MENG

4239: Advanced Manufacturing

Processes

Dr. Mohamed Serry

Assistant Professor
Department of Mechanical Engineering
The American University in Cairo
Midterm I Review Ques@ons
Spring 2015
The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

1- Discuss the different sources of energy used in
Manufacturing Processes, give examples.
2- Discuss the need for Nontraditional Manufacturing
Processes.
3- Nonabrasive operations are classified into _____ and
____ machining.
4- (T/F) Tool life is longer in continuous machining
processes

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

5- (T/F) Milling is multi-point, continuous-cutting
process
6- How is the feed rate expressed in the following
processes: Turning, Milling, Drilling
7- Manufacturing can be defined as the application of
physical and chemical processes to alter the geometry,
properties, or appearance of a given material
- Give one example to demonstrate the above
- How can this explained in light of the Economic
definition of manufacturing
The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

8- Whats the main purpose of Machining Processes?
9- Discuss the basic functions of a machine tool
10- When is continuous and discontinuous chips are
formed? Give material examples.
11- What are the turning process parameters? Discuss
why is it sometimes useful to fix a cutting inserts on a
tool flank?

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

90

70 mm = D
1

L= 70 mm

D 2 = 40 mm

13- Calculate the required compound wrist inclination

angle to achieve the above shape.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

14- What are the key factors in determining roughness
in machining processes?
15- How can you control geometric parameters to
enhance surface finish?
16- Discuss how can you adjust the machining
parameters to reduce machine vibrations?
17- Discuss how speed, feed and depth of cut are
selected in a roughing and finishing processes

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 1: Intro & TradiOonal Processes

18- Develop a process plan for the part shown below:

All surfaces are except as indicated

Raw material is 60 x 70.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Process Plan
1- Rough Turning 70mm 54.25 mm
2- Rough Turning 54.25 mm 44.25 mm
3- Facing (Surface A)
4- Finish Turning 44.25 44 mm (Surface B)
5- Drilling 20 mm
6- Boring 20 mm 25.75 mm
7- Reaming 25.75 mm 26 mm (Surface D)
8- Finish Turning, 54.25 mm 54 mm (Surface C)
9, 10- ParOng-o, Facing (Surface E)
11- Chamfering

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 2: AutomaOon
23- Can you give an example of an automated system,
which contains a control system as a part of it? What
are the other parts of the system?
24- State the basic profit function and then discuss
how can you increase profit by employing Automation.
25- Give examples of how production time can be
reduced by utilizing Automation.
26- How can Closed Loop control systems used to
accelerate/decelerate the action?
The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Module 2: AutomaOon
27- Give an example of analog temperature sensor.
28- How is precision motion is achieved in CNC
machines?

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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Module 2: AutomaOon
29 - Explain the Part Program segment given below.
Draw the trajectory of table motion that this program
seeks to create:

N0010G90;
N0011G01X1Y2;
N0012G01X2Y2;
N0013G91;
N0014G01X1;
N0015G91X2Y2;
N0016G01X1Y1;
N0017G92X0Y0Z0;
The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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30 Write the part program to machine the part shown.

Use absolute positioning. Use the lower left corner of
the part as the origin in the x-y axis system. 7-mm drill
is at tool position T04. 10-mm End mill is at position
T03.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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31 Write the part program to machine the part shown.

Use absolute positioning. Use the lower left corner of
the part as the origin in the x-y axis system. 10-mm End
mill is at position T03. Part thickness is 10 mm.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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32 Write the part program to machine the part shown.

Use absolute positioning. Use the lower left corner of
the part as the origin in the x-y axis system. 10-mm End
mill is at position T03. Part thickness is 10 mm.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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33 Write the part program to drill the through holes in

the part shown. Use absolute positioning. Use the
lower left corner of the part as the origin in the x-y axis
system. 10-mm drill is at tool position T04. Part
thickness is 12 mm.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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34- A DC servomotor is used to drive one of the table axes of

an NC milling machine. The motor coupled directly to the
leadscrew for the axis, and the leadscrew pitch = 5 mm. The
opDcal encoder aEached to the leadscrew emits 360 pulses
per revoluDon of the leadscrew. The motor rotates at a
maximum speed of 300 rev/min. Determine:
(a) BLU
(b) Frequency of the pulse train emiMed by the op@cal encoder
when the servomotor operates at full speed, and,
(c) Maximum travel rate of the table.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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35 The shown pulse train is generated by optical

encoder feedback sensor. Determine the worktable
position and velocity.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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36- Why is closed loop control required for continuous

axes and not for PTP axes?
37- What sort of sensors and controllers would you
recommend for continuous axis control?

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

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