ME 383 Exam 2
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8/19/2019 ME 383 Exam 2
1/9
ME 383,
EXAM
2
Exam
2
ME
383- Modern
Manufacturing
Process
Thursday
October
23'd,
2Ol4
8:00
-
9:15
AM
Open
Notes/Textbook
Calculators
allowed
Section
1:
5
pts
each
1.
Of
the
following,
which
products
@|be
manufactured
using
powder metallurgy?
G)s"."*,
(c)
Cutting
tools
2. In metal
forming
process,
what
kind
of deformation
results
in change
of shape
of the
work
piece?
(b)
Stress
$
ltu.ti.
(a)
Elastic
(c)
Yield
(a)
Single
point
(c)
Drill bit
(b)
Gears
(d)
Sprockets
(b)
Flat rolling
(d)
Forging
ffi*uo"
ru".
3. Deformation
process
in
which
a
thick-walled
ring
of
smaller
diameter
is rolled
into
a
thin-walled
ring
of larger
diameter
is called?
(a)
Thread
rolling
@
ning
rolling
4. The
face of a single
point
tool
that
constantly
comes
in contact
with
the
metal chip
during
machining
is
calledi
(a)
Flank
(c)
Chip
(d)
Relief
5. The
machine
tool used
in drilling
is an example
of
what kind
of tool?
$
uutti
point
(d)
Milling cutter
-/'-/----\
/
Page
1
of 10
SSSSSSSSSSSSSSSSSSSSSSSSSSS
SSSSSSSSSSSSSSSSSSSSSSSSSSS
SSSSSSSSSSSSSSSSSSSSSSSSSSS
SSSSSSSSSSSSSSSSSSSSSSSSSS
SSSSSSSSSSSSSSSSSSSSSSSSSS
SSSSSSSSSSSSSSSSSSSSSSSSSS
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8/19/2019 ME 383 Exam 2
2/9
ME 383, EXAM
2
6. Each ligures below
represent
a
manufacturing
process,
identify
the manufacturing
process
based on the figures.
Scrap
igure
{a}
Figure
ib)
\;/
F
Figure
1a;,
fl*ti,{
irirr
rr
Figure
fnl,
8lr,^Li&
8. Milling operation in which the cutting axis
is
perpendicular
to
machined
surface is called
(a)
Slab milling
(c)
Form milling
(b)
Peripheral milling
LDEace
milling
Page
2 of 10
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8/19/2019 ME 383 Exam 2
3/9
9.
Identiff
the
three
regions in the
plot
shown below
(a)
Neutral
(c)
Negative
6)poritiu"
Vr
r"rodegree
ME
383, EXAM
2
3
{
o
3
g
a
E
P
Time of cutting
(min
Region
d,,
B
rpa|'
i,, tr. i*
i
Region n,
J*,rn
lu,
-
-fr,f*"1t,
*trtr
,fl&
il
n
.
\|
Region
c,
i
r:tl,
,p
tlt|iln
10.
What
kind
of
rake
angle
results in
a
sharper and
pointed
cutting
edge
in a
single
point
tool?
11, High
precision
screw
threads are
manufactured
by
(a)
CNC
tuming
Q;
uitti"g
(d)
Metal deformation
(d)
Drilling
Accelerating
wear rate
SEE
NEXT
PAGE
Page 3 of 10
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8/19/2019 ME 383 Exam 2
4/9
\
ME
383,
EXAM 2
Section
2:
Solve
or answer brieflv
with
vour
iustification
(10
ots
eachl
1. A
part
with
various
geometrical
features shown
in
figure below is to be manufactured
out of a
cylindrical
steel
rod. If
you're
a
manufacturing
engineer,
please
suggest
(i)
What
kind of machine center
would
you
use
to
produce
the
final
part
shown
below?
(Hint:
all
of the
machining
should be done on ane single machine)
(ii)
Write
the
different
machining
processes
that needs to be done on the
initial
workpiece to
obtain
the
final
part.
(Hint:
calculate the initial
workpiece
length and
jinal
part
length
to
Jind
one of lhe hidden machining operation)
(ol:
5
cm
Dep:1cm)
l-:
5
cm,
D:
4
cm
:4cm,
D: 3 cm
/r
Through
hcle
{D
:
0.5
cm}
Blind hole
{D
: 1- crn, Dep : 2 crn}
1,,
lL.n"
Leneth
(L),
Diumeter
(Dt,
Depth
(Deol
$lot
Page 4
of
10
-
8/19/2019 ME 383 Exam 2
5/9
,r)rrr,
EXAM 2
Answer:
(i)
(ii)
Machiningc"n,.r,
t',ill
-
fi.t"n
Machining
processes
:
t)
ku,.fi
t(Lcn
I
J,6nrtt*
U
^;lt
flo.
$
l,;ti
],olo
it'
#,,r
f
I
2. Draw a neat
sketch of
metal rolling
process.
(all
the
different
parts
need
to be
mentioned
in
your
sketch)
Page
5 of 10
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8/19/2019 ME 383 Exam 2
6/9
What
are
the
differences
between-
(a)
Boring
and
Turning
(b)
Peripheral
and
Face
Milling
(Include
a
line
diagram)
ME 383,
EXAM
2
:
fi,,
F-f
Jil;..
i
r
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f
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r. t .' .iii
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{'i"'"l
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i,
,
)
fl,o,iy
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nilg
i;
,'*{t,**Y:
F,:
ll,e
131,r;J'3"
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fi
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ar
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.
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ti
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.&*
t-o
t&r
)q€
b,,,J
n,;llr;
r^J
u^J
ei.+;,ior
tr
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irr'y
firc{}'dn
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itr
c{
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iltijf n
J=Str
'*l'ie'i
pfrrc
Page
6 of
10
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8/19/2019 ME 383 Exam 2
7/9
ME 383, EXAM
2
4.In a
machining operation
that
approximates
orthogonal
cutting,
the cutting
tool
has a
rake angle of
450.
The
chip thickness
before
cut
to
is
1
cm
and after cut
the chip thickness
is tc
is 20
mm. Calculate
the shear
plane
angle
and shear strain
in
the operation.
*,,
i,
iL
J
{
*1'
;,
..
"..,
,r,-:
{'
n,
-
rl
ai"
t
-t.
'l
t'i{t,
t^ 4
,
z
ll C
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1 7l
li 1'',v'
{.,
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t ll, I
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Ur,
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yln,{
*g{r; t,,;
C'
c,5
t,,
{Ll*}
I"
t
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r-t
t
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l- .
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,,f
:
]tJ5ll
1.,,.i
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'r
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7
7i
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TO
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==*
Page 7
of
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8/19/2019 ME 383 Exam 2
8/9
ME 383,
EXAM
2
5.
A
customer
approaches
you to
manufacture
1000 bolts.
To
machine
qbo 1, the
following
calculations/parameters
were
noted.
Parameters
Time
(sec)
Cost
($)
Part
handline
30
(Tn)
0.50
(c")
Machining
300
(T,")
2.00
(c")
Tool
change/l0
parts 45
(Tr)
0.50
(c")
Toolins/10
parts
0.75
(@)
{',
,
j
np:
10
(no
of
purts machined
in
one
tool
life)
Maximum
production
Rate:
Tc:
Tn*
T-*
Ttlnp
Minimum
Cost
per
Unit:
C.= CoTn*
CoTm*
CoTt/np+Ctlnp
The
above
machining
economic
formulas
allow
the
optimal
cutting
speed
to
be
calculated
for
this
machining
process.
Scenario
1: Suppose
if
the
customer
needs
1000
bolts
to be
manufuctured
in two
days and
if cost
is not
a big
factor,
what
machining
economic
formula
would
you
use?
Show
the cilculations.
')
I
l { I
'?i
J
I
Ltt
L,/ /
,,f
_
1_ I
-u
Ir .,
l-
.I" Ll
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t'
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;
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);,
t,
i{{
Jl(.t
-t^"
""'
/r
l
jc
,'"J
t
I
I
Scenario
2: Suppose
if the
customer
wants
to minimize
the
cost
of manufacturing
each bolt
and
time
taken
to
manufacture
is
not u big
factor,
what
machining
economic
formula
wpuld
you
use?
Show
calculations.
i
r
.li
,I
i
'
,,"
1d
'
--
I
l.
l/,,
'r1
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Page
8
of
10
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8/19/2019 ME 383 Exam 2
9/9
Bonus
question
6. How are cutting fluids
classified?
What
are the functions
and
benefits of
cutting
fluid? If
you
were to machine
a steel
workpiece at
very low cutting
speeds,
what kind
of
cutting fluid
would you
chose
and why?
'.
ILul1,,,pg
d
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Page
9 of
10
