UNIVERSITY OF MAURITIUS

Faculty of Engineering

SPECIAL RETAKE EXAMINATIONS

(August 2016)

PROGRAMME BEng(Hons) Mechanical Engineering

BEng(Hons) Manufacturing Engineering

MODULE NAME Manufacturing Processes and Metrology

DATE Wednesday MODULE CODE MECH 3002Y(3)

31 August 2016

TIME 09:30-12:30 Hrs DURATION 3 Hours

NO. OF 5 NO. OF QUESTIONS TO BE 5

QUESTIONS SET ATTEMPTED

INSTRUCTIONS TO CANDIDATES

Answer ALL Questions.

Table of properties of steel and aluminium alloys (annealed condition) is attached at the end of the
questionnaire.
 MANUFACTURING PROCESSES AND METROLOGY – MECH 3002Y(3)

Answer ALL questions

Question 1 (24 marks)

(a) Explain briefly what is meant by the following terms when applied to a
measuring instrument:

(i) Accuracy;
(ii) Precision.
[1+1 marks]

(b) List 3 disadvantages of material standards. [3 marks]

(c) A wedge shaped job was measured using a sine bar of 250 mm length and the
top edge found to be level when gauge blocks totaling 46.376 mm were placed
under one of the rollers. What is the angle of the wedge?
[2.5 marks]

(d) Show for a sine bar, that the error of angular setting, , arising from errors of the
dimension (distance between the two roller centres) and h (height of gauge
blocks), is given by:

∆ ( )= ∆ℎ − ∆

[3 marks]

(e) (i) A length bar of 500mm length is used in horizontal position. Draw suitable
explanatory diagrams to show the effect of support distances in the following
cases:
1. If the supports are too close together;
2. If the supports are too far apart;
3. If the supports are at Airy points.

(ii) By considering Airy points, calculate the position of the two supports from
the ends of a horizontal bar of uniform section of 900mm length.

[6+2.5 marks]

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…/Continued next page

Question 1 (Continued)

(f) Figure 1 shows a vernier caliper. Determine the accuracy and calculate the
reading.

[5
marks]

Figure 1: Vernier Caliper

Question 2 (15 marks)

(a) A rectilinear pen recording of a diamond turned surface is shown in Figure 2.

The sampling length (L) used was 0.8mm and the Vertical/Horizontal
magnification ratio was 5000/100.

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 MANUFACTURING PROCESSES AND METROLOGY – MECH 3002Y(3)

Figure 2: Pen recording for Question 2

…/Continued next page

Question 2 (Continued)

Calculate the Ra value if the areas (in square millimetres) above and below the mean
line are as follows:

Table 1

A B C D E
74 129 110 106 123

[4 marks]

(b) The external diameter of the shaft shown in Figure 3 is to be checked by the help
of a Go, Not Go snap gauge. Design the gauge, sketch it and show its Go size and
Not go size dimensions. Assume a 5% wear allowance and a 10% gauge maker’s
tolerance. Explain your workings.
[11 marks]

Figure 3: External diameter to be qualified

(Dimension in inches)

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 MANUFACTURING PROCESSES AND METROLOGY – MECH 3002Y(3)

Question 3 (17 marks)

(a) Figure 4 shows a schematic representation of the basic bulk deformation process
rolling. On separate diagrams, indicate the region of the workpiece undergoing
grain transformation in:

(i) Hot rolling;

(ii) Cold rolling.
[2+2 marks]

Figure 4

(b) Deformation of fully annealed AA-1100 aluminium is governed by the Hollomon

equation. If a 10 cm long bar of this material is pulled in tension from a diameter
of 12.7 mm to a diameter of 11.5 mm, calculate the following:

(i) The ideal work per unit volume of aluminium required ;

(ii) The mean stress in the aluminium during deformation;
(iii) The peak stress applied to the aluminium.
[9+2+2 marks]

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 MANUFACTURING PROCESSES AND METROLOGY – MECH 3002Y(3)

Question 4 (24 marks)

(a) List the eight key elements of a Tribosystem. [4 marks]

(b) Explain the following lubrication regimes:

(i) Boundary lubrication;
(ii) Mixed lubrication;
(iii) Fluid film lubrication.
[2+2+2 marks]

(c) Explain a test method to determine the consistency of lubricating grease.

[3 marks]

(d) Many items of plant such as compressors and generators are powered by diesel
engines. Give three (3) pivotal roles of lubricating oils in these engines.
[3 marks]

(e) Outline two (2) main methods that can be used to minimise the following wear
problems:
(i) Corrosive wear;
(ii) Fatigue wear.
[2+2 marks]

(f) Explain why joining materials well apart in the galvanic series by threaded
connections are not recommended. Suggest two (2) alternative joining methods.

[4 marks]

Question 5 (20 marks)

(a) Using Bernoulli’s equation, derive an expression for the velocity of the liquid
metal at the base of a mold sprue as a function of the height of the sprue.
[6.5 marks]

(b) A mold sprue is 20 cm long, and the cross-sectional area at its base is 2.5 cm2. The
sprue feeds a horizontal runner leading into a mold cavity whose volume is 1560
cm3. Determine:
…/continued next page

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Question 5 (Continued)

(i) velocity of the molten metal at the base of the sprue;

(ii) volume rate of flow;
(iii) time to fill the mold.
[1+2+2 marks]

(c) A sand core has a volume equal to 1875 cm3 and is located inside a sand mold
cavity. Determine the buoyancy force tending to lift the core during pouring of
molten lead into the mold. The density of the sand core is 1.6 g/cm3 and the
density of lead is 11.3 g/cm3.
[3.5 marks]

(d) Outline one (1) advantage and one (1) disadvantage of the Vacuum Molding
process.
[2 marks]

(e) Explain the purpose of the following ingredients added to the metallic powders
during the blending and/or mixing step in Powder Metallurgy.
(i) Lubricants
(ii) Binders
(iii) Deflocculants

[3 marks]

END OF QUESTION PAPER

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