Manufacturing Processes Tutorial 3 Solution

(a) Corrosion resistant. Golden colour. Very strong and durable. But material and process are
expensive.

(b) Corrosion resistant. Silver colour. Durable. But both material and process are very expensive

(c) Cheap and strong but will corrode, crude and rough.Not for large scale production.

(d) Production is fast. Product is strong but expensive and will corrode, tends to be brittle

(e) Very large scale production possible. Corrosion resistant. Can come in many different
colours. Durable and cheap. But plastic looks cheap and unimpressive.

(f) Corrosion resistant. Can come in many different colours. Durable and cheap. Slow production
rate. Hollow, very light, can float in water, very soft, squeezable (not suitable for Merlion). But
plastic looks cheap and unimpressive.

(g) Moderately expensive because scale of production lower than injection molding. Corrosion
resistant. Can come in many different colours. Durable and cheap. But plastic looks cheap and
unimpressive. There will be flash. Since melamine is a thermoset, scrapped material cannot be
recycled.

(h) Cheap. Large scale production possible. Corrosion resistant. Durable. But aluminium has dull
metallic surface, not very impressive for Merlion. Needs constant polishing for shine.

Either

1. Sand cast with a central sand core, or

2. Press bronze sheets to form the two halves (L and R) of the Merlion surface, join by
welding (Gas weld if sheets are below 2 mm thick, arc weld if 2 mm and above, can TIG
weld if above 1 mm thick)
Manufacturing Processes Tutorial 4 Solution

(a) Cold drawn: Much stronger (work hardened), higher tensile yield strength.
Hot extruded: Lower yield strength. Spoke too thin to be extruded

(b) Rolling: Lower forces needed than in extrusion, cheaper, diameter too small for extrusion.
[Depending on shape and size, possible to cold draw.]

(c) Forged: Bending and fatigue strength needed for this component. Extrusion and casting
cannot give such strength.

(d) Forged: Bending and fatigue strength needed for this component because of reciprocating
forces. Rolling and casting cannot give this strength.

(e) Steel tube is quite small. A welded seam will weaken it. Strength is needed for this
component since the load passes directly through it from the wheel hub.

(f) Die cast: Convenient to get this shape from die casting using multiple dies. Strength should be
adequate. High production rate. Forgings give very high strength but the shape is not suitable -
needs subsequent cleaning up operations like machining of the holes.

(g) Resistance welding of metal strip. Cheapest way to make steel tubes. Extrusion gives
seamless stube, which is not necessary in this case.

(h) Forging gives bending and fatigue strength, which is especially important for the little gear
teeth. Case hardening gives wear resistant. Black oxide coating gives corrosion protection.
Investment casting will not give the necessary strength and wear resistance.

Low cost thermoplastics:

1. Low strength
2. Deteriorate under ultra-violet radiation (eg. sunlight)
3. Cannot stand high temperature (eg. PVC softens on a hot day)
4. Creep (dimensionally unstable)
5. Impossible to repair