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MM 361: Advanced Manufacturing

Faculty of Science Technology and Environment

School of Engineering and Physics

Final Examination
Semester 1 2017

Face to Face

Duration of Exam: 3 hours + 10 minutes


Reading Time: 10 minutes
Writing Time: 3 hours

INSTRUCTIONS

1. This paper carries 100 marks.


2. Answer all questions.
3. Check to see that you have a complete question paper - 3 pages
4. Write your answers in the answer booklet provided and start each
question on a fresh page.
5. This exam is worth 50% of your final marks.
6. Drawings and sketches may be completed in pencil however all
calculations and written work must be completed in ink.
7. All required data are provided, if you feel anything is necessary and is
missing you can assume and highlight your assumption with justification.
Question 1
Write numerical control part program for the given sketch as shown in Figure 1. The
program should be written in absolute coordinate form and briefly comment for each
line of program as what it indicates. Following are the details to be considered for the
programming, such as tool size is 0.25 inch, feed rate is 6 inch per minute, cutting
speed is 300 rpm, tool start position is (2.0, 2.0), programming in inches, motion of
tool is from p0 to p1 to p2 to p3 to p4 to p5 to p1 to p0 and the depth of cut is 0.25
inch. It can be assumed that in single pass the depth of cut shall be accomplished.
(20 marks)

Fig. 1: Work-model for NC part programming

Question 2
A. Explain the common approaches that are used in all of material addition
technologies to prepare the control instructions for rapid prototyping system.
(6 marks)

B. The cone shaped part is to be fabricated using laminated object manufacturing.


The radius of the cone at its base is 37 mm and its height is 42 mm. The layer
thickness is 0.25 mm. The laser beam can cut the sheet stock at a velocity of 600
mm/s. Compute an estimate for the time required to build the part, if 12 s are lost
each layer to lower the height of the platform that holds the part and advance the
sheet stock in preparation for the next layer. Ignore cutting of the cross-hatched
areas outside of the part since the cone should readily drop out of the stack owing
to its geometry. (14 marks)

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Question 3
Explain the primary operations of powder metallurgy process in detail. What are the
major set-back of the components produced through primary operations especially for
high-strength or structural applications and how would you eradicate those set-back,
discuss about it. (20 marks)

Question 4
A. Chemical milling is used in aircraft plant to create pockets in wing sections made
of an aluminum alloy. The starting thickness of one work-part of interest is 22
mm. A series of rectangular-shaped pockets 14 mm deep are to be etched with
dimensions 300 mm by 500 mm. The corners of each rectangle are radiused to 16
mm. The part is an aluminum alloy and the etchant is NaOH. The penetration rate
for this combination is 0.026 mm/min and the etch factor is 1.8. Determine (i)
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metal removal rate in mm /min, (ii) time required to etch to the specified depth,
and (iii) required dimensions of the opening in the cut and peel maskant to achieve
the desired pocket size on the part. (12 marks)

B. It is observed that laser technology is widely used in materials and manufacturing


process for various applications. Discuss how laser technology is used in solid
state alloying. (4 marks)

C. Explain nano-fabrication by scanning probe techniques under the bottom-up


processing approaches. (4 marks)

Question 5
A. What are the primary factors that led to development of computer integrated
manufacturing techniques? (4 marks)

B. What types of work material are usually preferred for extrusion process in the
context of plastic forming? Discuss in detail about the characteristics of work
material to be considered in the extrusion process. (16 marks)

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