EM/JAN 2012/MEM561/KJP516/470

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UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE

MANUFACTURING PROCESSES ll/MANUFACTURING

TECHNOLOGY/PRODUCTION TECHNOLOGY

COURSE CODE

MEM561/KJP516/470

EXAMINATION

JANUARY 2012

TIME

3 HOURS

INSTRUCTIONS TO CANDIDATES
1.

This question paper consists of seven (7) questions.

2.

Answer six (6) questions in the Answer Booklet. Start each answer on a new page.

3.

Do not bring any material into the examination room unless permission is given by the
invigilator.

4.

Please check to make sure that this examination pack consists of:
i)
ii)

the Question Paper

an Answer Booklet - provided by the Faculty

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of 4 printed pages
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EM/JAN 2012/MEM 561/KJP516/470

QUESTION 1
a)

How product manufacturers may use the strategic advantages of Cost - Time - Quality
to successfully compete in global world market?
(3 marks)

b)

Explain five (5) factors, which need to be considered in selecting different

manufacturing processes to fabricate a product.
(5 marks)

c)

From your point of view, why the manufacturing activities are very important for
economic development of a country?
(2 marks)

QUESTION 2
a)

Why measurement and metrology are very essential in manufacturing industries?

(2 marks)

b)

What is tolerance? State three (3) factors need to be considered in specifying

tolerance of a product designed.
(2 marks)

c)

Consider that you have a dial indicator which can be used in product measurement.
Differentiate the use of the dial indicator combined with other measurement
accessories in measuring straightness, roundness and angle (angular
measurement) of a product separately.
(6 marks)

QUESTION 3
a)

As a newly hired manufacturing engineer, you found out that in a lathe machine a high
frequency noise and serrated chips were produced. Apart from those occurrences,
cutting tool wear very fast and work piece is not meeting the dimensional accuracy:
i)

Name the occurring problem.

ii)

Suggest three (3) appropriate actions to overcome the problem.

(4 marks)

b)

For a turning process, calculate the suitable cutting speed if the tool life is one (1) hour
using the values of constant n = 0.25 and C = 300 m/min. What is the effect of
increasing the feed rate on tool life?
(3 marks)

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c)

EM/JAN 2012/MEM561/KJP516/470

Crater wear is a type of tool wear that normally occurs during metal cutting. What is
'crater wear'? Explain briefly how crater wear forms? How can crater wear be
minimized?
(4 marks)

QUESTION 4
Non-Traditional Machining (NTM) processes were initially used for aerospace applications. It
is a group of processes that utilise mechanical, thermal, electrical, chemical or the
combinations of those energies to remove the unwanted materials from the workpiece.
a)

NTM processes are not that popular compared to traditional machining processes.
Discuss four disadvantages of NTM.
(2 marks)

b)

If you are asked to produce a deep cavity on a mould from tool steel for injection
moulding process, select and describe a suitable process by giving its basic principles.
Use sketches, charts, etc. to substantiate your arguments.
(5 marks)

c)

Turbine blade can be produced using NTM such as Electro Chemical machining (ECM)
which consists of tool and electrolyte. Specify suitable properties of tool material and
the functions of electrolyte.
(3 marks)

QUESTION 5
a)

Describe briefly four (4) general factors which must be considered in the selection of
the machining centre so that it is an economical investment.
(2 marks)

b)

Discuss at least two (2) measures to reduce the total machining cost.
(4 marks)

c)

In a NC milling machine which operates with open loop control system, you found out
that the dimensional error was too high. All attempts to reduce the error were
unsuccessful. The management asked you to propose a measure to overcome this
problem. Purchasing a new machine is not an alternative. What is your suggestion and
explain briefly on the advantages and devices to be added.
(4 marks)

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EM/JAN 2012/MEM561/KJP516/470

QUESTION 6
a)

Shielded Metal Arc Welding (SMAW) is one of the fusion welding types which is still
used especially for steel construction and oil and gas industry. Explain the designation
of the electrode. What are three (3) limitation of SMAW and three (3) functions of
electrode coating?
(5 marks)

b)

If you are asked to weld butt joint of two plates with thickness of 5 mm made of
Aluminum, which welding process are you going to propose? The welding process
must be a solid state welding. Use schematic illustration to support your answer.
(3 marks)

c)

Describe briefly Resistance Seam Welding process.

(2 marks)

QUESTION 7
a)

Example of surface treatment categories are surface cleaning, surface hardening,

coating and painting. Explain four (4) purposes of surface treatment.
(2 marks)

b)

State four (4) examples of products which apply surface coating technology as an
alternative of product surface treatments.
(2 marks)

c)

You are asked to outline the surface coating processes; consider your explanation by
comparing or contrasting between the Physical Vapor Deposition and Chemical Vapor
Deposition technology in terms of the process principle, coating materials, and
substrate materials to be coated.
(6 marks)

END OF QUESTION PAPER

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