Midterm I Revisionxs

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Dr. Mohamed Serry Assistant Professor

Department of Mechanical Engineering The American University in Cairo

Spring 2015

MENG 4239: Advanced Manufacturing Processes

Midterm I Review Ques@ons

1

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision 2

Module 1: Intro & TradiOonal Processes 1- Discuss the different sources of energy used in Manufacturing Processes, give examples. 2- Discuss the need for Nontraditional Manufacturing Processes.

3- Nonabrasive operations are classified into _____ and ____ machining.

4- (T/F) Tool life is longer in continuous machining processes


Module 1: Intro & TradiOonal Processes 5- (T/F) Milling is multi-point, continuous-cutting process 6- How is the feed rate expressed in the following processes: Turning, Milling, Drilling

7- Manufacturing can be defined as the application of physical and chemical processes to alter the geometry, properties, or appearance of a given material - Give one example to demonstrate the above - How can this explained in light of the Economic definition of manufacturing


Module 1: Intro & TradiOonal Processes 8- Whats the main purpose of Machining Processes? 9- Discuss the basic functions of a machine tool 10- When is continuous and discontinuous chips are formed? Give material examples. 11- What are the turning process parameters? Discuss why is it sometimes useful to fix a cutting inserts on a tool flank?


Module 1: Intro & TradiOonal Processes

13- Calculate the required compound wrist inclination angle to achieve the above shape.

CB

A L

D90 2D1 = 40 mm 70 mm =

= 70 mm


Module 1: Intro & TradiOonal Processes 14- What are the key factors in determining roughness in machining processes? 15- How can you control geometric parameters to enhance surface finish? 16- Discuss how can you adjust the machining parameters to reduce machine vibrations? 17- Discuss how speed, feed and depth of cut are selected in a roughing and finishing processes


Module 1: Intro & TradiOonal Processes 18- Develop a process plan for the part shown below:

All surfaces are except as indicated Raw material is 60 x 70.

The American University in Cairo- MENG 4239 Mohamed Serry Fall 2014- Midterm Revision

Process Plan 1- Rough Turning 70mm 54.25 mm 2- Rough Turning 54.25 mm 44.25 mm 3- Facing (Surface A) 4- Finish Turning 44.25 44 mm (Surface B) 5- Drilling 20 mm 6- Boring 20 mm 25.75 mm 7- Reaming 25.75 mm 26 mm (Surface D) 8- Finish Turning, 54.25 mm 54 mm (Surface C) 9, 10- ParOng-o, Facing (Surface E) 11- Chamfering

8


Module 2: AutomaOon 23- Can you give an example of an automated system, which contains a control system as a part of it? What are the other parts of the system? 24- State the basic profit function and then discuss how can you increase profit by employing Automation. 25- Give examples of how production time can be reduced by utilizing Automation. 26- How can Closed Loop control systems used to accelerate/decelerate the action?


Module 2: AutomaOon 27- Give an example of analog temperature sensor. 28- How is precision motion is achieved in CNC machines?


Module 2: AutomaOon 29 - Explain the Part Program segment given below. Draw the trajectory of table motion that this program seeks to create:

N0010G90; N0011G01X1Y2; N0012G01X2Y2; N0013G91; N0014G01X1; N0015G91X2Y2; N0016G01X1Y1; N0017G92X0Y0Z0;


30 Write the part program to machine the part shown. Use absolute positioning. Use the lower left corner of the part as the origin in the x-y axis system. 7-mm drill is at tool position T04. 10-mm End mill is at position T03.


31 Write the part program to machine the part shown. Use absolute positioning. Use the lower left corner of the part as the origin in the x-y axis system. 10-mm End mill is at position T03. Part thickness is 10 mm.


32 Write the part program to machine the part shown. Use absolute positioning. Use the lower left corner of the part as the origin in the x-y axis system. 10-mm End mill is at position T03. Part thickness is 10 mm.


33 Write the part program to drill the through holes in the part shown. Use absolute positioning. Use the lower left corner of the part as the origin in the x-y axis system. 10-mm drill is at tool position T04. Part thickness is 12 mm.


34- A DC servomotor is used to drive one of the table axes of an NC milling machine. The motor coupled directly to the leadscrew for the axis, and the leadscrew pitch = 5 mm. The opDcal encoder aEached to the leadscrew emits 360 pulses per revoluDon of the leadscrew. The motor rotates at a maximum speed of 300 rev/min. Determine: (a) BLU (b) Frequency of the pulse train emiMed by the op@cal encoder when the servomotor operates at full speed, and, (c) Maximum travel rate of the table.


35 The shown pulse train is generated by optical encoder feedback sensor. Determine the worktable position and velocity.


36- Why is closed loop control required for continuous axes and not for PTP axes?

37- What sort of sensors and controllers would you recommend for continuous axis control?

Midterm I Revisionxs

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