UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

SECOND SEMESTER EXAMINATIONS

MAY 2010

PROGRAMME BEng (Hons) Manufacturing Engineering/

BEng (Hons) Mechanical Engineering

MODULE NAME Manufacturing Processes & Metrology

DATE Monday
03 May 2010 MODULE CODE MECH 3002Y(3)

TIME 9:30 – 12:30 hrs DURATION 3 Hours

NO. OF 6 NO. OF QUESTIONS 6

QUESTIONS SET TO BE ATTEMPTED

INSTRUCTIONS TO CANDIDATES

Answer All questions.

All questions carry equal marks.

ISO Limits and Fits Tables are attached.

 MANUFACTURING PROCESSES AND METROLOGY- MECH 3002Y(3)

Answer all questions.

All questions carry equal marks.

Question 1 - (Total 25 marks)

(a) Explain five (5) main sources of error which can occur during a measurement
process when using a vernier caliper.
[10 marks]

(b) Does a verner caliper obeys ABBE’s rule of alignment? Clearly explain the
answer and support with a proper labeled schematic diagram.
[5 marks]

(c) In a small low speed motorized earth ploughing machine (for land
preparation prior to crop plantation), a small worm disc is powered by an
engine. The shaft of the worm disc rotates in between two ball bearings. Each
ball bearing is located in a fixed bearing housing, and the latter is provided
with a lubricating point. The bearing and shaft assembly has a nominal
diameter of 25 mm, and at regular planned interval of time, the user has to
lubricate the bearing in order to achieve a hydrodynamic fluid regime
condition of the lubricant. Using the ISO fits tables, select the most
appropriate class of fit and calculate the maximum and minimum metal limits
of both the shaft and of the bearing. Explain your answer.

Determine the greatest and least differences in the shaft and bearing
dimensions and comment on the results. [10 marks]

Question 2 - (25 marks)

(a) A student is attempting to compare the surface roughness of the following

two (2) surfaces: a lapped surface (with SiC 500 grits size at a speed of 300
rpm), and an electrodischarge surface (discharge current of 2 A, pulse
duration of 25 µs, pulse off time of 100 µs and mean discharge voltage of 50
V).

(i) List and explain four (4) most appropriate 2D surface roughness
parameters which can be used to differentiate the two surfaces. Justify
the answer. [12 marks]

(ii) Explain what would be the most appropriate cut-off value that the
student should used. Justify the answer. [3 marks]

(b) Explain an appropriate technique for verifying the flatness and parallelism of
a reference grade gauge block. Support the answer with schematic diagrams.
[10 marks]

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 MANUFACTURING PROCESSES AND METROLOGY- MECH 3002Y(3)

Question 3 - (Total 25 marks)

(a) Using three (3) industrial examples, explain the main advantages of using
powder metallurgy as a manufacturing process. [9 marks]

(b) In a sugar cane harvesting machine, there is a basecutter which cuts the cane
stalks at the ground level, and there is a chopper drum which cuts the cane
stalks into smaller pieces (billets).

The basecutter consists of a removable disc which has five (5) metal (stainless
steel 304) blades attached to it. A driving shaft rotates the disc which in turn
spins the 5 blades, thereby cutting the cane stalks at ground level. Each blade
is 95 mm long, 50 mm width and 6 mm thick. Each blade is connected to the
disc by means of a stainless steel 304 bolt and nut system.

The chopper drum consists of a rotating drum on which are mounted three (3)
rectangular blades (1.2 % carbon steel), each of 600 mm long, 75 mm width
and 6 mm thick. When the drum rotates, the rotary movement of the 3 blades
cut the incoming cane stalks into small pieces. Each blade is accurately
positioned and fixed on the drum by means of six (6) screws (stainless steel
304).

(i) With the help of an appropriate methodology, explain the types of

wear problems that can occur at the basecutter/disc and at the chopper
drum. Justify the answer.

(ii) Based on the types of wear problems identified in Question 3(b)(i)

above, propose an appropriate solution for each problem.
[16 marks]

Question 4 - (Total 25 marks)

(a) List five (5) main differences between shell and investment casting methods.
[5 marks]

(b) An engineer is proposing to use conventional sand casting process to produce

a cast iron bearing housing support. The part is of the following outer
dimensions: 450 mm (length) × 300 mm (width) × 150 mm (height).

The engineer is proposing to use a cope and drag assembly box system, and
each box is of the following dimensions: 900 mm (length) × 600 mm (width) ×
300 mm (height). The engineer is planning to design the pouring basin and
the sprue in the cope, while the entire mould cavity for the part will be
designed into the drag part of the mould. The pattern for the part will be laid
down in such a way that its length and width are aligned with the length and
width of the drag box respectively.

[continued next page]

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 MANUFACTURING PROCESSES AND METROLOGY- MECH 3002Y(3)

Question 4 (continued)

The sprue will be designed with a circular cross sectional area, and the sprue
entrance area is assumed to be 1200 mm2. The engineer is using a draft of 2°
for the design of the sprue.

(i) Calculate the pouring basing height,

(ii) If the engineer is using a simple vertical gating system, calculate the
sprue exit diameter and the pouring time to fill the mould cavity.
(iii) If the engineer is using a bottom gating system, calculate the sprue exit
diameter and the pouring time to fill the mould cavity. It may be
assumed that the sprue is connected directly to a short narrow runner
(circular cross section). The exit diameter of the runner, that is, the
mould cavity ingate diameter is taken to be 35 mm.
(iv) Comment on the answers for part (ii) and (iii) above.

State all assumptions made for the computation of the above-

mentioned parameters.
[20 marks]

Question 5 - (Total 25 marks)

(a) (i) Explain the main problem which can occur during an open die forging
process.

(ii) Propose two possible solutions to minimize the problem identified in

Question 5(a)(i) above. Justify the answer.

[7 marks]

(b) Explain the main conditions which govern the selection of either the closed or
open die operation for the forging process. Draw appropriate diagrams to
support the answer.
[10 marks]

(c) Briefly explain the three (3) main cleaning steps prior to a hot dip galvanizing
process.
[8 marks]

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 MANUFACTURING PROCESSES AND METROLOGY- MECH 3002Y(3)

Question 6 - (Total 25 marks)

(a) A student is attempting to investigate the presence of internal cracks in an

aluminium metal sheet of 5 mm thickness.

Explain two (2) appropriate non-hazardous non-destructive tests that the

student can use. Justify the answer.
[8 marks]

(b) (i) Explain the area effect as applied in galvanic corrosion.

(ii) What is the recommended solution to minimize the problem as

identified in Question 6b(i) above.
[7 marks]

(c) Using a Tafel plot, draw and explain a well labeled theoretical polarization
curve for a corrosion test of stainless steel 316 in a saturated solution of
sodium hypochorite at room temperature. Justify the answer.
[10 marks]

END OF QUESTION PAPER

sg/

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