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FINAL EXAMINATION
SEMESTER II, SESSION 2009/2010

COURSE CODE : SME 2713

COURSE NAME : MANUFACTURING PROCESSES

PROGRAMME : SMM/SMP/SMI/SMB/SMT/SMV/SZM

DURATION : 2½ HOURS

DATE : APRIL, 2010

INSTRUCTION TO CANDIDATES : ANSWER ALL QUESTIONS

WARNING!

Students caught copying/cheating during the examination

are liable for disciplinary actions and the Faculty may recommend
the students to be expelled from the University

THIS EXAMINATION PAPER CONSISTS OF (8) PRINTED PAGES ONLY

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QUESTION 1 (20 MARKS)

A. Choose the correct answer in questions i. to v.:

Pilih jawapan yang betul bagi soalan i. hingga v.:

i. Car roof panel is made from mild steel sheet using this process;
Panel bumbung kereta diperbuat dari kepingan keluli lembut melalui proses ini;

a. Indirect extrusion b. Contour rolling

Penyempritan tak langsung Gelekan kontur
c. Stamping d. Press Forging
Kerja tekan Tempaan tekanan
e. Cold Heading
Tempaan kepala sejuk

ii. Long, continuous pipes can be made from the following processes, except:
Paip yang panjang dan berterusan boleh dihasilkan dengan proses-proses berikut, kecuali;

a. Forging b. Direct extrusion

Tempaan Penyempritan langsung
c. Indirect extrusion d. Tube drawing
Penyempritan tak langsung Penarikan tiub
e. Contour rolling
Gelekan kontur

iii. Drink canister bodies can be made from the following processes, except:
Badan tin minuman ringan boleh dihasilkan menggunakan proses-proses berikut kecuali;

a. Deep drawing b. Cup drawing

Penarikan dalam Penarikan cawan
c. Impact extrusion d. Press forging
Penyempritan hentaman Tempaan tekanan
e. Contour rolling
Gelekan kontur

iv. The followings are defects that can be produced in deep drawing, except:
Berikut adalah kecacatan yang boleh terhasil dari proses penarikan dalam, kecuali;

a. Wrinkling b. Wall tearing

Kedutan Koyak dinding
c. Earring d. Burnishing
Menelinga/cuping Kilatan
e. Fish tail
Ekor ikan
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v. The followings will reduce the tendency for formation of wrinkles in cup drawing, except:
Perkara-perkara berikut akan mengurangkan kemungkinan berlakunya kedutan dalam penarikan
cawan, kecuali;

a. Increasing the blank holder pressure b. Increasing the sheet thickness

Meningkatkan tekanan pemegang Meningkatkan ketebalan kepingan
contoh kosong
c. Reducing the blank size d. Enlarging the air hole size in the die
Mengecilkan saiz contoh kosong Membesarkan saiz liang udara dalam dai
e. Increasing the number of draws.
Meningkatkan bilangan penarikan
(5 marks / markah)

B. Automotive connecting rods can be made using many processes including:

Rod penyambung automotif boleh dihasilkan menggunakan beberapa proses termasuk;

(a). Machining from a blank/Memesin dari suatu contoh kosong

(b). Sand casting/Tuangan pasir
(c). Forging/Tempaan

i). Comment on the advantages/disadvantages and suitability of each of the three methods in making
connecting rods.
Komen ke atas kelebihan/kekurangan dan kesesuaian setiap satu proses di atas dalam
menghasilkan rod penyambung.

ii). Describe method number (c) in making the product.

Jelaskan penghasilan produk di atas menggunakan cara nombor (c).
(10 marks / markah)

C. With the help of sketch, describe the process of wire drawing. Your description should include the type of
die and equipment used and two (2) precautions taken to reduce the tendency for wire breakage during
drawing.
Dengan bantuan lakaran, jelaskan proses penarikan wayar. Penjelasan anda seharusnya melibatkan jenis
dai dan peralatan yang digunakan, dan dua (2) langkah penjagaan bagi mengurangkan kemungkinan
berlaku wayar putus semasa penarikan.
(5 marks / markah)
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QUESTION 2 (20 MARKS)

A. Discuss three (3) importance of joining processes in product manufacturing. Relate your discussion with
relevant examples.
Bincangkan tiga (3) kepentingan proses-proses penyambungan dalam pembuatan produk. Hubungkan
perbincangan anda dengan contoh-contoh yang munasabah.
(6 marks / markah)

B. Explain two (2) situations in which brazing or soldering process is preferable to be used as compared with
fusion welding. List three (3) advantages of brazing or soldering as compared with welding process.
Jelaskan dua (2) keadaan di mana proses pateri lembut atau keras adalah lebih sesuai digunakan
berbanding kimpalan lakuran. Senaraikan tiga (3) kelebihan proses pateri berbanding proses kimpalan.
(5 marks / markah)

C. Explain four (4) functions of flux coating on the arc welding electrode with respect to the electrode, arc
control, or welding result.
Jelaskan empat (4) fungsi salutan pada elektrod yang digunakan dalam proses kimpalan arka dengan
mengambil kira electrod, kawalan arka, atau hasil kimpalan.
(4 marks / markah)

D. With the aid of appropriate sketches, explain the oxy-acetylene process with regards to the following
aspects:
Berbantukan lakaran yang bersesuaian, terangkan proses oksi-asitelena berhubung perkara-perkara
berikut;

i. The acetylene system, its characteristics and advantages compared to other welding processes.
Ciri-ciri dan kelebihan sistem-asitelena berbanding proses-proses kimpalan lain.

ii. Types of flames generated from gas mixing and related application.
Jenis-jenis nyalaan dari percampuran gas dan kegunaan berkaitan.
(5 marks / markah)

\
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QUESTION 3 (20 MARKS)

A. Give three (3) advantages and three (3) disadvantages of the machining process.
Berikan tiga (3) kelebihan dan tiga (3) kekurangan proses pemesinan.
(3 marks / markah)

B. i. State three (3) types of chip formation in metal cutting.

Nyatakan tiga (3) jenis pembentukan tatal dalam pemotongan logam.

ii. Which is the most preferred type of chip and give two (2) reasons why it is preferred.
Apakah jenis tatal yang lazimnya dikehendaki dan berikan dua (2) alasan ia disukai.

iii. Explain the disadvantages of the other two (2) types of chip.
Terangkan kekurangan pada dua (2) jenis tatal yang tidak dikehendaki.
(6 marks / markah)

Figure Q3(C): Orthogonal Cutting

Rajah Q3(C): Pemotongan Sudut Tepat

C. Figure Q3(C) shows a schematic diagram of an orthogonal cutting operation;

Rajah skematik Q3(C) menunjukkan operasi pemotongan sudut tepat;

i. Name six (6) parameters labelled (A)-(F) on the diagram.

Namakan enam (6) parameter yang dilabel (A)-(F).

ii. Locate the primary and secondary shear zones in the diagram.
Di dalam rajah tunjukkan kedudukan zon ricih utama dan kedua.
(4 marks / markah)
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C. Tool wear and material removal rate (MRR) relationship is very influential in the metal cutting process.
Hubungan kehausan matalat dengan kadar pemotogan bahan adalah sangat mempengaruhi proses
pemotongan logam;

i. Briefly explain two (2) relations of cutting speed with tool wear.
Jelaskan secara ringkas dua (2) hubungan antara kelajuan pemotongan dan kehausan matalat.

ii. Sketch a flank tool wear and give two (2) reasons why it develops. What would be the effect to the
cutting process?
Lakarkan kehausan rasuk matalat dan berikan dua (2) alasan kenapa kehausan ini berlaku. Apakah
kesannya pada proses pemotongan?
(6 marks / markah)

QUESTION 4 (20 MARKS)

A. Refer to Figure Q4(A):

Rujuk kepada Rajah Q4(A)

Up (conventional) milling Down (climb) milling

Mengisar Lazim Mengisar Daki
Figure (Rajah) Q4(A)

i. Explain two (2) advantages of down milling as compared to up milling.

Terangkan dua (2) kelebihan mengisar lazim dibandingkan dengan mengisar mendaki.

ii. Why down milling is less recommended when using an old milling machine?
Kenapakah mengisar lazim tidak digalakkan jika menggunakan mesin kisar yang telah lama?
(4 marks / markah)
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B. By using Table Q4(B), indicate one (1) example and one (1) use of each of the additive materials listed.
Please copy Table Q4(B) when answering.
Dengan menggunakan Jadual Q4(B), nyatakan satu (1) contoh dan satu(1) fungsi setiap jenis bahan
campuran plastik. Sila salin Jadual Q4(B) untuk menjawab.

Table(Jadual) Q4(B)

Type of additives
Example Function
(Jenis Bahan
(Contoh) (Fungsi)
Campuran)
Plasticizer
(i) (iii)
(Pemplastik)
Stabiliser
(ii) (iv)
(Penstabil)

(3 marks / markah)

C. Referring to Table Q4(C), fill in the blanks with the correct answer: Please copy Table Q4(C) when
answering.
Merujuk kepada Jadual Q4(C), isi ruang kosong dengan jawapan yang betul. Sila salin Jadual Q4(C)
untuk menjawab

Table(Jadual) Q4(C)

Thermoplastic
(Plastic Haba)
Plastic type according to degree of
crystallinity
i). Crystalline iv). ______________
(Jenis plastik mengikut darjah
penghabluran)

ii). _____________ v). Polystyrene (PS)

Name of plastics
(Nama plastik)
iii). _____________ vi). ______________

(2 marks / markah)
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a) Plastic Spoon b) Drinking bottle

(Material: Thermoplastic - PP) (Material: Thermoplastic – PET)

Figure (Rajah) Q4(D): Plastic products (Product plastik)

D. Select only one (1) of the two(2) plastic products shown in Figure Q4(D) and answer the following
questions:
Pilih hanya satu (1) daripada dua(2) produk plastik yang ditunjukkan pada Rajah Q4(D) dan jawab
soalan-soalan berikut:

i). State the suitable process to manufacture the product of your choice.
Nyatakan proses yang bersesuaian bagi menghasilkan produk pilihan anda
ii). Explain the process steps. Incorporate with suitable sketches.
Jelaskan langkah-langkah proses penghasilan produk. Kembarkan lakaran-lakaran yang
bersesuaian.
iii). State one (1) advantage and one (1) disadvantage of the process.
Nyatakan satu (1) kelebihan dan satu (1) kekurangan proses yang dipilih.
(10 marks / markah))
Filename: final paper_23mac_hm.doc
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Title: QUESTION 3 (20 MARKS)
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Author: Norizah Redzuan
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