Department of Polymer and Process Engineering

Take-Home Comprehensive Examination (ODL System) 2018

Polymer Product Design, 8th Semester, 2016 Session

General Instruction (Please read carefully for full compliance)

1. This is a take home exam that allows books and all other materials resources to be consulted BUT you
cannot consult with each other and any other individual. Therefore, the solution(s) has to be unique and
detailed. If a substantial level of similarity between any two solutions is found, both will be rejected.
So neither discuss nor share your working with your fellow students. A plagiarized solution (similarity
index > 19%) will be completely rejected.
2. To make the solution specific and unique, an appreciable quantitative content has to be incorporated
with numbers, figures, data from books and internet sources and be processed through engineering
equations and formulae, where required. The trends/conclusions/claims will only be acceptable supported
with valid data.
3. The solution/answer sheet will be hand written with your name and reg# written on it. Once done, it
will be scanned, compressed (below 5 MB) and emailed (pdf) by the student to the following email i.d.
within stipulated time. The same will be sent through WhatsApp as well.
Email: asifaliqaiser@uet.edu.pk
CC: komalnaveed14@gmail.com
WhatsApp: +92 312 4084828 (Ms. Komal Naveed)
4. The total time for this exam is Four (04) Hours and 20 Min (10:00 a.m. to 02:20 p.m. on Monday,
22nd June 2020) including scanning and submission time and you have to submit within stipulated time
for marking.

Examination Questions (Please attempt any two questions, all questions carry equal marks.)
(CLO-1: 40%, CLO-2: 30%, CLO-3: 15%, CLO-4: 15%)
Max. Marks: 50
Q1.
A chemical manufacturing company desires to fabricate plastic containers for the storage, shipment and
market of their product containing following composition.
Butyl Acetate 98%
They are looking for a 55L capacity, serviceable to extreme conditions of temperature and loads during
various service life phases and also be aesthetically appealing. This container is to be designed along with a
suitable lid and handle(s). Design the container going through the following design steps in detail. The
solution complete with all aspects of product application and design including structural analysis,
comprehensive materials survey and selection, machine and die/mold specifications, and realistic cost

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estimation with locally implementable conditions and values would likely to get maximum marks. You will
support your solution with correct and realistic data, calculations, material suppliers/service providers’
details etc. Please mention the sources of all data in the parenthesis along with the data/numbers/graphs etc.
where these appear in the solution.
(i) Product’s functional requirements
(ii) Drawing/Concept generation
(iii) Material Selection
(iv) Part Design and Structural Analysis
(v) Process Selection and machine specifications
(vi) Die/Mold Design and Specifications
(vii) Cost estimation for production in local market

Q2.
You are required to design a room door (6.5 x 3.5 ft) along with its frame replacing existing wood doors for
in-house installation made up of plastics (or its composites). A complete design is required covering
functional/service requirements, hinges, and various options for either molded in or subsequent installation
of handles, locks etc. and appearance. A special and detailed focus on manufacturing process’ specification
and tool/die design is required.
Design the door going through the following design steps in detail. The solution complete with all aspects of
product application and design including structural analysis, comprehensive materials survey and selection,
machine and die/mold specifications, and realistic cost estimation with locally implementable conditions and
values would likely to get maximum marks. You will support your solution with correct and realistic data,
calculations, material suppliers/service providers’ details etc. Please mention the sources of all data in the
parenthesis along with the data/numbers/graphs etc. where these appear in the solution.
(i) Product’s functional requirements
(ii) Drawing/Concept generation
(iii) Material Selection
(iv) Part Design and Structural Analysis
(v) Process Selection and machine specifications
(vi) Die/Mold Design and Specifications
(vii) Cost estimation for production in local market

Q3.
Design of a 4 in i.d. plastic pipe for a water distribution line joined with a main transmission line 8 in i.d. is
required. The design must be carried out either using relevant ASTM or ISO standards. The associated data
may be acquired from other sources such as PPI etc. The design will be considered complete with the design
of a Tee and a 90o Elbow joint accessories as per relevant ASTM (or ISO) standards. The line pressure is a
normal municipal water supply line pressure in Lahore and the required life span is 40 years at normal
temperature variations during a year. Please note that ASTM standards a freely available online, now-a-days.

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Design the pipe and fittings through the following design steps in detail for each individually. The solution
complete with all aspects of product application and design including structural analysis, comprehensive
materials survey and selection, machine and die/mold specifications, and realistic cost estimation with locally
implementable conditions and values would likely to get maximum marks. You will support your solution
with correct and realistic data, calculations, material suppliers/service providers’ details etc. Please mention
the sources of all data in the parenthesis along with the data/numbers/graphs etc. where these appear in the
solution.
(i) Product’s functional requirements
(ii) Drawing/Concept generation
(iii)Material Selection
(iv) Part Design and Structural Analysis
(v) Process Selection and machine specifications
(vi) Die/Mold Design and Specifications
(vii) Cost estimation for production in local market

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