RIFT VALLEY INSTITUTE OF SCIENCE AND TECHNOLOGY DEPARTMENT OF AGRICULTURAL AND MECHANICAL ENGINEERING UNIT TITLE: Production Technology

Attempt any three questions

1 a. (i) A component with right hand helical fluted, 64 mm in diameter and 550 mm lead having 12 flutes of 8 mm depth is to be gashed on a universal milling machine. If the lead screw pitch of the machine is 6 mm. calculate I. II. III. Indexing required Gearing required Angular setting of the table

Take the hole circle plate available as: Plate No 1; 15, 16, 17, 18, 19, 20 Plate No 2; 21, 23, 27, 29, 31, 33 Plate No 3; 37, 39, 41, 43, 47, 49 Gears available 24(2), 28, 32, 40, 44, 48, 56, 64, 72, 86, and 100 teeth

(ii) With reference to (a) (i), sketch the following I. II. Gearing set - up Plan view of the work/ table set up (10 marks)

b. Determine the differential indexing required to machine 83 teeth on a gear blank using the information provided in (a) (i). (4 marks)

c. A cam whose lift is 24 mm in 85 is to be cut on a vertical milling machine. If the machine has a lead of 240 mm. calculate the following using the information provided in (a) (i). (i) The gears required;

(ii) Work spindle inclination angle; (iii)Illustrate the machine set up for producing the cam (6 marks) 2 a. With the aid of a sketch, describe the principle of gear hobbing. (5 marks) b. An involute spur gear having 39 teeth is to be produced on a gear hobber. If the hob diameter is 74 mm and the module is 44 mm, determine the following details:i. ii. iii. iv. v. Blank diameter Full depth of teeth; Tooth thickness on the base circle Angle of tilt for the hob head. Indexing change gears required, and sketch the arrangement.

Take Pressure angle = 20 Clearance = 0.25 of module Standard gears available: 24(2), 32, 40, 48, 56, 64, 72, 78, 86 and 100 teeth Indexing expression: gear ratio = Where H = 1 = single start case. N = number of teeth to cut. (9 marks) c. The minimum total time required to machine in one pass 8 gears of the type in (b) on a gear hobber is 44 minutes. If the distance through the bore of each blank is 17 mm and the speed of table is 48rev/min, calculate the feed of the hob in:(i) Millimeters per minute (ii) Millimeters per revolution of the table (6 marks)

3 a. State four differences between orthogonal and oblique cutting. (4 marks) b. In an orthogonal cutting experiment the following data were obtained: Feed force Tangent force Rake angle Feed rate Chip thickness = 1475 N = 903 N = 12 = 0.2 mm/rev = 0.42 Determine using Merchants theory, the:-

Chip thickness ratio = 0.7

(i) Coefficient of friction (ii) Shear plane angle (iii)Shear force on the shear plane (iv)Compressive force on the shear plane (v) Friction force on the rake face. (16 marks)

4a. A helical gear is to be cut on a milling machine. The lead of this machine is 10 inches, and the lead to be cut on the gear is 7.882 inches. The dividing head to be use is a Cincinnati Universal Dividing head. Calculate the change gears required to cut the teeth on this gear and the total error in the lead when the selected gears are used. Take:Hole plate: 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43, 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, and 66 holes (9 marks) b. Describe the shaping process used in gear manufacturing (4 marks) c. Sketch the construction and design of a cutter grinder and:(i) Label and explain the main features

(ii)

Explain the relevance of cutter grinding in manufacturing (7 marks)