CONFIDENTIAL, UNIVERSITI KUALA LUMPUR INSTITUTE OF PRODUCT DESIGN AND MANUFACTURING FINAL EXAMINATION SEPTEMBER 2015 SEMESTER COURSE CODE : PPB 15104 COURSE NAME : MANUFACTURING TECHNOLOGY PROGRAMME NAME : BACHELOR DATE : 29 DECEMBER 2015 TIME : 09:00 AM — 11:30 AM. DURATION : 2,5 HOURS INSTRUCTIONS TO CANDIDATES 1. Please CAREFULLY read the instructions given in the question paper. 2. This question paper has information printed on both sides of the paper. 3. This question paper consists of ONE (1) section only; Section A. 4. Answer ANY FOUR (4) of FIVE (5) questions, 5, Please write your answers on the answer booklet provided. 6, Answer all questions in English language ONLY. THERE ARE 4 PAGES OF QUESTIONS, INCLUDING THIS PAGE.‘SEPTEMBER 2015 CONFIDENTIAL SECTION A (Total: 100 marks) INSTRUCTION: Answer ANY FOUR (4) questions. Please use the answer booklet provided. Question 1 (a) Define the following term of material properties. i Tensile Strength (2 marks) ii, Elasticity (2 marks) ii, Duetility (2 marks) {b) Describe at least TWO (2) differences between expendable and permanent moulds. (4 marks) (c) Explain the production sequence of sand casting starting from sand preparation until finished. (40 marks) (4) Explain the term ‘Nucleation’ and ‘Growth’ in casting solidification. (5 marks) Question 2 (a) Explain the three steps in ‘Expended Polystyrene’ casting process. ( marks) (b) Identify TWO (2) defects and causes of the defect that normally occur in injection moulding process (4 marks) (©) Sketch the stress strain diagram for mild steel and briefly explain the behavior of this material. (6 marks) PPB15104 MANUFACTURING TECHNOLOGY Page 1 of 3SEPTEMBER 2015 CONFIDENTIAL (4) Explain briefly the step of shell mould process. Describe TWO (2) advantages of the process. (©) _ Discuss on the investment casting including TWO (2) advantages. Question 3 (5 marks) (5 marks) (2) Tensile testing is one of the most fundamental types of mechanical tests performed on a material. Plot, label and explain the stress-strain curve behavior for a mild steel material as the test specimen. (8 marks) (0) Compare and differentiate between hot and cold working processes and explain the possible objective of hot working process. (©) _ Define the effect of recrystallization temperature to a metal. (d) Provide FIVE (5) advantages of cold working process of a metal Question 4 (2) Compare the following manufacturing process: i Net shape and near net shape ji. Open die and Impression die forging (>) With the aid of drawing, differentiate: i. Up milling and down miling ii, Peripheral miling and face miling (c) Explain and sketch the parting process in turning operation. (d) Name five operations that can be performed using lathe machine. PPB15104 MANUFACTURING TECHNOLOGY (6 marks) (6 marks) (6 marks) (4 marks) (4 marks) (3 marks) (3 marks) (6 marks) (6 marks) Page 2 of 3SEPTEMBER 2015 CONFIDENTIAL Question 5 (a) () @ () Describe FOUR (4) important features that can be observed in rake and clearance angle of a cutting tool. (4 marks) Differentiate between dressing and truing in reference to grinding wheels preparation {5 marks) Explain the term ‘Continuous Chip’ and ‘Discontinuous Chip’ in metal cutting, (6 marks) Explain five characteristics of a cutting tool material (S marks) Explain the term ‘Chip with BUE’ in metal cutting. (6 marks) END OF EXAMINATION PAPER PPB15104 MANUFACTURING TECHNOLOGY Page 3 of