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UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FINAL EXAMINATIONSEMESTER II

SESSTON 2012t2013

COURSE NAME DESIGN FOR MANUFACTURE ANDASSEMBLY

BDD 40t3t40103

BACHELOR OF MECFIANICALENGINEERING WITH HONOURS

JUNE 2OI3

2 HOURS 30 MINUTES

ANSWER ANY FOURFROM FIVE QUESTIONS PROVIDED

COURSE CODE

PROGRAMME

DATE OF EXAMINATION

DURATION

INSTRUCTION

THIS PAPER CONTAINS FryE (5) PAGES

CONFIDENTIAL

BDD 4013/40103

MAXIMUM MARKS: 100

Answer any four (4) from five (5) questions.

Ql (a) Analyze the reasons for rough surface roughness in machining and how to improvesmooth surface roughness

(5 marks)

(b) How manufacturing industries can be classified and what are all the industries in thatcategory? Give examples for each industry.

(5 marks)

(c) A turning machine works at 1900 revolutions per minute to finish a round work pieceof diameter 50 mm to 45 mm having length of 200 mm. The work piece to be turnedto 125 mm. A single point cutting tool is used. The cutting tool moves by 0.15 mmper work piece revolution. The depth of cut is 2.5 mm per travel of the cutting tool.

Calculate the following:

(i) The cutting velocity of the work piece.(iD The totaltime taken to machine 125 mm tength to reduce to diameter of 45

mm(iii) The material removal rate

(9 marks)

(d) Drilling of holes is to be done in a work piece of 40 mm thickness x 100 mm lengthwork piece. The hole diameter is l0 mm and it is through hole. The cutting speed ofthe drill is 30 m/min. The point angle is I l8 degree. The feed rate is 0. l2 mm perrevolution.

Calculate the following:

(i) Time taken to drill(ii) Material removal rate.

(6 marks)

(a)

(b)

(c)

Q2 In a product development, many engineers are involved. Discuss theeach ofthem briefly.

Discuss the product life cycle in an engineering enterprise.

Discuss the advantages in adopting DFMA.

functions of

(4 marks)

(6 marks)

(6 marks)

(d)Q2

(a)Q3

(b)

(e)

BDD 4013/40103

Metals used in an industry are all combination of three basic materials.basic metal combinations.

Discuss various cost elements involved in estimating the cost offactorv level.

Discuss the

(4 marks)

component at

(5 marks)

There are two (2) materials which are used in injection molding process. Discusstheir quality characteristics.

(6 marks)

There are some design guidelines for injection molding. State three (3) of thesedesign guidelines and explain briefly why it is importance?

(6 marks)

Explain the injection molding process? State your answers with simple sketch.(6 marks)

Identiff various defects that are likely to occur in Injection molding process.(7 marks)

Figure Q4 shows in the appendix is the size of the rectangular shape that surroundthese five holes is 180 x l00mm and the perimeter of non-standard shape for hole"+" is 180mm. Assume that 50mm space was allowed at surrounding area of part atthe die set and the die manufacture rate is RM40 per hour. Determine the cost ofpiercing die for drilling these five holes? The shear strength of the material is 45 kg imm2.

Determine the following:

(i) Force required cutting the metal and the type of machine that can perform theoperation.

(ii) State the type of operation involved and their sequence.(iiD Calculate the cost of material per piece and total weight of material involved.(iv) Determine the total cost of die to produce the part

(25 marks)

(c)

(d)

(a)Q4