ME 383, EXAM 2

Exam 2

//-/'-/----\

ME 383- Modern Manufacturing Process

Thursday October 23'd, 2Ol4
8:00

9:15 AM

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Open Notes/Textbook

Calculators allowed

Section 1: 5 pts each

1. Of the following,

which products

G)s"."*,
(c) Cutting tools

@|be

manufactured using powder metallurgy?

(b) Gears
(d) Sprockets

In metal forming process, what kind of deformation results in change of shape of the
work piece?

2.

(a) Elastic

(b) Stress

(c) Yield

ltu.ti.

3. Deformation process in which a thick-walled ring of smaller diameter is rolled into a

thin-walled ring of larger diameter is called?
(a) Thread rolling

(b) Flat rolling

@ ning rolling

(d) Forging

4. The face of a single point tool that constantly comes in contact

machining is calledi
(a) Flank

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(c) Chip

(d) Relief

5. The machine

tool used in drilling is an example of what kind of tool?

(a) Single point

(c)

with the metal chip during

Drill bit

uutti point

(d) Milling cutter

Page 1 of 10

ME 383, EXAM 2

6. Each ligures below represent a manufacturing process,

identify the manufacturing

process based on the figures.

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Figure

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Milling operation in which the cutting axis is perpendicular to machined surface is called
(a) Slab milling

(b) Peripheral milling

(c) Form milling

LDEace milling

Page 2 of 10

ME 383, EXAM 2

9.

Identiff the three regions in the plot shown below

Accelerating
wear rate

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g
a!

E
P
Time of cutting (min!

Region

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Region

n,

Region

10.

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What kind of rake angle results in a sharper and pointed cutting edge in a single point

tool?

11,

(a) Neutral

6)poritiu"

(c) Negative

Vr r"rodegree

High precision screw threads are manufactured by

tuming
(d) Metal deformation
(a) CNC

Q;
(d)

uitti"g
Drilling

SEE NEXT PAGE

Page 3 of 10

\
ME 383, EXAM 2

Section 2: Solve or answer brieflv with vour iustification (10 ots eachl

1.

A part with various geometrical features shown in figure below is to be manufactured

out of a cylindrical steel rod. If you're a manufacturing engineer, please suggest

(i) What kind of machine center would you use to produce the final part shown
below? (Hint: all of the machining should be done on ane single machine)

(ii) Write the different machining processes that needs to be done on the initial
workpiece to obtain the final part. (Hint: calculate the initial workpiece length and

jinal part length

to

Jind one of lhe hidden machining operation)

(ol:

5 cm

$lot
Dep:1cm)

l-: 5 cm, D: 4 cm

:4cm, D: 3 cm

/r
Through hcle {D : 0.5 cm}

Blind hole

1,,

{D :

1-

crn, Dep : 2 crn}

lL.n"

Leneth (L), Diumeter (Dt, Depth (Deol

Page 4 of 10

,r)rrr,

EXAM 2

Answer:
(i)

Machiningc"n,.r,

(ii)

Machining processes

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2. Draw a neat sketch of metal rolling process. (all the different parts need to be mentioned

in your sketch)

Page 5 of 10

ME 383, EXAM 2

What are the differences between(a) Boring and Turning

(b) Peripheral and Face Milling (Include a line diagram)

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Page 6 of 10

ME 383, EXAM 2

4.In

a machining operation that approximates orthogonal cutting, the cutting tool has a

rake angle of 450. The chip thickness before cut to is 1 cm and after cut the chip thickness
is tc is 20 mm. Calculate the shear plane angle and shear strain in the operation.

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Page 7 of 10

ME 383, EXAM 2

5. A customer approaches you to manufacture 1000 bolts. To machine

qbo!1,

the

following calculations/parameters were noted.

Cost ($)
0.50 (c")
2.00 (c")
0.50 (c")
0.75 (@)

Time (sec)
Parameters
30 (Tn)
Part handline
300 (T,")
Machining
parts
45 (Tr)
Tool change/l0
Toolins/10 parts
np: 10 (no of purts machined in one tool life)

Maximum production Rate: Tc: Tn*

T-*

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Ttlnp

Minimum Cost per Unit: C.= CoTn* CoTm* CoTt/np+Ctlnp

The above machining economic formulas allow the optimal cutting speed to be calculated for
this machining process.
Scenario 1: Suppose if the customer needs 1000 bolts to be manufuctured in two days and if cost
is not a big factor, what machining economic formula would you use? Show the cilculations.
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Scenario 2: Suppose if the customer wants to minimize the cost of manufacturing each bolt and
time taken to manufacture is not u big factor, what machining economic formula wpuld you
use? Show calculations.
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Page 8 of 10

Bonus question

If

6. How are cutting fluids classified? What are the functions and benefits of cutting fluid?
you were to machine a steel workpiece at very low cutting speeds, what kind of cutting fluid

would you chose and why?

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Page 9 of 10