in a machine shop and you only have a lathe that is
available for machining. You are required to machine a hole of diameter 10 mm on
surface A of the aluminum workpiece shown in Figure 1. All other features are
machined and assume the missing dimensions. Using neat sketches, propose a fixture
which can be used to machine the hole using a lathe.

In your proposed solution clearly indicate the following:

(i) Locating methods

(ii) Supporting methods
(iii) Clamping methods
(13 marks)

(b) Clearly state if the following statements are true / false. Give the correct statement if
it is found to be false.
(12 marks)

(i) Equalizing supports are a form of adjustable support used when locating on
irregular surfaces.
(ii) Fool proofing pin is used to help in proper loading and unloading and also to
locate the workpiece accurately.
(iii) Conical locator is used when there is considerable variation in the dimension
of the feature to be located.
(iv) Spherical washer is used to accommodate large variations in the dimensions of
the part.
(v) Spring loaded locators are used to positively locate the workpiece such that it
does not move during machining.
(vi) Cam activated clamps are used to facilitate easy loading and unloading of the
part and hence improve the productivity.
PAGE 3 ME4261/ME4261E

Figure 1
 PAGE 4 ME4261/ME4261E

QUESTION 3

A tungsten carbide single-point cutting tool with the tool rake angle o 5 , relief angle
o 6 , inclination angle 4 , side cutting edge angle s 25 , end cutting edge
angle e 5 , and with a chip breaker, is used for rough turning of a cast iron (250 BHN)
workpiece at the feed rate f = 5 mm/rev and depth of cut d = 5 mm. The workpiece diameter
is D = 100 mm. The tool cutting edge is set 2 mm below the workpiece rotation axis. The
tool orientation is set with the orientation setting angles G=+5, H =0 and L=0.

(a) determine the tool working angles oe , oe , e , se , and ee ; (The differences of rake
angle and relief angle measured within Pfe, Poe, and Pne planes can be ignored)
(15 marks)

(b) give your opinion and explanation on whether or not the tool is suitable for the
specified cutting process?
(10 marks)
(Note: 1 in = 25.4 mm, 1 psi = 6.89410 N/m )
3 2

QUESTION 4

Design a single-point tungsten carbide cutting tool for finish turning of an alloy steel
workpiece ( u 1.1 10 9 N/m2). If the workpiece diameter is D 160 mm, the feed rate is
f 0.25 mm/rev, the tool major cutting edge is set to be 5 mm above the workpiece turning
axis, and tool orientation setting angles G 0 , H 0 and L 10 ,

(a) show the cutting elements of the tool;

(5 marks)

(b) determine the optimum values for the tool angles n , n , , s , and e . (The
differences of rake angle and relief angle measured within Pfe, Poe, and Pne planes
can be ignored)
(20 marks)

(Note: 1 in = 25.4 mm, 1 psi = 6.89410 3 N/m2)

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