FINAL EXAMINATION

SEMESTER II, SESSION 2016/2017

COURSE CODE : SKMM 2713 / SME 2713

COURSE NAME : MANUFACTURING PROCESSES

PROGRAMME : SKMM/SKMP/SKMI/SKMB/SKMT/SKMV/SKMO

DURATION : 3 HOURS

DATE : JUNE, 2017

INSTRUCTION TO CANDIDATES:

PART A: ANSWER ALL QUESTIONS.

(QUESTION 1, QUESTION 2, QUESTION 3, AND QUESTION 4)

PART B: ANSWER ONLY ONE (1) OF TWO (2) QUESTIONS.

(QUESTION 5 OR QUESTION 6)

ANSWER EACH QUESTIONS IN A NEW PAGE OF ANSWERS SCRIPT

WARNING!
Students caught copying/cheating during the examination
are liable for disciplinary actions and the Faculty may recommend
the students to be expelled from the University

THIS EXAMINATION PAPER CONSISTS OF SIXTEEN (16) PRINTED PAGES ONLY

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SKMM/SME 2713
PART A (ANSWER ALL QUESTIONS)

QUESTION 1 (20 MARKS)

The unit melting energy for aluminum is 3.7 J/mm3. The thickness of each of the TWO (2) sheets
to be spot welded is 4.0 mm. To achieve required strength, it is desired to form a weld nugget that
is 6.0 mm in diameter and 3.0 mm thick. The weld duration will be set at 0.3 sec. If the electrical
resistance between the surfaces is 140 x 10-6 ohms, and only one-third of the electrical energy
generated will be used to form the weld nugget (the rest being dissipated), determine the minimum
current level required in this operation.
(4 marks)

A 0.5 mm thick metal sheet is to be drawn with a limiting drawing ratio (LDR) of 1.8 to produce a
cup (refer Figure Q1(B)) with an inside diameter of 50 mm and a height of 65 mm. Tensile strength
is 175 MPa. Assume the thickness of the bottom and the walls of the cup remain unchanged.
i. Calculate the diameter of the initial circular blank necessary.
ii. For drawing the same initial circular blank, check if single drawing is enough and then if not,
calculate the smallest possible punch diameter for the first step and estimate the number of
redrawing necessary.
iii. Calculate the drawing force for the first step.
(6 marks)
Ø50
65

Ø51
(a) (b)
Figure Q1(B): (a) Detail dimension (b) final product
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SKMM/SME 2713

A cylindrical Stainless Steel with a Ø80 mm and a length 200 mm, will be reduced to Ø70 mm and
100 mm along the cylindrical by turning process in ONE (1) pass. The spindle rotates at 500 rpm,
and the tool is travelling at an axial velocity of 200 mm/min.
(hint: The specific cutting energy of Stainless Steel range from 3.0 – 5.3 W.s/mm3)
Calculate:
i. The cutting speed
ii. The material removal rate
iii. The cutting time
iv. The power required
v. The cutting force
(10 marks)

(a)

200 mm
Ø 80 mm

Ø 70 mm

100 mm

(b)
Figure Q1(C): (a) Turning operation (b) Detail Dimension
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SKMM/SME 2713

QUESTION 2 (20 MARKS)

Define what is sustainable manufacturing? Explain what is the FOUR (4) basic area that Coca-Cola
is focusing on?
(5 marks)

Describe TWO (2) reasons why Coca-Cola has to pay more attention in the sustainable
manufacturing issues in the design and production of their products.
(2 marks)

In the hierarchy of recycling, differentiate what is meant by; (i) Reuse, (ii) Recycle, and (iii) Reduce.
Gives ONE (1) example on how the application of (i), (ii), and (iii) is implemented in Coca-Cola.
(6 marks)

Discuss the possible target of sustainable manufacturing goals and the strategies to green
manufacturing implemented in beverage companies like Coca-Cola. You may discuss based on the
approach that is achievable by these companies.
(7 marks)

QUESTION 3 (20 MARKS)

Explain briefly, TWO (2) differences of between cold working and hot working in metal forming
processes.
(4 marks)

Explain with the help of sketches in detail the blanking and punching process.
(4 marks)

Select any ONE (1) of the applications listed in Table Q3(C):

Table Q3(C): Metal forming products

(a) (b) (c)
Wire Rod T - Beam Conneting Rod

Product

Length: 5.0 m
Dimension Diameter: 5.0 mm Length: 250.0 mm
Thickness: 5.0 mm
Material Steel Aluminium Stainless Steel
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SKMM/SME 2713

Then, answer the following:

i. Suggest the most suitable metal forming process and justify your suggestion.
ii. With aid of sketches, explain how the suggested process works.
iii. Describe ONE (1) possible defects that may occur.
(6 marks)

Explain the main reason of occurring the defects shown in Figure Q3(D) that occurred during the
rolling process and suggest a solution.
(6 marks)

(a) (b) (c)

Alligatoring Wavy Edges Edge Cracks

Figure Q3(D): Defects in Rolling process

QUESTION 4 (20 MARKS)

Identify TWO (2) situations in which brazing or soldering process is preferable to be used as
compared with fusion welding. List TWO (2) advantages and TWO (2) disadvantages of brazing or
soldering as compared with the welding process.
(5 marks)

Based on the description and welding processes in Table Q4(B) below;

Table Q4(B)
Descriptions Welding processes

 Uses a non-consumable electrode to  Oxy-acetylene welding (OAW)

produce the weld.
 Most commonly used to weld stainless  Gas Metal Arc Welding (GMAW)
steel and nonferrous materials, such as
aluminum and magnesium.  Resistance spot welding (RSW)
 Pressure is not required during the process
of welding.  Gas tungsten arc welding (GTAW)

i. Namely ONE (1) of the most suitable process based on the information given. With the help of
sketches, clearly explain the principle of the welding operation.
(4 marks)
ii. Describe ONE (1) problem that may be faced in this welding process and ONE (1) method to
overcome it.
(2 marks)
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SKMM/SME 2713

With the aid of appropriate sketches, explain the oxy-acetylene process with regards to the following
aspects:
i. The oxy-acetylene system, its characteristics and advantages compared to other welding
processes.
ii. Type of flames used in oxy-acetylene process.
(6 marks)

Choose ONE (1) of the types of non-destructive welding inspection (NDT) listed below. Explain
with simple sketches to illustrate your explanation.
i. Ultrasonic test.
ii. Liquid penetrant test.
iii. Magnetic particle test.
(3 marks)
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SKMM/SME 2713
PART B: ANSWER ONLY ONE (1) OF TWO (2) QUESTIONS.
(QUESTION 5 OR QUESTION 6)

QUESTION 5 (20 MARKS)

What is Built-Up-Edge (BUE). Explain THREE (3) problems caused by the presence of Built-Up-
Edge (BUE).
(4 marks)

Explain THREE (3) functions of a cutting fluid in machining operation. List FOUR (4) problems
arise if no cutting fluid is used during machining.
(5 marks)

Refer to Figure Q5(C):

(a) Climb Milling (b) Conventional (up) Milling

Figure Q5(C): Schematic of milling processes

i. Explain TWO (2) advantages of climb milling as compared to up milling.

ii. Why climb milling is less recommended when using an old milling machine?
(5 marks)

Explain in details the function of rake angle, and discuss at least TWO (2) differences between
positive and negative rake angles in order to improve tool life.
(6 marks)
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SKMM/SME 2713

QUESTION 6 (20 MARKS)

What is Built-Up-Edge (BUE). Explain THREE (3) problems caused by the presence of Built-Up-
Edge (BUE).
(4 marks)

Explain THREE (3) functions of cutting fluids.

(3 marks)

In metal cutting operation, there are TWO (2) types of wear occurring on the cutting tool, i.e. flank
wear and crater wear.
i. With the aid of appropriate sketches, clearly explain both types of wear.
ii. State TWO (2) effects of each type of wear towards the metal cutting operation.
(6 marks)

State with the help of sketches the basic steps in performing the soldering process.
(3 marks)

Refer the Figure Q6(E), name the type of extrusion process shown. State TWO (2) advantages and
TWO (2) disadvantages of this process.
(4 marks)

Figure Q6(E): Extrusion Process

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SKMM/SME 2713
BAHAGIAN A (JAWAB SEMUA SOALAN)

SOALAN 1 (20 MARKAH)

Unit bagi tahap peleburan tenaga untuk Aluminium adalah 3.7 J/mm3. Ketebalan setiap DUA (2)
keping plat Aluminium untuk dikimpal ialah 4.0 mm. Untuk mencapai kekuatan kimpalan bintik
yang dikehendaki, pembentukan naget kimpalan adalah diameter 6.0 mm dan ketebalan ialah 3.0
mm. Masa kimpalan adalah 0.3 saat. Jika rintangan elektrik diantara permukaan ialah 140 x 10-6
ohm, dan hanya satu pertiga daripada tenaga elektrik yang dihasilkan akan digunakan untuk
membentuk naget kimpalan (selebihnya dilesapkan), tentukan tahap semasa minimum arus elektrik
yang diperlukan dalam proses ini.
(4 markah)

Satu kepingan logam berketebalan 0.5 mm akan ditarik dengan nisbah menghad penarikan (LDR)
adalah 1.8 untuk menghasilkan satu cawan (rujuk Rajah Q1(B)) dengan diameter dalam adalah 50
mm dan tinggi adalah 65 mm. Kekuatan tegangan adalah 175 MPa. Andaikan ketebalan bahagian
bawah dan dinding cawan adalah tidak berubah.
i. Kirakan diameter awal kepingan yang diperlukan.
ii. Untuk proses penarikan bagi diameter awal kepingan, semak sekiranya penarikan tunggal
mencukupi dan sekiranya tidak kirakan diameter penumbuk untuk langkah pertama tersebut
dan jangkakan bilangan penarikan yang diperlukan.
iii. Kirakan daya penarikan untuk langkah pertama.
(6 markah)
Ø50
65

Ø51
(a) (b)

Rajah Q1(B): (a) Dimensi terperinci dan (b) Produk akhir

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SKMM/SME 2713

Satu selinder Keluli Tahan Karat dengan Ø80 mm dan panjangnya 200 mm, akan dikurangkan
kepada Ø70 mm dan 100 mm sepanjang selinder tersebut dengan menggunakan proses melarik
dengan SATU (1) laluan pemotongan sahaja. Gelendong berpusing dengan kelajuan 500 ppm, dan
matalat bergerak pada paksi alat dengan kelajuan 200 mm/min.
(Petunjuk: Tenaga Tentu pemotongan untuk Keluli Tahan Karat adalah diantara 3.0 – 5.3
W.s/mm3)
Kirakan:
i. Kelajuan Pemotongan
ii. Kadar Pembuangan bahan
iii. Masa Pemotongan
iv. Kuasa diperlukan
v. Daya pemotongan
(10 markah)

(a)

200 mm
Ø 80 mm

Ø 70 mm

100 mm

(b)

Rajah Q1(C): (a) Proses Melarik (b) Dimensi terperinci

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SKMM/SME 2713

SOALAN 2 (20 MARKAH)

Takrifkan apa itu pembuatan lestari. Bincangkan EMPAT (4) kawasan utama yang difokus oleh
syarikat Coca-Cola.
(5 markah)

Terangkan secara ringkas DUA (2) sebab kenapa Coca-Cola harus tumpu pada isu pembuatan lestari
dalam rekabentuk dan pengeluaran produk mereka.
(2 markah)

Dalam hierarki kitar semula, bezakan makna diantara; (i) Guna semula (Reuse), (ii) Kitar semula
(Recycle), and (iii) Pengurangan (Reduce). Berikan SATU (1) contoh untuk (i), (ii), dan (iii) yang
diimplimentasikan di syarikat Coca-Cola.
(6 markah)

Bincangkan sasaran yang mungkin bagi matlamat pembuatan mampan dan strategi untuk
pembuatan hijau dilaksanakan di syarikat Coca-Cola. Anda boleh membincangkan berdasarkan
pendekatan yang boleh dicapai oleh syarikat ini.
(7 markah)

SOALAN 3 (20 MARKAH)

Terangkan secara ringkas, DUA (2) perbezaan diantara pengerjaan sejuk dan pengerjaan panas
dalam proses pembentukan logam.
(4 markah)

Dengan bantuan lakaran, terangkan secara terperinci bagaimana proses pengosongan dan
penembusan dilakukan.
(4 markah)

Pilih salah SATU (1) daripada produk yang disenaraikan di dalam Jadual Q3(C):

Jadual Q3(C). Produk pembentukan logam

(a) (b) (c)
Rod Wayar Rasuk - T Rod Penyambung

Produk

Panjang: 5.0 m
Dimensi Diameter: 5.0 mm Panjang: 250.0 mm
Tebal: 5.0 mm
Bahan Keluli Aluminium Keluli Tahan Karat
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SKMM/SME 2713

Kemudian, jawab soalan berikut:

i. Cadangkan proses pembuatan yang paling sesuai dan berikan kewajaran cadangan anda.
ii. Dengan bantuan lakaran, terangkan bagaimana proses yang dicadangkan ini berfungsi.
iii. Terangkan SATU (1) kecacatan yang mungkin berlaku.
(6 markah)

Terangkan sebab utama berlaku kecacatan yang ditunjukkan dalam Rajah Q3(D) yang berlaku
semasa proses penggelekan dan cadangkan satu penyelesaiannya.
(6 markah)

(a) (b) (c)

Mulut buaya Tepian beralun Rekahan tepi

Rajah Q3(D): Kecacatan di dalam proses penggelekan

SOALAN 4 (20 MARKAH)

Jelaskan DUA (2) keadaan di mana proses pateri keras atau lembut lebih sesuai digunakan
berbanding kimpalan lakuran. Senaraikan DUA (2) kelebihan dan DUA (2) kelemahan proses
pateri berbanding proses kimpalan.
(5 markah)

Berdasarkan kepada kenyataan dan proses kimpalan di Jadual Q4(B) di bawah;

Jadual Q4(B)
Keterangan Proses Kimpalan
 Menggunakan elektrod kekal untuk  Kimpalan Gas Oksi-Asitelina (OAW)
menghasilkan kimpalan.
 Kebiasaan digunakan untuk mengimpal  Kimpalan Arka Logam Gas (GMAW)
Keluli Tahan Karat dan bahan-bahan
bukan ferus, seperti Aluminium dan  Kimpalan Rintangan Bintik (RSW).
Magnesium.
 Tekanan tidak diperlukan semasa proses  Kimpalan Arka Tungsten Gas (GTAW)
kimpalan.

i. Namakan SATU (1) proses kimpalan yang paling sesuai berasaskan keterangan yang diberikan.
Berbantukan lakaran-lakaran, terangkan dengan jelas prinsip operasi kimpalan tersebut.
(4 markah)
ii. Terangkan SATU (1) masalah dalam proses kimpalan ini dan SATU (1) cara penyelesaiannya.
(2 markah)
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SKMM/SME 2713

Berbantukan lakaran yang bersesuaian, terangkan proses oksi-asitelena berhubung perkaraperkara

berikut;
i. Ciri-ciri dan kelebihan sistem oksi-asitelena berbanding proses-proses kimpalan lain.
ii. Jenis nyalaan api yang digunakan dalan proses oksi-asitelena.
(6 markah)

Pilih SATU (1) dari jenis pemeriksaan ujian tanpa musnah (NDT) yang disenaraikan di bawah.
Berbantukan lakaran, terangkan proses pemeriksaan yang dipilih.
i. Ujian Ultrabunyi
ii. Ujian Penerapan Cecair
iii. Ujian Partikel Magnet
(3 markah)
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SKMM/SME 2713
BAHAGIAN B (JAWAB HANYA SATU (1) DARI DUA (2) SOALAN)
(SOALAN 5 ATAU SOALAN 6)

SOALAN 5 (20 MARKAH)

Apakah itu Pinggir Terbina (BUE). Jelaskan TIGA (3) masalah yang disebabkan oleh kewujudan
Pinggir Terbina (BUE).
(4 markah)

Terangkan TIGA (3) fungsi bendalir pemotongan semasa operasi pemesinan. Senaraikan EMPAT
(4) masalah yang timbul sekiranya bendalir pemotongan tidak digunakan semasa pemesinan.
(5 markah)

Rujuk kepada Rajah Q5(C);

(a) Pengisaran Daki (b) Pengisaran Lazim

Rajah Q5(C): Proses Mengisar

i. Terangkan DUA (2) kelebihan mengisar daki dibandingkan dengan mengisar lazim.
ii. Kenapakah mengisar daki tidak digalakkan jika menggunakan mesin kisar yang telah lama.
(5 markah)

Terangkan dengan terperinci fungsi sudut sadak, dan bincangkan sekurang-kurangnya DUA (2)
perbezaan diantara sudut sadak positif dan sudut sadak negatif terhadap jangka-hayat mata alat.
(6 markah)
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SKMM/SME 2713

SOALAN 6 (20 MARKAH)

Apakah itu Pinggir Terbina (BUE). Jelaskan TIGA (3) masalah yang disebabkan oleh kewujudan
Pinggir Terbina (BUE).
(4 markah)

Jelaskan TIGA (3) fungsi bendalir pemotongan.

(3 markah)

Dalam operasi memotong logam, terdapat DUA (2) jenis kehausan yang berlaku pada alat
pemotongan iaitu kehausan rasuk dan kehausan kawah;
i. Dengan bantuan lakaran yang sesuai, terangkan dengan jelas kedua-dua jenis kehausan tersebut.
ii. Nyatakan DUA (2) kesan setiap jenis kehausan keatas operasi pemotongan logam.
(6 markah)

Terangkan dengan bantuan lakaran, langkah-langkah asas dalam melaksanakan proses pematerian
lembut.
(3 markah)

Merujuk kepada Rajah Q6(E), namakan jenis proses penyemperitan yang ditunjukkan. Nyatakan
DUA (2) kelebihan dan DUA (2) kekurangan bagi proses ini.
(4 markah)

Rajah Q6(E): Proses Penyemperitan

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SKMM/SME 2713

APPENDIX /LAMPIRAN:

Metal Forming Machining (Turning)

Volume (Isipadu):  V= xNx (m/min)
 Cylindrical (Selinder):
V = 4 D H  MRR = V x f x d (mm3/min)

 Cone (Kon):
 t= (second)
V= 12 D H

 Cube (Kiub):  P = MRR x = T x ω (kW / N.m/min)

V= a
 ω=2 N (radians/min)
 Rectangular Boxes (Kotak Segiempat tepat)
V=LxWxH  1 watt = 1 N.m/s = 60 N/min

Drawing Ratio (Nisbah penarikan):

 T = Fc x 2 (N.m)
Cylindrical Shape,
DR =
 v = fN (mm/min)

Reduction (Pengurangan): Cylindrical Shape

r=
 Value of r should be less than 0.50

Thickness-to-diameter ratio =
 Desirable for t/Db ratio to be greater than 1%
 As t/Db decreases, tendency for wrinkling
increases Welding:

Drawing Force = t (TS)( - 0.7)

 v=e

Blanking Force = t (SS)  Q = I2Rt = UmV

 Weld Nugget volume, V = 4 D d

 TS = Tensile Strength
 SS = Shear Strength
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SKMM/SME 2713