University of Mauritius

UNIVERSITY OF MAURITIUS
Faculty of Engineering
SECOND SEMESTER EXAMINATIONS
(May 2016)
PROGRAMME BEng (Hons) Mechanical Engineering

BEng (Hons) Manufacturing Engineering
MODULE NAME Manufacturing Processes and Metrology

(NORMAL + SPECIAL PAPER)
DATE Thursday MODULE CODE MECH 3002Y(3)

19 May 2016
TIME 09:30 – 12:30 hrs DURATION 3 Hours
NO. OF 5 NO. OF QUESTIONS TO 5

QUESTIONS SET BE ATTEMPTED
INSTRUCTIONS TO CANDIDATES
Answer ALL questions.
Table of properties of steel and aluminium alloys (annealed condition) is attached at the
end of the questionnaire.
MANUFACTURING PROCESSES AND METROLOGY – MECH 3002Y(3)
Answer all questions
Question 1 [20 marks]
(a) Give two (2) advantages of keeping gold plug line at neutral axis in the Imperial
Standard Yard.
[2 marks]
(b) Explain with the help of a figure the occurrence of cosine error in measuring the
length of any part with a scale.
[2 marks]
(c) Sir G.B. Airy was able to show that supporting a bar at two critical points gives a
condition for which the ends of the bar remain horizontal. With point O as the
origin of the x and y axes, the equation of portion AB of the bar shown in Figure
1 is given by = × [4 − +4 ( −3 ) + ( − ) ], where W is the
weight per unit length, E is Young’s modulus and I is the second moment of
area. Derive an expression for airy point, a, in terms of .
Figure 1: Bar to be supported
[5 marks]
(d) Figure 2 shows a vernier protractor with each graduation on the main scale
representing one degree and the vernier scale graduated in minutes. The
coinciding division on the vernier scale and the main scale is shown by an arrow.
Determine the accuracy and calculate the reading.
[5 marks]
1
Question 1 (Continued)
Figure 2: Vernier Protractor
(e) Describe briefly with the help of diagrams how an autocollimator is used in the
following situations:
(i) To check for straightness of movement

(ii) To check the angle of workpieces
[3+3 marks]
Question 2 – [15 marks]

(a) Define the following surface roughness parameters: Rt and Rz. Explain the
limitation of Rt in providing meaningful results compared to Rz.
[4 marks]
(b) The internal diameter shown in Figure 3 is to be checked by the help of a Go, Not
Go plug gauge. Design the gauge, sketch it and show its Go size and Not go size
dimensions. Assume a 5% wear allowance and a 10% gauge maker’s tolerance.
Explain your workings.
[11 marks]
Figure 3: Internal Diameter to be qualified

(Dimension in millimetres)
2
(a) Figure 4 shows the true stress-strain curve of a material subjected to a

deformation process, illustrating energy per unit volume, u, as area below curve.
σtm is the mean true stress for deformation to ε1. Derive an expression for the
mean true flow stress as a function of the total strain.
Figure 4: Stress-Strain curve [4 marks]
(b) A billet of fully annealed AA-1100 aluminium 25 mm diameter x 24 mm long is

compressed by an open die forging process to a length of 19 mm. Find the
frictionless workdone in deforming the material.
[8 marks]
(c) Outline two (2) techniques to control the inside diameter and finish when
drawing tubular materials.
[2 marks]
(d) In automotive applications, friction plays a distinct role. Describe two situations
where moderate to high friction is necessary for safe operation of a vehicle. In
your answer give one (1) situation where moderate friction is needed and one (1)
situation where high friction is needed.
[3+3 marks]
(e) Outline two (2) techniques of wear particle analysis. Explain one (1) main test
which can be carried out under each category.
[2+6 marks]
3
(a) A well water copper piping system failed because of pitting corrosion. The water
had a pH of 7.0 to 7.7, and pitting was caused by dissolved carbon dioxide.
During failure analysis, researchers noticed that corrosion attack also occurred
where a new replacement copper pipe section was joined into a copper pipe
section that was in service for several years. The two pieces of copper were of the
same designation, C1100, which is electrolytic tough pitch (ETP) copper
(99.95Cu-0.04O). The replacement pipe was only in service for about two months
before significant galvanic corrosion occurred. The old section had a passive film
and a noble electrochemical potential. The new section had an active potential
surface not yet protected by an oxide film. Explain three (3) measures to prevent
galvanic corrosion when a new pipe section has to be joined to an old pipe
section in the system described above.
[3x2 marks]
(b) Figure 5 shows the anodic and cathodic polarization curves of iron in H2SO4.
Illustrate the effect of an anodic inhibitor on the corrosion current i1 and
corrosion potential E1.
[3 marks]
Figure 5: Polarization curves of iron in H2SO4
4
Question 4 (Continued)
(c) Electroplating can coat electrically conductive textile materials with a layer of metal
particles by means of electrical current. It produces a thick, stiff and heavy coat of
metal on textiles. Metals like cadmium, chromium, copper, gold, iron, nickel, silver
and zinc can be plated on fabric surfaces with this technology.
(i) Illustrate using a labelled diagram how the electrolytic process for
decorative buttons is performed in an electrolytic cell.
[3 marks]
(ii) Explain two (2) problems with electroplated coatings.
[2x2 marks]
Question 5 – [21 marks]
(a) Describe using self-explanatory diagrams the location of the choke in a

pressurized gating system and an unpressurized gating system. [5 marks]
(b) A foundry is producing grey-iron blocks of dimensions of 300 mm x 150 mm x

100 mm. The parting line is at the midpoint of the height of the block so that
there the mould cavity extends 50 mm into both the cope and the drag. The flasks
are of dimensions 450 mm x 250 mm x 120 mm, so the combined height of the
cope and drag is 240 mm. The mould is poured with molten grey-iron which
weighs 0.0597 N/cm3 and the compacted sand weighs 0.0157 N/cm3. What
would be the net lifting force in Newtons tending to separate the cope from the
drag as a result of the metallostatic pressure within the mould? [7 marks]
(c) Describe briefly two (2) Non-destructive test methods used to detect internal
defects of a casting. [2x2 marks]
(d) How is the technique used in Vacuum Permanent-Mold Casting different from
that used in Low-Pressure Casting? Give one benefit of the vacuum technique
over low-pressure casting.
[3 marks]
(e) Give two (2) reasons why Powder Metallurgy Technology is so well suited to the
production of gears and bearings. [2 marks]
END OF QUESTION PAPER
5

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UNIVERSITY OF MAURITIUS

SECOND SEMESTER EXAMINATIONS

PROGRAMME BEng (Hons) Mechanical Engineering

MODULE NAME Manufacturing Processes and Metrology

DATE Thursday MODULE CODE MECH 3002Y(3)

TIME 09:30 – 12:30 hrs DURATION 3 Hours

NO. OF 5 NO. OF QUESTIONS TO 5

Answer ALL questions.

Answer all questions

Question 1 [20 marks]

Figure 1: Bar to be supported

Figure 2: Vernier Protractor

(i) To check for straightness of movement

Question 2 – [15 marks]

Figure 3: Internal Diameter to be qualified

Question 3 [28 marks]

(a) Figure 4 shows the true stress-strain curve of a material subjected to a

Figure 4: Stress-Strain curve [4 marks]

(b) A billet of fully annealed AA-1100 aluminium 25 mm diameter x 24 mm long is

Question 4 [16 marks]

Figure 5: Polarization curves of iron in H2SO4

Question 5 – [21 marks]

(a) Describe using self-explanatory diagrams the location of the choke in a

(b) A foundry is producing grey-iron blocks of dimensions of 300 mm x 150 mm x

END OF QUESTION PAPER

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