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UNIVERSITI TUN HUSSEIN ONN MALAYSIA

TEST 1
SEMESTER I (OCTOBER 2014)
SESSION 2014/2015

COURSE NAME

MANUFACTURING TECHNOLOGY

COURSE CODE

BDA 30502

PROGRAMME

BACHELOR OF MECHANICAL ENGINEERING

WITH HONOURS

DURATION

1.5 HOUR ONLY

INSTRUCTION

ANSWER ALL SIX (6) QUESTIONS

STUDENT NAME : ________________________________

STUDENT ID NO : ________________________________
LECTURER NAME : _________________________________
SECTION

: _________________________________

THIS PAPER CONTAINS OF FOUR (4) PAGES

1. List and explain THREE (3) main groups of material removal process and the example
(3 marks)

2. Draw define the location of a SIX (6) element of single-point tool geometry discussed
on class
(6 marks)

..
3. Compare THREE (3) differences between orthogonal and oblique cutting
consideration and its explanation.
(7 marks)

4. Differentiate between up-milling and down-milling using a sketch.

(4 marks)

..
5. In an orthogonal cutting operation, the 6 mm wide tool has a rake angle of 8.The lathe is
set so the chip thickness before the cut is 0.45 mm. After the cut, the deformed chip
thickness is measured to 0.55 mm. Calculate:
(a) the shear plane angle and
(b) the shear strain for the operation.
(5 marks)

6. A face milling operation is performed to finish the top surface of a steel rectangular work
piece 200 mm long by 40 mm wide. The milling cutter has four teeth (cemented carbide
inserts) and a 65 mm diameter. Cutting conditions are: v = 600 m/min, f = 0.25 mm /
tooth, and d = 4.00 mm.
Determine:
(a)
(b)

the time to make one pass across the surface.

the metal removal rate during the cut.

- END OF QUESTIONS
4

(5 marks)

TEST 1
BDA 30502 SEM 2 2014/2015
Q1(a) Manufacturing processes involves processing and assembly operations. List and describe
elements for these two operations.
Processing Operation:
Shaping process
Property enhancing process
Surface processing operations
Assembly Operations
Permanent joining process
Mechanical Fastening
(5 marks)
Q1(b) Sketch an appropriate example of a product that can explain the implementation of design for
manufacture and assembly (DFMA) concept.
Any example that can show the implementation of DFMA in the products
(5 marks)
Q1(c)

Explain the definition of four stages of product life cycles and relate it with sales, cost and profit
with relevant examples.

Explanation that relate to these two figures

(10 marks)

2 a)

What is material removal process? Classify three (3) main types of material removal
processes and their example.
(5 marks)
It is shaping operations, it remove material from a starting workpart so the remaining part
has the desired geometry
(2 marks)
Three main groups:
1) Machining material removal by a sharp cutting tool, e.g., turning, milling, drilling
(1 mark)
2) Abrasive processes material removal by hard, abrasive particles, e.g., grinding
(1 mark)
3) Non-traditional processes - various energy forms other than sharp cutting tool to
remove material, e.g. laser, electron beam, water-jet, edm.
(1 mark)

b)

By the aid of simple sketch, name the three (3) angles required to form a sharp cutting
tool. Briefly explain the purpose of any two of the angles.
(5 marks)

Rake
Cutting
Relief

Rake angle

(1 mark)
Cutting angle (1 mark)
Relief angle
(1 mark)
Purpose of the angle,
Rake angle = to strengthen the cutting edge
Cutting angle = to form the cutting edge
Relief angle = to prevent the bottom surface of the cutting edge from scratching the
surface of the workpiece,
(Any two = 2 marks)

c)

In a cutting operation, it was found that the shear strain is 3.82. If the value of shear angle was
15 calculate:
i)

the value of

angle,

g = tan (f -a) + cot f

3.82 = tan (15 - a) + 3.731
3.82 3.731 = tan (15 - a)
5.1 = (15-a)
a = 9.9 or 10
ii)

(1 mark)

(1 mark)

- (1 mark)

the thickness of chip after the cut, where the thickness of the cut is 0.5 mm.
(5 marks)

sin
cos( )

r = 0.259/ 0.996 =0.26

t
r o
tc
0.26 = 0.5/tc
tc = 1.92 mm

iii)

(3 marks)

- (1 mark)

- (1 mark)
- (1 mark)
- (1 mark)
- (1 mark)

from this cutting operation, if refer to the cutting metal theory, what will happen if
the cutting tool having a positive angle value of 15 compared to the existing
rake angle ?
(2 marks)
1) The strength of the cutting tool edge decrease (1 mark)
2) The cutting tool edge become sharper
(1 mark)