CONFIDENTIAL

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FINAL EXAMINATION
SEMESTER I
SESSION 2014/2015
COURSE NAME

: MANUFACTURING TECHNOLOGY

COURSE CODE

: BDA 30502

PROGRAMME

: 3 BDD

EXAMINATION DATE

: DECEMBER 2014/JANUARY 2015

DURATION

: 2 HOURS

INSTRUCTION

: ANSWER FOUR (4) QUESTIONS ONLY

THIS QUESTION PAPER CONSISTS OF FIVE (5) PAGES

CONFIDENTIAL

BDA30502

Q1

(a)

In turning operation, FIVE (5) basic cutting techniques have been used
widely in industries to perform shape and contour. Illustrate in figure and
label completely.
(5 marks)

(b)

There are FOUR (4) types of chip during machining influences by the
cutting speed, spindle speed, material etc. Draw each of the chip formation
and label with the explanation.
(8 marks)

(c)

A slab milling operation is performed to finish the top surface of a steel

rectangular work piece 250 mm long by 70 mm wide. The helical milling
cutter, which has a 80 in diameter and eight teeth, is set up to overhang the
width of the part on both sides. Cutting conditions are: v = 50 m/min, f =
0.12 mm/tooth, and d = 3.00 mm. Determine:
(a)
(b)

the time to make one pass across the surface.

the metal removal rate during the cut.
(12 marks)

Q2

(a)

Describe what mean by the investment casting and give THREE (3)
examples of products that are normally made by such technique?
(5 marks)

(b)

Discuss the different between the mould for sand casting and die casting dies
(10 marks)

(c)

Explain how the die casting works with the aid of a diagram
(10 marks)

Q3

(a)

Describe what mean by the hot working and cold working than give TWO
(2) examples of products that is normally made by such technique?
(5 marks)

(b)

Discuss the different between the upsetting and heading with the aid of
diagram
(10 marks)

(c)

Explain how the impressive die works with the aid of a diagram
(10 marks)

Q4

(a)

Explain how the blow-molding technique works?

(4 marks)

(b)

Describe what it means by calendaring process and give THREE (3)

examples of products that is normally made by such technique?
(5 marks)
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Q5

(c)

Explain how the compression molding works with the aid of a diagram?
(8 marks)

(d)

Discuss the difference between the mold for injection molding and the mold
for compression molding process?
(8 marks)

(a)

State FIVE (5) reasons why powder technology is important?

(5 marks)

(b)

List FIVE (5) methods that are normally used to produce metal powders?
(5 marks)

(c)

Explain what it means by sintering in powder metallurgy?

(3 marks)

Q6

(d)

State FIVE (5) advantages and the disadvantages of powder technology?

(12 marks)

(a)

What is the basic principle of fusion welding?

(5 marks)

(b)

Describe in detail a typical Arc Welding Process complete with aid of

diagram
(10 marks)

(c)

Compare the advantages and disadvantages of Solid State Welding (SSW)

and Fusion Welding (FW)
(10 marks)

- END OF QUESTION -

BDA30502

ANSWER
Q1

(a)
Operation type

Characteristic
Facing
-

Remove face of workpiece

Control the workpiece length
etc

Contour turning
-

Instead of feeding tool parallel to axis of rotation,

tool follows a contour that is other than straight,

thus creating a contoured shap

Chamfering
-

Cutting edge cut an angle on the corner of the

cylinder, forming chamfer

Cut off or Parting

-

Tool is radially into rotating work at some location

to cut end of part

Threading
-

Pointed form tool is fed linearly across surface of

rotating workpart parallel to axis of rotation at a
large feed rate, thus creating threads

(4 marks)

BDA30502

(b)
Chip type

Characteristic
Brittle work materials
Low cutting speeds
Large feed and depth of cut
High tool-chip friction

Ductile work materials

High cutting speeds
Small feeds and depths
Sharp cutting edge
Low tool-chip friction

Ductile materials
Low-to-medium cutting speeds
Tool-chip friction causes portions of chip to adhere to rake
face
BUE forms, then breaks off, cyclically

Semicontinuous - saw-tooth appearance

Cyclical chip forms with alternating high shear strain then
low shear strain
Associated with difficult-to-machine metals at high cutting
speeds

(c)

(v)

BDA30502

Q2

(a) A pattern made of wax is coated with a refractory material to make mold, after
which wax is melted away prior to pouring molten metal
-cast rotor, jewelery, knee

(b)
Sand casting
Need the core
Need the pattern
Green sand material
Expandable Mold

Die casting
No need core
No need the pattern (Need the cooling channel)
Tool Steel
Permanent mold

(c)
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(a) die is closed

(b) plunger is withdrawn
(c) Molten metal flow into the chamber
(d) plunger forced molten metal into the die
(e) maintain pressure during solidification
(f) die is open and the part is ejected

Q3

(a) cold working-the working has perform slightly above at room temperature
blanking, drawing
hot working-the working has deformation at temperatures above the recrystallization
temperature
hot forging, impressive die

(b) upsetting
- wire stock is fed to the stop
- gripping dies close on the stock and the stop is retracted
- punch moves forward
- bottoms to form the head

heading
-heading a nail using open dies
- round head formed by punch
- two common head styles for screws formed by die
- carriage bolt head formed by punch and die

BDA30502

(c)
impression die work process by compression of workpart through the dies with inverse of
desired part shape as following,
-prior to initial contact with raw workpiece
-partial compression
-final die closure, causing flash to form in gap between die plates

Q4

(a)
i)
ii)
iii)
iv)

extrusion of parison (1)

parison is pinched at the top and sealed at the bottom around a metal
blow pin as the two halves of the mold come together (1)
the tube is inflated so that it takes the shape of the mold cavity (1)
mold is opened to remove the solidified part (1)

(b) Calendaring process is a process of pass the feedstock through a series of rolls (1)
to reduce the thickness to desired gage (1). Product examples: PVC floor covering,
shower curtains, vinyl table cloths, pool liners, and inflatable boats and toys (3)
(c)

(3)

i)

Charge (raw material) is loaded (1)

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ii)
iii)

charge is compressed (pressure) and cured (heat) (2)

part is ejected and removed (2)

(d)
Mold for injection
Pack with cooling system and runner
system
Has sprue and runner system
Simple and complex geometry

No heat involved on the mold

Q5

Mold for compression

Simpler and no cooling system and
runner system
No sprue and runner system
Process itself generally limited to
simpler part geometries due to lower
flow capabilities of TS materials
Mold must be heated, usually by
electric resistance, steam, or hot oil
circulation

(a)
i) PM parts can be mass produced to net shape or near net shape, eliminating
or reducing the need for subsequent machining
ii) PM process wastes very little material - ~ 97% of starting powders are
converted to product
iii) PM parts can be made with a specified level of porosity, to produce porous
metal Parts. Examples: filters, oil-impregnated bearings and gears
iv) Certain metals that are difficult to fabricate by other methods can be
shaped by powder metallurgy
v) Tungsten filaments for incandescent lamp bulbs are made by PM
vi) Certain alloy combinations and cermets made by PM cannot be produced
in other Ways
vii) PM compares favorably to most casting processes in dimensional control
viii) PM production methods can be automated for economical production

(b)
i)
ii)
iii)
iv)
v)

Atomization
Reduction
Electrolytic deposition
Carbonyls
Comminution

(c)
Sintering is the process whereby green compacts are heated in a controlledatmosphere furnace to a temperature below the melting point but sufficiently
high to allow bonding (fusion) of the individual particles

BDA30502

(d)
Advantages
i)
Although the cost of metal powder is high, there is no loss of material.
The parts can be produced clean & bright, ready for use.- Net shape and
near shape products.
ii)
Composition of product can be controlled. No risk of contamination.
iii)
Close dimensional tolerances can be maintained.
iv)
Non-metallic substances can be produced and in any proportion to get
the final product.
v)
A wide range of properties such as density, porosity and particle size
can be obtained for particular applications.
vi)
It is possible to unite materials that cannot be alloyed in the normal
sense or would not yield the desired characteristics
vii) Useful for magnetic core having special desirable properties.
viii) Reduction in the production time.
ix)
No skill labor is required.
x)
Saving material and 97 % is possible.
xi)
Composition, structure and properties can be controlled more easily and
closely than any other fabricating process.
Disadvantages
i)
Pure metal powders are very expensive to produce.
ii)
Size of the products to be produced is limited because of the large
presses are required.
iii)
Lack of metals powder like steels, bronzes, brasses etc.
iv)
Strength properties are lower than those of similar article produced by
conventional methods.
v)
Poor plastic properties impact strength and elongation.
vi)
Die design limit the size of products.
vii)
Dies required are very expensive and needed large quantities of
products. Volume must be justified.

Q6

(a) A fusion welding process in which coalescence of the metals is achieved by the
heat from an electric arc between an electrode and the work

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(b)

- A pool of molten metal is formed near electrode tip, and as electrode is moved along joint,
molten weld pool solidifies in its wake
- Electric energy from the arc produces temperatures ~ 10,000 F (5500 C), hot enough to
melt any metal
-Most AW processes add filler metal to increase volume and strength of weld joint
-An electric arc is a discharge of electric current across a gap in a circuit
-It is sustained by an ionized column of gas (plasma) through which the current flows
-To initiate the arc in AW, electrode is brought into contact with work and then quickly
separated from it by a short distance

(c)
-If no melting, then no heat affected zone, so metal around joint retains original properties
-Many SSW processes produce welded joints that bond the entire contact interface
between two parts rather than at distinct spots or seams
- Some SSW processes can be used to bond dissimilar metals, without concerns about
relative melting points, thermal expansions, and other problems that arise in FW

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