CONFIDENTIAL EM/APR 2008/KJP471/556/MEM560

UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE : MANUFACTURING PROCESSES

COURSE CODE : KJP471/556/MEM560

EXAMINATION : APRIL 2008

TIME : 3 HOURS

INSTRUCTIONS TO CANDIDATES

1. This question paper consists of six (6) questions.

2. Answer five (5) questions in the Answer Booklet. Start each answer on a new page.

3. Do not bring any material into the examination room unless permission is given by the
invigilator.

4. Please check to make sure that this examination pack consists of:

i) the Question Paper

ii) an Answer Booklet - provided by the Faculty

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

This examination paper consists of 5 printed pages
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CONFIDENTIAL 2 EM/APR 2008/KJP471/556/MEM560

QUESTION 1

a) Indicate four advantages of cold working relative to warm and hot working.
(4 marks)

b) (i) What is the primary factor that makes the mechanical performance of forged
parts better than cast parts?
(2 marks)

(ii) Illustrate and describe a simple upset forging operation to form the head of a
bolt.
(5 marks)

c) State four differences between extrusion and drawing process.

(4 marks)

d) (i) Describe briefly the drawing process in sheet-metalworking.

(3 marks)

(ii) What do you know about deep drawing as compared to normal drawing in sheet-
metalworking?

(2 marks)

QUESTION 2

a) Sketch and describe the process of making a square washer in a progressive die.
(8 marks)

b) (i) What is the composition of green sand in sand casting process as

compared to the CO 2 moulding process?
(2 marks)

(ii) List some of the operations required in sand casting after the casting is
removed from the mould.
(2 marks)

(iii) State the main advantages and disadvantages of sand casting over investment
casting.
(3 marks)

c) Compare the process between pressure die casting and shell moulding.
(5 marks)

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QUESTION 3

a) What are the advantages of die casting over sand casting in terms of their mechanical
properties or design capabilities?
(4 marks)

b) Explain briefly the properties that will determine the quality of a sand mould for sand
casting.
(3 marks)

c) (i) What is meant by the term "green compact" in Powder Metallurgy (PM)?
(2 marks)

(ii) What are the three steps in the PM sintering cycle?

(3 marks)

d) Give reasons as to why PM technology is so well suited to the production of gears and
bearings.
(4 marks)

e) Quote some of the disadvantages of PM methods.

(4 marks)

QUESTION 4

a) (i) What are the differences between traditional and new ceramics as far as raw
materials are concerned?
(3 marks)

(ii) List the basic steps in the traditional ceramics processing sequence.
(2 marks)

b) (i) Describe slip casting process in traditional ceramics processing and provide
an example of one product made from this process.
(4 marks)

(ii) How does Powder Injection Moulding (PIM) differ from Powder Metallurgy process?
Describe the process involved in PIM.
(4 marks)

c) Suggest and describe one method of producing sheet or plate glass for windows.
(4 marks)

d) State three reasons why plastic shaping processes are more favourable than other
materials processing.
(3 marks)

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CONFIDENTIAL 4 EM/APR 2008/KJP471/556/MEM560

QUESTION 5

a) Briefly describe plastic extrusion process.

(3 marks)

b) (i) What are the significant differences in the equipment and operating procedures

between injection moulding of thermoplastics and injection moulding of thermosets?

(3 marks)

(ii) List the stages of extrusion blow moulding.

(3 marks)
c) Discuss some of the defects that may occur in plastic injection moulding.
(4 marks)

d) Describe the primary purposes of the matrix and the reinforcement in a composite.
(3 marks)

e) (i) Name two primary production methods of open mould fiber reinforce thermoset
polymer composite and state one product produced from each of these methods.

(2 marks)

(ii) State two advantages of closed mould fiber reinforced polymer composite
processes.
(2 marks)

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QUESTION 6

a) (i) What are the sequence of processing steps required to produce finished rubber
goods?
(3 marks)

(ii) What are some of the additives that are combined with rubber during compounding?
(2 marks)

b) (i) What is an integrated circuit?

(2 marks)

(ii) List the three (3) important semiconductor materials.

(2 marks)

c) What are the three major stages in the production of silicon-based integrated circuits?
(4 marks)

d) In the world of manufacturing, changes and trends are having a significant impact on the
manufacturing processes. Discuss their impacts on their manufacturing processes.
(7 marks)

END OF QUESTION PAPER

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