UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

FIRST SEMESTER EXAMINATIONS

NOVEMBER/DECEMBER 2014

PROGRAMME BEng (Hons) Manufacturing Engineering

BEng (Hons) Mechanical Engineering

MODULE NAME Manufacturing Processes & Metrology (Special Paper)

DATE Tuesday MODULE CODE MECH 3002Y

9 December 2014

TIME 09.30 – 12.30 Hrs DURATION 3 hours

NO. OF 5 NO. OF QUESTIONS 5

QUESTIONS SET TO BE ATTEMPTED

INSTRUCTIONS TO CANDIDATES

Answer ALL questions.

 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y

Answer ALL questions

Question 1 (Total 10 marks)

(a) Explain with justifications the most important aspect of a vernier height gauge
with respect to a measurement process.
[4 marks]
(b) Define the following terms as applied to a micrometer, and explain their
respective practical occurrences: periodic and progressive errors.
[6 marks]

Question 2 (Total 25 marks)

(a) Sketch and explain a proper Abbot Firestone curve for each of the two processes: a
die sink EDM and a lapping process. Also discuss the engineering functionality of
the curves.
[12 marks]
(b) Based on the answer of part (a) above, explain what would be an appropriate
skewness value (or range) for each of the two processes.
[3 marks]
(c) Clearly explain, with the help of an appropriate schematic diagram, how a laser
interferometer system can be used to measure the length of a gauge block of 100
mm.
[10 marks]

Question 3 (Total 20 marks)

(a) An engineer is proposing to forge a 0.45 % solid carbon steel cylindrical rod
(Dimensions: 25 mm diameter and 300 mm length) into a solid ‘T’ shape
structure. The ‘T’ shape structure will have the dimensions as shown in Figure A.
All dimensions are in millimeters.

Explain in details, and by using any appropriate calculation(s) how the engineer
will proceed to obtain the forged ‘T’ shape structure. The answer should include
the justification(s) of the chosen process, and the main steps of the procedure for
the actual operation, and any assumptions (Note:  represents diameter).
[10 marks]
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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y

(Question 3 continued)

1 = 60 2 = 25

t1 t2 = 150

Figure A: ‘T’ shape forged part with all dimensions in mm.

(b) A rectangular sand mould of size 800 mm (length) × 600 mm (width) × 450 mm
(height) is to be filled with a molten magnesium alloy.

The height of the pouring basin is 100 mm, and the sprue height is 550 mm. The
molten magnesium is expected to have a laminar flow when flowing through the
ingate (from the sprue to the mould cavity), with a velocity of 20 mm/s.

Calculate the mould filling time for the bottom gating system. Assume the
following: acceleration due to gravity to be 10 m/s2, density of magnesium alloy =
1800 kg/m3, dynamic viscosity of liquid magnesium = 1.23 mPa.s. State any
assumptions.
[10 marks]

Question 4 (Total 25 marks)

(a) A maintenance engineer has to inspect a rectangular plate of aluminium alloy

(Dimensions: 25 mm thickness × 100 mm width × 150 mm length) using a non
destructive technique. It is assumed that no equipment based on sound wave
energy technology is available, and that the inspection has to be done quickly
during normal office hours with other employees working in close vicinity.
Assume the following values for the Aluminium alloy: density = 2800 kg/m3;
electrical conductivity = 40 % IACS (2.32 × 10 7 S/m); permeability constant =
4×10 -7 Hm-1.

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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y

(Question 4 continued)

(i) Explain with justification(s) one most appropriate non destructive

technique which can be used to detect both surface and sub-surface flaws.

(ii) If the engineer believed that any flaws would only occur within a
maximum depth of 2 mm beneath the surface, determine the value of the
important parameter of the chosen technique that would need to be
defined in order to meet the expected detection range of the method.

(iii) If the engineer has to also inspect a 0.85 % carbon steel plate (of the same
dimensions as the aluminium plate), discuss on the efficiency and
reliability of the same chosen method of part (i) above in inspecting for any
surface and sub-surface flaws.
[15 marks]

(b) Clearly explain four (4) main reasons why some components can best be
manufactured by the Powder Metallurgy (PM) method. For each main reason,
support the answer with an example of a component manufactured by PM, and
explain its application.
[10 marks]

Question 5 (Total 20 marks)

(a) Explain with a practical example, the ‘area effect’ as applied in galvanic corrosion.
[6 marks]

(b) Explain with justification the main type(s) of wear problem (including the wear
mechanism) that is likely to occur in the following cases:

(i) A chemical dosing pump is use to inject a small volume of sodium

hypochlorite solution at regular interval of time to a mixing tank. The
impeller (stainless steel 304) of the pump is firmly secured in position onto
the pump shaft by means of two (2) countersunk bolts. The shaft and the
bolts are all made of the same material as the impeller.

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 MANUFACTURING PROCESSES & METROLOGY – MECH 3002Y

Question 5 continued

(ii) A surface crack was observed on a mill roller (0.19 % C steel) of 300 mm
external diameter, which is used in a paper mill industry. The crack was
repaired by welding, and the resulting out of roundness of the shaft on
which the roller is press fit is 100 µm. The mill roller normally operates at a
speed of 550 rpm.

For each wear problem highlighted, propose a meaningful solution to mitigate

the problem. Justify your answer.
[9+5=14 marks]

END OF QUESTION PAPER

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