Name:

Matrix No:
UNIVERSITI SAINS MALAYSIA
TEST 1
EPP 331 – MANUFACTURING TECHNOLOGY II 2018/2019
Duration: 1 hour
INSTRUCTIONS:
- There are total of TWO questions.
- Answer ALL questions.
- Please submit your question and answer sheets together.

Question 1 (60 marks)

a) Figure 1 shows an example of automotive plastic bumper product with the defect at two positions of
mounting adapters that used to mount the bumper to the automotive structure.
i) Name the type of defect as shown in Figure 1.
ii) Suggest and explain TWO solutions that can be applied to avoid the defect for the sustainability
production of the bumper for the automotive manufacturer.
iii) Assuming that you are the Design Engineer who is responsible for the design of the bumper
mounting adapter. Sketch ONE possible design that can avoid the defect. Justify why your design is
appropriate for the mounting adapter.

Figure 1: Bumper and cross section of the mounting adapter

b) Preparing of raw material is an initial step for the process of making the ceramic part. In this step,
the additives can be added to improve the quality for the sustainability production of the ceramic part.
Suggest and explain the function of TWO raw material additives.

Question 2 - 40 marks

The high efficiency cutting speed range is given as 65.54 m/min ≤ Vo ≤ 67.08 m/min for both minimum
cost and minimum production time in producing an automotive engine block. Due to global economic
challenges in 2018, the labor rate has to be increased to RM 40.00 per hour and the general overhead
rate is RM 20.00 per hour. In this production, the tool used is carbide (n = 0.5) with five faces and costs
RM 30.00, which take six minutes to change and two minutes to index. (Given C = 120)
a) Using given equations, calculate the new cutting speed for both cost and production time perspectives.
b) Based on your answer in 2a), decide whether it still effective or not for the company to produce the
engine block based on the current charges of labor and overhead rates?
 Solution Test 1 (EPP 3312018/2019)

1a)
iiSink Mark ''
ii) Any two:
- Simulation software: Can simulation mold flow based on design and early sink mark detection can
be observed frorn the simulation results
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- Temperature control: A proper machine and flow temperature control can result uniform mold
flow in the machine and avoid sink mark
- Pressure control: A proper pressure control such as in injection molding can resulting a good
finishing of the plastic product
iii) The previous design adapter has a thick adapter ratio to the bumper surface, so that the sink
mark can be happen easily. The new proposed design has thinner adapter to avoid the sink mark at
the bumper strengthen th"
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1b) Any two:

Binder: for holding the ceramic particles together L
Lubricant: to reduce the friction between particles during molding Ll

Wetting agent: to improve mixing

Plasticizer: to make the mix more plastic and easier to shape {o
Deflocculent: to make the ceramic-water suspension more uniform /

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