CONFIDENTIAL

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UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FINAL EXAMINATION
SEMESTER

II

SESSTON 2012t2013
COURSE NAME

DESIGN FOR MANUFACTURE AND

ASSEMBLY
COURSE CODE

BDD 40t3t40103

PROGRAMME

BACHELOR OF MECFIANICAL
ENGINEERING WITH HONOURS

DATE OF EXAMINATION

JUNE 2OI3

DURATION

2 HOURS 30 MINUTES

INSTRUCTION

ANSWER ANY FOUR

FROM FIVE QUESTIONS PROVIDED

THIS PAPER CONTAINS FryE (5) PAGES

CONFIDENTIAL

BDD 4013/40103

MAXIMUM MARKS:

100

Answer any four (4) from five (5) questions.

Ql

(a)

Analyze the reasons for rough surface roughness in machining and how to improve
smooth surface roughness
(5 marks)

(b)

How manufacturing industries can be classified and what are all the industries in that
category? Give examples for each industry.
(5 marks)

(c)

A turning machine works at 1900 revolutions per minute to finish a round work piece
of diameter 50 mm to 45 mm having length of 200 mm. The work piece to be turned
to 125 mm. A single point cutting tool is used. The cutting tool moves by 0.15 mm
per work piece revolution. The depth of cut is 2.5 mm per travel of the cutting tool.
Calculate the following:

(i)
(iD
(iii)
(d)

The cutting velocity of the work piece.

The totaltime taken to machine 125 mm tength to reduce to diameter of 45
mm
The material removal rate
(9 marks)

Drilling of holes is to be done in a work piece of 40 mm thickness x 100 mm length

work piece. The hole diameter is l0 mm and it is through hole. The cutting speed of
the drill is 30 m/min. The point angle is I l8 degree. The feed rate is 0. l2 mm per
revolution.
Calculate the following:

(i)
(ii)

Time taken to drill

Material removal rate.
(6 marks)

Q2

(a)

In a product development, many engineers are involved. Discuss the functions of

each ofthem briefly.
(4 marks)

(b)

Discuss the product life cycle in an engineering enterprise.

(6 marks)

(c)

Discuss the advantages in adopting DFMA.

(6 marks)

BDD 4013/40103

Q2

(d)

Metals used in an industry are all combination of three basic materials. Discuss the
basic metal combinations.
(4 marks)

(e)

Discuss various cost elements involved

factorv level.

in estimating the cost of component at

(5 marks)

Q3

(a)

There are two (2) materials which are used in injection molding process. Discuss
their quality characteristics.
(6 marks)

(b)

There are some design guidelines for injection molding. State three (3) of these
design guidelines and explain briefly why it is importance?
(6 marks)

(c)

Explain the injection molding process? State your answers with simple sketch.

(6
(d)

Identiff various defects that

are

marks)

likely to occur in Injection molding process.

(7 marks)

Q4

(a)

Figure Q4 shows in the appendix is the size of the rectangular shape that surround
these five holes is 180 x l00mm and the perimeter of non-standard shape for hole
"+" is 180mm. Assume that 50mm space was allowed at surrounding area of part at
the die set and the die manufacture rate is RM40 per hour. Determine the cost of
piercing die for drilling these five holes? The shear strength of the material is 45 kg i
mm2.

Determine the following:

(i)
(ii)
(iiD
(iv)

Force required cutting the metal and the type of machine that can perform the
operation.
State the type of operation involved and their sequence.
Calculate the cost of material per piece and total weight of material involved.
Determine the total cost of die to produce the part

(25 marks)