CONCORDIA UNIVERSITY

FACULTY OF ENGINEERING AND COMPUTER SCIENCE

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING
MIDTERM EXAMINATION MECH 31l-MANUFACTURING PROCESSES
FALL 2009
Date: October 15,2009 Duration: I hour
Materials allowed: NO Calculators: YES
Class instructors: sections T and X: Dr. M. Packirisamy and Mr. A.Changizi
Instructions: Answer the multiple choice type questions on the first page of the first answer
sheet by darkening the correct answer on the corresponding line indicated by the number ofthe
question. Select the most appropriate answer. For an example, if a question would ask: "What
is the benefit of hardening the surface of the tool ?" and it would offer option answers as: a)
Higher cutting speed b) Extended life of the tool, c) Reduce thermal effect on the tool or d)
Lower lifespan cost of the cutting tool. You should select b) as your answer because d) is a
consequence of the extended life ofthe tool.
The objective answer questions will be solved in your answer book and only the final
requested answers will be written in the separate answer tables. No answer in the answer box
will receive zero marks. Make sure that your name is written on the exam book and the answer
sheets. You can do the calculation in your exam book itself.
At the end of the exam, gather the question book and the answer sheets in the answer book and
submit them all. Please, do not forget to sign out.
Student's name: ............................... .
Student's I.D. #: .............. .
Student's Signature: ................ .
MARKS' Total 40
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1
I
I I
I
Select the MOST appropriate answer. (Total Marks 20)
Ql. What are the two most significant parameters that influence the tool life as per
Taylor's model
A: I. The material of the tool and the material ofthe work
Q) The material of the tool and the cutting speed
3. The material of the tool and the cutting feed
4. The material of the work and the chip thickness
Q2. During metal cutting, a significant amount of heat is generated. The heat is
distributed among the chip, tool, work and the cutting fluid. What is the type of
regime at which the cutting is recommended?
A: I. Slow speeds to enable heat removal
2. Optimal speed, such that the heat is optimally distributed
(DHigh speed, for better distribution of heat among the four bodies
4. The optimization of heat is carried out through the optimal feed rate.
Q3) The effectiveness of the cutting expressed through the shear angle can be adjusted
through a judicious sharpening of the cutting tool. Which geometric feature of the cutting
tools would you recommend to improve the efficiency of the cutting, according to the
theory of the orthogonal cutting?
A: I. Relief angle
2. Tool wedge angle
3. Tool width
@l Back rake angle
Q4) A cutting edge of the following machining tool has varying rake angle:
I. Shaping
2. Planing
3. Boring
(9 Drilling
2
I

Q5) What is the most appropriate sequence of hot hardness from the best to the worst in
terms of their cutting speed.
a) Ceramics
b) Diamond
c) HSS
d) Carbon and Low/medium alloy steels
A:(D b-a-c-d
2. c-a-b-d
3. d-b-a-c
4. d-c-a-b
Q6) In a finishing orthogonal metal cutting operation with the cutting speed of 20m/min
and 0 back rake angle, what would' be the chip velocity if the material shears at 45?
A : d) 20mlmin
2. 10mlmin
3. 28.28m1min
\" Vl If J
4. 14.142 mlmin
V 01: '2A:> 'II J &II:'"
Q7) Assume you are production in-charge to establish a manufacturing process for
making a part with a tolerance range of O.lmm. What will be the maximum standard
deviation you would aim in order to qualify the process for production?
A: 1. 0.1252mm
(J) 0.01252mm
3. 0.0250mm
4. O.IOOOmm
Q8) In a finishing orthogonal metal cutting operation with the cutting speed of 100m/min
and 0 back rake angle, what would be the chip thickness if the material shears at 45
and the uncut chip thickness is 2mm?
1>:: K
sin ,/, r, cosa 2cosa rl:; 0 /
---'----, tan I" = , & = ) "t
cos(-a) I -r, sin a I+sina
c.(
'c'-

t
(Note: r = - =
, t
,
A:
0
2mm
2. Imm
3. 1.414mm
4. 2.828mm
3
J

Q9) Identify a method that will be used for surface crack detection.
A: ([) FPI
2. Eddy current
3. X-Ray
4. Ultrasonic
QI0) Identify the critical parameter that influences the thrust force in drilling.
A: 1. Helical angle
2. Point angle
0':l Chisel edge
V Lip
.'

Qll) Which is the right sequence for machining a hole in order to get very close
positional tolerance and size tolerance:
,
A : ~ Centering drill-drilling ,reaming
Centering drill-drilling,boring
. Drilling-centering drill, boring
4. Centering drill-drilling-boring-reaming
Q12) Identify the angle maked below for the cutting tool .
\
I
i
\
A: 1. Back rake angle
<D Wedge angle
3. Relief angle
4. Side rake angle
-
4
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Q13) Identify the type of machining process depicted in the following figure.
I. Deep Hole Grinding
G> Ejector Drilling
3. Lapping
4. Forging
Q14) Assume that you have performed a process capability (PC) study and ended up with a
process capability index C p = 1.60 and a mismatch value D which is close to zero. Find the
standard deviation of the process if the upper and lower specification limits are 40.5 mm and
40.05 mm, respectively. 1'-0') _"-'oJ
T r
1
2.
(!>
4.
0.0938mm
0.0234mm
0.0469mm
0.1876mm
(). 't-S-
tt-\ oO'tI>'t
--
).6')(h
QlS) A 4" diameter rod is cut by turning at a speed around 60 m/min. The approximate N
RPM of the spindle ofthe lathe must be: , 1\0 tJ S"1I' of.
V... 1- 00l-
@189rpm 2) 300 rpm 3) 412 rpm 4) 590 rpm ::. 'f. 4-
Q16) Which production process has less roughness?
I. Drilling
(p Lapping
3. Girding
4. Sawing
Q17) For which case we cannot use MPI
1. Detecting surface cracks
2. Detecting sub-surface cracks
(j) Detecting crack in aluminum
4. Cracks perpendicular to flaws direction
Q18) How to make a square hole?
I. Drilling
q>
Broaching
Milling
4. Shaping

5
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Q19) What are the name of these reamers and their application
1. Expansion reamers, to fit the hole size after regrinding
o Chucking reamers, for soft materials
3. Adjustable reamers, to fit the hole size after regrinding
4. Taper reamer, for finishing hole to produce exact taper
Q20) The identified part of the drill is called
CD
Web
2. Flute
3. Shank
4. Point
6
PART B: TECHNOLOGY DESIGN PROBLEM
I.) Consider the following component to be machined in a slab milling machine. The
machining has to be done only on the three surfaces marked. Other surfaces are left as cast.
Assume that an allowance of Imm on the machined surfaces to be removed in single pass
on each side. The slab milling cutter of 70mm diameter and 160mm long with 8 teeth is
used. The maximum allowed cutting speed is 20m/min. The maximum feed per tooth is
O.lmm. The specific power, mechanical efficiency and correction factor can be assumed as
1.3 Ws/mm" 75 % and 1.15. Neglect the cutting allowance. You can neglect the
machining stock for calculation. (20 Marks)
Find out the following:
a) The maximum rpm ofthe cutter
b) The maximum possible width ofthe cut at any time, in mm
c) The maximum feed per minute in mmlmin
d) The total cutting time to machine the three faces in min
e) The maximum possible MRR in mm
3
/min
t) The actual MRR with no allowance in mm
3
/min
g) The maximum motor power required in Watts
h) The total machining cost( Assume $2751hr) in $
P
specijicpower * MRR * CF
ower =
77

2 marks
2 marks
2 marks
3 marks
3 marks
3 marks
3 marks
2 marks
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