UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING Mechanical & Production Engineering Department Academic year 2008/2009 Semester 2 MECH 3002Y CLASS TEST Answer ALL Questions (Total maximum marks = 60 marks) [45 minutes]

1(a) A rectangular sand mould of size 1000 mm (length) 500 mm (width) 300 mm (height) is to be filled with molten cast iron. The height of the pouring basin is 45 mm, and the sprue height is 325 mm. The diameter of the ingate is 90 mm. Calculate the mould filling time for the vertical and bottom gating systems. Comment on the answers. Assume acceleration due to gravity to be 9.81 m/s2. State any assumptions. [10 marks] (b) The engineer is proposing to have one open riser for the sand casting in part (a) above. Explain five (5) methods that can be used to prevent the molten metal for solidifying too quickly in the riser. [10 marks] (c) Explain the use and function of chills in the sand casting process. [5 marks] 2. Outline the punching and blanking operations for sheet metal operations, and explain their practical applications in the manufacturing industry. Support your answer with practical examples. [10 marks]

3. A plane carbon steel rectangular slab has to be forged so that the final length is 600 mm and final thickness is 300 mm assuming unit width. Assume that the average yield stress for the steel is 300 N/mm2. Using Von Mises Criterion and a coefficient of friction of 0.35, calculate the maximum forging force required. [17 marks] 4(i) Explain the phenomenon of foaming, which occurs in industrial oil lubricating systems. (ii) How can the occurrence of foaming be minimized? Explain the answer. [4+4=8 marks]