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EM/APR 2007/KJP556

UNIVERSITI TEKNOLOGI MARA FINAL EXAMINATION

COURSE COURSE CODE EXAMINATION TIME

: : : :

MANUFACTURING PROCESSES KJP556 APRIL 2007 3 HOURS

INSTRUCTIONS TO CANDIDATES 1. 2. 3. 4. This question paper consists of eight (8) questions. Answer six (6) questions only. Answer ALL questions in the Answer Booklet. Start each answer on a new page. Do not bring any material into the examination room unless permission is given by the invigilator. Please check to make sure that this examination pack consists of: i) ii) the Question Paper an Answer Booklet - provided by the Faculty

5.

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of 4 printed pages
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EM/APR 2007/KJP556

QUESTION 1 a) Both rolling and forging produce a "grain" flow pattern in the material similar to the grain in wood. i) What is "grain" flow? (2 marks) ii) How does this affect the mechanical properties of the material? (2 marks) iii) Illustrate how the "grain" flow pattern varies in products produced by machining and casting. (1 mark) b) i) Extrusion can be done as either cold or hot working operation. State two advantages that cold extrusion has over hot extrusion. (2 marks) What are the differences between hydrostatic extrusion and forward extrusion? (3 marks)

ii)

QUESTION 2 a) Describe the operation and set-up of a two-high and three-high rolling mill. Provide diagrams to illustrate the rolling mill arrangement. (5 marks) What are the differences between a progressive die and a compound die used in sheet-metal forming operations? Explain with the use of diagrams for each of the die set-up. (5 marks)

b)

QUESTION 3 a) i) What are risers and sprues? (3 marks)

ii) Explain how these are used in a sand casting process. Illustrate with appropriate sketches. (3 marks) b) Differentiate the following casting defects and explain the methods of prevention, i) misrun and cold shut; ii) blow hole and pin hole porosity. (4 marks)

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EM/APR 2007/KJP556

QUESTION 4 a) Compare investment casting and pressure die casting in terms of its process, production cost involved and the quality of products produced. (6 marks) i) What are thermoplastic and thermosetting polymers? (2 marks) ii) What characteristics of polymers that are advantages for applications such as gears as compared to metals? (2 marks) QUESTION 5 a) Describe how a three-plate mold operates in an injection moulding process as compared to a two-plate mold. (4 marks)

b)

b)

Describe the process for making a one-piece hollow plastic bottle. Illustrate with the use of diagrams. (6 marks)

QUESTION 6 a) State three reasons why powder metallurgy process is more and more commercially accepted. (3 marks) What are the main advantages of isostatic pressing as compared to other compacting processes performed on powder metallurgy parts. (3 marks) Describe the differences in the process between injection molding of metal (MIM) and injection molding of plastics. (4 marks)

b)

c)

QUESTION 7 a) i) What is a polymer-matrix composite (PMC)? (1 mark) ii) List four attractive features that distinguish fiber-reinforced plastics (FRPs) as an engineering material. (2 marks)

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EM/APR 2007/KJP556

b)

The following processes are available for shaping of ceramics. List two advantages and limitations for each of these processes, i) slip casting; ii) jiggering. (3 marks) i) What are synthetic rubbers? (1 mark) ii) List three typical applications of synthetic rubbers. (1 mark) iii) What properties do synthetic rubbers have which are better than natural rubbers? (2 marks)

c)

QUESTION 8 a) An inventor has asked the Matilda Manufacturing Co. to prepare a quotation for the production of a new gardening tool. What factors would the company need to consider in determining the most suitable manufacturing process? Make your own assumptions where necessary. (7 marks)

b)

i) What are semiconductors? (1 mark) ii) Name three widely used materials in semiconductor devices. (1 mark) iii) List three common semiconductor devices. (1 mark)

END OF QUESTION PAPER

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