MEE4207 (F) Page 1 of 4

INTI INTERNATIONAL UNIVERSITY

MECHANICAL ENGINEERING DEGREE PROGRAMME
MEE4207: MANUFACTURING PROCESS
FINAL EXAMINATIONS: AUGUST 2015 SESSION
This paper consists of FIVE (5) questions. Answer all THREE (3) questions from PART A and
ONE (1) question from PART B in the answer booklet provided. All questions carry equal
marks.
PART A
Question 1
Figure Q1 below shows a drawing of a connecting rod for an engine use, made out of steel. The
current process of sand casting could not cater for an increasing demand of about 20,000 units
per year.
a) Suggest a better alternative manufacturing process if any and describe at least 5 key
processes required to produce the connecting rod below. Suggest the required raw material
for the process.
(15 Marks)
b) Discuss the reasons for your choice of manufacturing if its different than sand casting. Make
your comparisons between the current process and the proposed manufacturing process, if
any.
(10 Marks)

Figure Q1
Question 2
a) The operation in Figure Q2(a) is performed on the top surface of a rectangular work part
which is 400 mm long by 60 mm wide. The milling cutter, which is 80 mm in diameter and
has five teeth, overhangs the width of the part on both sides. The cutting speed is 70 m/min,
the chip load is 0.25 mm/tooth, and the depth of cut is 5.0 mm. Determine:

MEE4207 (F) Page 2 of 4

i.

the time to make one pass across the surface, and

ii.

the maximum material removal rate during the cut.

(5 Marks)
(5 Marks)

Figure Q2(a)
b) A machinability rating is to be determined for a new work material using the cutting speed
for a 60 min tool life as the basis of comparison. For the base material (B1112 steel), test data
resulted in Taylor equation parameter values of n = 0.29 and C = 500, where speed is in
m/min and tool life is min. For the new material, the parameter values were n = 0.21 and C =
400. These results were obtained using cemented carbide tooling.
i.
ii.

iii.

Compute a machinability rating for the new material.

(5 Marks)
Suppose the machinability criterion were the cutting speed for a 10 min tool life
rather than the present criterion. Compute the machinability rating for this case.
(5 Marks)
What do the results of the two calculations show about the difficulties in
machinability measurement?
(5 Marks)

Question 3
The total solidification times of three casting shapes are to be compared, a sphere with diameter
= 10 cm, a cylinder with diameter and length both = 10 cm, and a cube with each side = 10 cm.
The same casting alloy is used in the three cases. (n=2)
(a) Determine the relative solidification times for each geometry.
(7 Marks)
2

(b) If the mold constant = 3.5 min/cm in Chvorinov's Rule, compute the total solidification time
for each casting.
(7 Marks)
(c) Based on the results of part (b), which geometric element would make the best riser?
(6 Marks)

MEE4207 (F) Page 3 of 4

(d) Describe five important properties that determine the quality of a sand mold for sand casting.

(5 Marks)
PART B
Question 4
(a) A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and the
initial height is 40 mm. The height after forging is 25 mm. The coefficient of friction at the
die-work interface is 0.20. The work material has a flow curve defined by a strength
coefficient of 600 MPa and a strain hardening exponent of 0.12. Determine the force in the
operation
i.
just as the yield point is reached (yield at strain = 0.002),
(5 Marks)
ii.
at a height of 35 mm, and
(5 Marks)
iii. at a height of 25 mm.
(5 Marks)
(b) A cup is to be drawn in a deep drawing operation. The height of the cup is 75 mm and its
inside diameter = 100 mm. The sheet metal thickness = 2 mm. If the blank diameter = 225
mm, determine
i.
drawing ratio,
(2 Marks)
ii.
reduction, and
(2 Marks)
iii. thickness-to-diameter ratio.
(2 Marks)
iv.
Does the operation seem feasible?
(4 Marks)
Question 5
(a) In welding process, a heat source can transfer 3500 J/sec to a metal part surface. The heated
area is circular, and the heat intensity decreases as the radius increases, as follows: 70% of
the heat is concentrated in a circular area that is 3.75 mm in diameter. Is the resulting power
density enough to melt metal?
(6 Marks)
2
(b) A fillet weld has a cross-sectional area of 25.0 mm and is 300 mm long.
i.
What quantity of heat (in joules) is required to accomplish the weld, if the metal
to be welded is low carbon steel?
(3 Marks)
ii.
How much heat must be generated at the welding source, if the heat transfer
factor is 0.75 and the melting factor = 0.63?
(3 Marks)

MEE4207 (F) Page 4 of 4

(c) In a certain welding operation on an aluminum alloy makes a groove weld. The cross section
area of the weld is 30.0 mm2. The welding velocity is 4.0 mm/sec. The heat transfer factor is
0.92 and the melting factor is 0.48. The melting temperature of the aluminum alloy is 650C.
Determine the rate of heat generation required at the welding source to accomplish this weld.
(6 Marks)
(d) Describe the sequence of steps in the cycle of a resistance spot welding operation with an aid of a
diagram.
(7 Marks)

THE END
MEE 4207/AUGUST 2015/ ENGR. GERALD/ 110315