ME4261/ME4261E

NATIONAL UNIVERSITY OF SINGAPORE

ME4261/ME4261E TOOL ENGINEERING

(Semester II : AY2009/2010)

Time Allowed : 2 Hours

INSTRUCTIONS TO CANDIDATES:

1. This examination paper contains FOUR (4) questions and comprises SIX (6) printed
pages.

2. Answer all FOUR (4) questions.

3. All questions carry equal marks.

4. This is an OPEN-BOOK EXAMINATION.

 PAGE 2 ME4261/ME4261E

QUESTION 1

(a) Clearly state if the following statements are true or false. Give the correct answer if it
is found to be false.

(i) Equalizing support is used to locate irregular surfaces.

(ii) Fool proofing pin can be used to locate the workpiece so that both improper
loading and accurate location can be achieved.

(iii) In a fixture, two clamping forces cannot act opposite to each other.

(iv) In a 4-2-1 locating scheme all pins must be fixed except one pin on the
primary datum plane.

(v) Long locators with proper relief must be provided to avoid improper location.

(vi) During mass production screw clamps can be used to clamp and secure a
workpiece.

(vii) The indexing plate is fixed in relation to the position of the part being indexed.

(viii) Spring locating pins can be used to locate workpiece with loose tolerance.

(ix) The v-locator can be positioned such that its axis is parallel to that of the drill
bush.

(x) For large volume production, plate clamps can be used to locate more than two
workpieces simultaneously.

(18 marks)
 PAGE 3 ME4261/ME4261E

(b) An aluminum die cast workpiece is to be accurately located for machining the top
surface. The designer chooses to locate using a double V-block. Discuss on the
locating arrangements shown in Figure 1, and suggest improvements if any, with neat
sketches.

(7 marks)

Figure 1
 PAGE 4 ME4261/ME4261E

QUESTION 2

A batch of 100 pieces of a part to be machined is given in Figure 2.

Using neat sketches propose jig(s)/fixture(s) to machine the following:

Operation 1: To machine a hole of diameter 88 mm using a lathe

Operation 2: To machine surface I using a vertical machining centre.

All dimensions are in mm. All other operations are completed and assume the missing
dimensions. In your proposed solution clearly indicate the supporting, locating and clamping
methods.
(25 marks)
PAGE 5 ME4261/ME4261E

88

Figure 2
 PAGE 6 ME4261/ME4261E

QUESTION 3

For rough grinding of a large batch of hardened steel (Knoop hardness 1100) workpieces,

(a) select a grinding wheel for the grinding process and show the 5 elements of the wheel
specification;
(5 marks)

(b) justify your selection for each of the 5 elements;

(5 marks)

(c) describe how the wheel should be prepared for the grinding process, explain why the
wheel should be prepared in that ways, and describe the working mechanisms of the
methods.
(15 marks)

QUESTION 4

Design a single-point tungsten carbide cutting tool for rough turning of a steel workpiece
( u = 1.1 10 9 N/m2). If the workpiece diameter is D = 160 mm, the feed rate is f = 0.15
mm/rev, the tool cutting edge is set 5 mm below the workpiece turning axis, and tool
orientation setting angles G = +15 , H = 0 and L = 0 ,

(a) show the cutting elements of the tool ;

(5 marks)

(b) determine the optimum values for the tool angles n , n , , s and e in tool-in-
hand system, assuming that the difference between the orthogonal angles o , o and
the normal angles n , n can be ignored.
(20 marks)
3 2
(Note: 1 psi = 6.89410 N/m )

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