Guides To Solutions: (Ref To Slides 3 and 5 in Notes "Machining (2) "

Sampling questions on Manufacturing processes (1)
MBE 3119 Manufacturing Technology
1) Fig, 1(a) shows the configuration structure of a horizontal milling

machine and Fig. 1(b) of that its counterpart on vertical milling
machine. Fig. 1(c) illustrates the setup of peripheral milling while Fig.
1(d) and Fig. 1(e) the setup of face milling and end milling, respectively.
(i) From the configuration structural point of view, comment
on the rigidity of the cutter in operations with the
individual types of machines.
(ii) Discuss the advantages and limitations of the individual
types of milling machines.
(iii) Elaborate why peripheral milling generally using
horizontal milling machine while face mills and end milling
commonly performed by vertical milling.
(a) horizontal milling (b) vertical milling (c) Peripheral milling

machine machine
Fig. 1: Structural
configuration of
horizontal and vertical
milling machines, and
three types of milling
(d) Face milling (e) End milling operations
Guides to Solutions: (Ref to Slides 3 and 5 in notes “Machining (2)”

(i) For the horizontal milling machine, the free end of overarm is
mounted with bearing to hold shaft on which the cutter can be
mounted. Such feature makes the shaft relatively more rigid
since it forms as built-in beam with less defection occurring.
The cutter mounted to the cutter holder spindle forma a
cantilever system, which likely produces large defection or
unstable condition during heavy milling.
(ii) For horizontal milling machine, the cutter blades rotating about
horizontal shaft results in a non-sharp slope f in both
conventional milling and climbing milling (Fig. G1(A)) and hence it
is hard: (a) to terminate a cut in anywhere along cutting path,
and (b) to generate sharp slope at the termination position.
However, the rigidity and cutting methods make the machine to
be best for straddle milling, form milling, slotting, and slitting,
as seen in Fig. G1(B).
Cutting with cutter on horizontal

milling process – hard to
terminate anywhere in cutting
path, hard to produce sharp
edge on termination position.
(A)
The rigidity of the horizontal

milling machine allows mounting
of two cutters as shown in (a)
for straddle milling, and two
back to back cutters for form
milling as shown in (b).
Furthermore, it is rigid enough
for performing relatively heavy
slotting as shown in (c) and
slitting as shown in (d) with good
quality and relatively perfect
straightness.
(B)
For vertical milling machine, the mounting of cutter into the

chuck of vertical spindle forms a cantilever structure, which
may create larger defection relative to the cutter tip. Such
arrangement generally means the cutter blades are orientating
vertically. As a result, it would produce sharp edge in face (Fig.
1(d)) and end (Fig. 1(e)) millings. The milling can also stop
anywhere in the cutting path. The design of cutters also allows
more versatile in cutting many features on or in a workpiece.
(iii) In peripheral milling, it only involves with shaping the peripheral
surfaces of a workpiece to the anticipated dimensions with
sufficient flatness and straightness. The mounting of cutter
(Fig. 1(c)) in a manner of built-in beam enhances the rigidity of
the system to absorb larger reaction force, and performs heavy
duty of metal removal to speed up cutting process.
In face milling (Fig. 1(d)) with cutter mounted to spindle chuck
vertically, the large cutting base and tapping upwardly of cutter
may spread out cutting force relatively and absorb certain
amount of end defection of the cutter mounting spindle. It
allows facing a regional or whole surface with shallower cut. In
end milling (Fig. 1(e)), the side blades of cutter are orientating
vertically to remove materials from their vertical vicinities.
Furthermore, the cutting tip on the bottom face of cutter
removes materials from the horizontal surface. Hence, its
mounting into the vertical milling machine facilitates the milling
local slot or feature from the end surface of a workpiece.
2) Fig. 2 shows a milled T-slot in a block of workpiece. From the milling

feature and the design of both horizontal and/or vertical milling
machines, mention with adequate reasoning the type of milling machine
to be used for milling such slot. Give sequence of operations to
achieve such T-slot.
Fig. 2: A milled T-slot in a block of workpiece
Guides to solutions: (Ref to Slides 9, 3, and 5 in notes “Machining (2)”)

From the feature of T-slot with the large slot in the bottom which is
followed with an open slot on the top. Such arrangement of slot makes
the large bottom slot hard to be producible by horizontal milling
machine. Hence, vertical milling machine can be utilized to accomplish
such slot. Basically, the slot can be produced by firstly cutting the
narrow to the depth of the T-slot as shown in Fig. G2(a), which is
followed by milling the bottom wider slot using the cutter tool as
shown in Fig. G2(b) with the cutter shown in Fig. G2(c) mounted at its
end.
(c) The cutter mounted

(a) First cut to the depth
(b) Cutting tool for to the bottom of
of the T-slot
milling wider slot cutting tool shown in
(b)
Fig. G2: Cutting tool and sequence for milling T-slot
3) The complexity of a casting varies with the fluidity of melt. Describe

with the aid of sketches the setup features and operational principles
of a system for comparing such fluidity.
Guides to solutions: (Ref to Slide 6 in notes “Manufacturing Processes
(1)”
Note: Fluidity of melt is a measure of ability of fluid to flow. Higher
fluidity means lower the viscosity and eases of fluid in filling narrow
and thin channel for the production of more intricate geometry of a
casting. Although there is viscometer available, it is impossible using it
to compare metallic materials since their solidification will jam and
spoil the viscometer.
In foundry, the device, as sketched in Fig G3, is normally used to

compare fluidity of metallic melts.
Fig. G3: A device for comparing fluidity of metallic melts
The setup feature consists of a pouring cup connected to a well or

barrel at the bottom by a sprue. Spiral tubes are connected to the
barrel as shown in Fig. G3.
The operational principles: Liquid metal is poured via pouring to sprue,
barrel, and flow through spiral tube. Due to heat loss, the melt at flow
front is cooled to its frozen temperature and solidified. The
solidification stops the liquid metal flow across the solidified flow
front. Hence, longest the solidified flow front from the barrel means
highest the fluidity of the liquid metal.
4) The bisected shell wall (Fig. 3) of casting, which is formed by pouring

melt into the cavity of a mold and leaving to cool for 1 minute,
followed by pouring away the remaining melt. Elaborate why the
corner A is thinner than Corner B. What is the implication of such
finding?
Fig. 3: Bisected shell wall of a casting poured away the remaining melts after
1 minute cooling
Guides to solutions: (Ref to Slide 9 in notes of “Manufacturing Processes

(1)”
If we take an element height dx on the vertical surface of the smaller
outer wall for the inner corner A and on that of large outer wall for the
outer corner B. Their corresponding surface with dx high for corner B is
larger than that for inner corner A. Hence, more heat can be transferred
via the surface at external corner B than that via that at inner corner A.
This partly attributes to form thicker casing at B than A. Furthermore,
there are horizontal surface and vertical surface for heat to disperse
from the mold to give higher amount of heat accumulation and
temperature at A. The external corner B only allows heat to disperse
outwardly and hence no heat accumulation at B, thus with lower corner
temperature. As TA > TB, the melt thus transfers more heat out at B then
at A to give thicker shell wall at B than at A.
5) Fig. 4 shows a casting design which is just removed from the molds
and still with solidified casting materials remained in pouring cup,
sprue, well, runner, gate, side riser, and top riser. Mention the
functions of riser in casting. Discuss the likely problem occurs in the
casting if the risers are completely absent.
Fig. 4: Profile of a casting with frozen materials in its gating systems and
risers
Guides to solutions: (refer to Slide 6 in notes “Manufacturing

Processes (1)”)
Functions of risers in casting: (i) entrapping air from the cavity and
gating systems; (ii) ensuring completely filling of melt into mold cavity;
(iii) re-distributing temperature of mold wall in controlling the
solidification direction of melt in mold cavity; and (iv) remaining melt
in riser to refill any possible shrinkage cavity in the middle of bulk
melt region in casting.
Problem without risers: Melt in some cross sectional plane between
the two larger bulk materials at either end is likely to solidify first,
which isolates the melts at either side of the early solidified plane.
Hence, the middle of the largest bulk at the far side from pouring cup
may have melt to solidify the latest and it creates shrinkage cavity
due to contraction problem when the remaining melt finally solidified.
The problem clearly indicates that utilizing risers to modify the

temperature distribution of mold wall so as to promote direction
solidification is favourable in casting process. Additional, designing
casting with appropriate geometries is a must in ensuring the casting
quality.
6) Briefly mention the sequence of operations of sand casting process.

Guides to solutions: (Ref to Slide 16 in notes “Manufacturing
processes (1)”)
The sequence of operations is illustrated as sketches below.
It basically involves with the following steps. The flask is rammed with
sand and the plate and inserts are removed. (h) The drag half is
produced in a similar manner with the pattern inserted. A bottom
board is placed below the drag and aligned with pins. (i) The pattern ,
flask, and bottom board are inverted; and the pattern is withdrawn,
leaving the appropriate imprint. (j) The core is set in place within the
drag cavity. (k) The mold is closed by placing the cope on top of the
drag and securing the assembly with pins. The flasks the are
subjected to pressure to counteract buoyant forces in the liquid,
which might lift the cope. (l) After the metal solidifies, the casting is
removed from the mold. (m) The sprue and risers are cut off and
recycled, and the casting is cleaned, inspected, and heat treated
(when necessary).
7) Describe with the aid of sketches the setup features and operational
principles of squeeze-casting.
Guides to solutions: (Refer to Slide 20 in notes “Manufacturing
processes (1)”)
Following sketches the setup features and illustrates its operational
principles.
Basically, the setup features (LHS Figure) include a bottom die with
cavity at its top, an ejector pin at its bottom hole, a top die with
protrusion part at its bottom, and a crucible for scooping melt from
furnace.
Its operational principles include (i) firstly melt the metal and setup
the features accordingly; (ii) scooping the melt from furnace and pour
the molten metal into the cavity of the bottom die with the crucible;
(iii) lowering the top die with its protrusion part squeezing the molten
metal in the cavity of bottom die; (iv) the molten metal in the bottom
die is squeezed to fill the clearance formed between the inner wall of
bottom die cavity and the outer surface of the protrusion part of the
top die; (v) the melt in the clearance is then allowed to cool and
solidify; and (iv) lifting up the top die and ejecting the ejector pin up
to retrieve the solidified cup from the cavity of bottom die.
of ring rolling process. Mention how to use the process to pattern the
inner wall as shown in Fig. 5.
Fig. 5: The inner wall pattern of a rolled ring

processes (2)”)
The sketch of the setup is as shown in Fig. G4 below.
Fig. G4: Setup of a ring rolling process
Setup features: The setup includes (i) a main roll which is driven by
power transmission machine, (ii) an idler roll, (iii) a rounding roll, and
(iv) a pair of edging rolls if needed, together with the pre-formed and
cut ring workpience, as shown in Fig. G4.
Operational Principles: After the setting of the rolling system as

shown in Fig. G4, the ring wall at the positions where are in contact
with main roll, idler roll, and rounding roll is compressed by the
exertion of compression between idler roll and main roll, and between
the idler roll and rounding roll. The annular between them is thus
getting thinner, with its height and both inner/external diameters
increase. By suitably setting the gap between the pair of tapped
edging rolls, it is possible to control the height or depth of the
annular wall.
Inner wall pattern of the rolled ring, as shown in Fig. 5, is achievable

by properly shape the anticipated profile on the idler roll which is
subsequently compressing against the flat main roll and the flat
rounding roll.
9) Fig. 6(a) shows a simple upsetting process to height of an original
workpiece while Fig. 6(b) illustrates the setup features of a cogging
operation in progressively forging a workpiece with smaller die-
workpiece contact. Elucidate the corresponding advantages and
limitations of the two processes.
(a) Upsetting a billet from ho to h1 (b) Cogging of a workpiece
Fig. 6: Two upsetting processes in reducing height of workpiece
Guides to solutions: (Refer to Slides 14 and 15 in notes

“Manufacturing processes (2)”)
For the upsetting of billet with the use of a pair of flat dies as shown
in Fig. 6(a), the volume due reduction of height from ho to h1 is
suitable amortized to expand the volume around its surface, which
leads to increase in instantaneously contact surface Ac between die
and billet. On the basis that force F to initiate the instantaneous
deformation can be approximately expressed as F = Yf Ac in which Yf
is the instantaneous yield stress of the billet. Theoretically, the
forging force of the process is thus increasing with the increase in Ac
as the forging is progressing. It may come to a stage that the tonnage
of a press may be exhausted and not possible to precede further (let
alone the possible increase in Yf). Furthermore, its deformation can
be quick under the limiting surface contact.
For the cogging process as shown in Fig. 6(b), the die width is kept
constant, hence giving constant contact surface area of Ac which
means the forging force is supposed to be constant throughout any
cogging stage. The progressive cogging allows the deformation of
large surface to be achievable with limiting press tonnage although its
summative power involved in the deformation may be much higher than
the case in Fig. 6(a). Furthermore, the completion of deformation is
relatively much slower.
10) Fig. 7 shows the various pre-forming stages in forging a cylindrical
rod (Fig. 7(1)) to a finished product as shown in Fig. 7(5). Elaborate
why the shape in Fig. 7(1) should firstly change to the shape as
illustrated in Fig. 7(2). Describe with the aid of sketches the setup
features and operational principles to the two processes which can be
used to transform the shapes.
Fig. 7: Stages of pre-forming involved in converting a cylindrical rod

to finishing product of a connecting rod.

Processes (2)”)
Comparing the shape of the raw material (Fig. 7(1)) with the finished
product (Fig. 7(5)), it requires more materials accumulating to either
end of the product to form both end-features (Fig. 7(5)) and also to
squeeze the materials from the connecting part at the centre. As
seen in the geometry of the part shown in Fig. 7(2), it consists of the
large bulk of material which is connected by the slim region in the
middle to a small bulk of material at the other end. The large bulk is
for the production of the l.h.s. feature and the small bulk for making
the r.h.s. feature of that shown in Fig. 7(5).
Ref to the sketches of the two processes as shown in Fig. G5, the one
shown in Fig. G5(a) is for squeezing away materials from the middle to
either end. The one shown in Fig. G5(b) is to accumulate materials
from either end to the middle.
Fig. G5: Two processes to displace and/or to accumulate materials
Fig. G5(a) is a fullering process and its setup consists of a pair of

convex dies. During the operation, a workpiece is sandwiched in
between, its convex surface when is pressed into the workpiece
serves to displace materials from the centre to either end of the dies.
Fig. G5(b) is an edging process and its setup consists of a pair of

concave dies where allows the accumulation of materials from either
end of the die pair, when a workpiece is compressed between the pair
of dies.
principles of (i) a direct extrusion process and (ii) a tube drawing
process. Contrast the two processes.
Guides to solutions: (Refer to Slides 22 and 25 in notes

“Manufacturing processes (2)”)
(a) Direct extrusion (b) Tube drawing
Fig. G6: Illustration of extrusion and/or drawing processes
Direction Extrusion Process:

Setup features: As shown in Fig. G6(a), it consists of a container or
chamber in which container liner is mounted. A die with opening for
the shape of product is located in front of the chamber and mounted
tightly onto the end surface of its outlet by a die backer. At the back
of the container, a press stem is activated to move to and fro by a
hydraulic cylinder. There is a dummy block sandwiching between the
workpiece in the chamber and the piston of the press stem.
Operational principles: After setting up the system, a workpiece is

placed in the inner hole of container line. The hydraulic cylinder is
then activated to move the press stem forward, which creates force
to compress and deform the workpiece within the chamber.
Subsequently, the deformed workpiece is pressed out from the
opening of the die situated in front of the chamber. Generally, the
relative slip between the inner surface of container liner and
workpiece wears of the liner which can be replaced easily and cheaply.
The indented dummy block can also be easily be replaced so that it
would not affect the throughput during replacement duration.
Tube drawing process:

Setup features: As illustrated in Fig. G6(b), a die with opening for the
shape of product is mounted in a drawing bench rigidly.
Operational principles: A tube which is pre-fabricated by other

process is firstly shaped to insert through the die opening. A clamping
mechanism is then gripping on the inserted through end and pulling the
pre-fabricated tube out from the die opening. Subsequently, the tube
outside and inner diameters are reduced with possibility of wall
thickening.
Contrasting the two processes:

In extrusion, the workpiece is placed in a container/chamber and
being pushed by a press stem to deform flowing out from the die
opening. The constraint of chamber wall prevents the workpiece to be
buckling during compression. However, the interfacial contact between
container inner wall and the workpiece creates friction when relative
slip takes slip as press stem moving the workpiece forward in direct
extrusion. In direct extrusion, such friction force is reducing with the
workpiece being shortened in the container.
In tube drawing, the tube is not placed in container and its surface
upstream of the opening of die is not constrained, hence no friction
involved. Loading force may not be possibly applied to compress the
tube forward through the die since buckling likely hinders the
successful operation of the process. The front end of the tube is thus
pre-formed to insert through the opening of die, which is followed by
gripping to pull it out from the die. As the pulling may apply tensile
force to deform the drawn tube, hence sufficient cross sectional area
should be given to prevent any premature breakage during drawing.
MBE3119 ed:6th March 2
9 Test(1) Date 2018; For Oddd Number seaats

MBBE 3119 – Maanufacturing TTechnology
Test 1(a) – Processes for manufactturing metal p
parts
Date: 6 March 20118
Answeer All Questio ns
1) Fiig. 1(a) illustrates alloy solidification and temperatu re distributio
on in the mold
d. Fig. 1(b) is tthe
phase diagram m of Ni‐Cu.

(a) Illustrration of alloyy composition
n and (b) A Phase Diagraam of Ni‐Cu
solidificatio
on in mold

Figg. 1: Composittion and solid
dification of a lloy, and phaase diagram o
of Ni‐Cu

(i) On the be the illustraation phenom
e basis of illusstration in Figg. 1(a), describ mena of alloy
compo osition and so olidification inn mold, and aalso its effect on freezing leength in
solidifiication front
(5 marks)
Answer: ((Guides to solution)
Fig. 1(a) illustrates that the solid plane is growingg from mold w wall to the co
ore of mold. In n
progressio on of solidificaation, the tip of dendrites orientating to o the core is tthe solidificattion
front, whe ere solidificatiion starts and d propagates.. As shown in the part of p phase change
diagram in n LHS of Fig. 1 1(a), the incre
ease in the co ncentration o of lower meltting point element
compositio on tends to in ncrease the distance of sollid plane and the solidificaation front, w which
is the length of freezingg range. Gene erally, longer freezing rangge means more side branches
of dendrite es is likely forrmed. Higher probability oof such branch hes from vicinnity grows to
touch and block off rem maining metal solution wit hin branchess from other liquid from co ore.
1

MBE3119
9 Test(1) Dateed:6th March 22018; For Odd d Number seaats

(ii) On thee basis of the idea acquiredd from (i) aboove and the p
phase diagram m shown in Fiig.
1(b), d
describe whatt individual cu
urves are rep resenting forr and, with a ssuitable reaso
oning
and skketch if appro
opriate, the in
nfluence of al loy composition (or space distance bettween
the tw
wo curves) on the quality, in term of thee formation oof microporossities, within tthe
castingg when the caasting is unde
er the conditi on of naturall cooling.
(18 marks)

Answer: ((Guides to solution)
Th he top curve

e is the liquidus curve, which
w represeents the corrresponding ccomposition eeither
coompletely me elt when heatted to the resspective tempperature, or sstarting to so olidify when ccooled
frrom some tem mperature much beyond ccompletely m molten state. TThe bottom ccurve is the so olidus
cuurve which m means solid co ommencing to o melt or com mpletely solidified when heeated or cooled.

Th he spacing between
b two
o curves is firstly
f divergiing to a maximum and then followeed by
coonverging to low melting point Cu, with reducing the concentrration of high h melting point Ni
an nd increasingg concentration of low me elting point eelement com mposition. Geenerally, the wider
sppacing meanss longer freezzing range wh hich tends to rresult in longger dendrite tip from solid plane.
Th his gives morre side branch hes along eacch dendrite, aalso a pair of neighboring dendrites ten nds to
grrow, touch each
e other, and
a subseque ently block ooff those remmaining liquid
d alloy from those
liq
quids outside e the branch hes complete ely. Hence, tthese entrap pped liquid aalloy when ffinally
soolidified contracts to form microporositties, during n atural coolingg.

es the cavity in a casting mold which is derived to verify Chvorrinov’s Rule, w
2) Fiig. 2 illustrate which
sttipulates thatt:
(1)
Describe with the aid of suitable sketches the exxperiment yo ou have learrnt, which caan be
performed to pprove Chvorin nov’s rule as specified in EEquation (1) aabove.
(14 marks)

Fig. 2: The bis
F ected solidifie
ed cavity shell of casting m
mold which is poured with metallic melt and
overturnned to drain aaway those reemained mettallic liquid affter 5 s solidiffication time

2

MBE31199 Test(1) Date ed:6th March 2 2018; For Odd d Number seaats

Answer: (Guid
A des to solution)
Th he experimen nt involves of
o making 4 id dentical moldds having sm
maller cavity aat the bottom m and
laargest cavity at the top, and an interm mediate size ccavity in the middle. All three cavitiess have
saame height. TThe four mold ully with sam e liquid metaal, and alloweed to cool for 5 s, 1
ds are filled fu
min,
m 2 min, an nd 6 min, resspectively. Th
he remainingg liquid meta l in individuaal molds is po
oured
aw way and thee solidified shell
s is taken
n out. Obse rving the co
orresponding solidified skkin in
in
ndividual cavitties facilitates the provingg of the Chvorrinov’s rule, EEq. (1) as show wn.

Basically, afterr 6 min of solidification, th he smallest voolume it givees completelyy solidification n with
thhe cavity containing smallest amount o of liquid meltt, which is folllowed by alm most half solidified
laarger cavity whilst the largest
l one gives largesst empty ho ole after pou uring away those
unsolidified melt.
m This imp plies solidification is propportional to volume of mmelt. Furtherm more,
affter I and 2 min of solidification, the average soli dification skiin for larger surface is th
hicker,
im
mplying solidification time is inversely p proportional tto surface areea.

3) Describe with the aid of skketches the fe eatures and ttheir corresp ponding causing mechanisms of
thhe following d defects likelyy to be observved in castingg. Suggest meethod or app proach to min nimize
thheir taking plaace in castingg.

(i) Hot tear in casting aa tall and largge annular coolumn (5 marks)
(ii) Blisterr (5 marks)
(iii) Wash (5 marks)
(ivv) Misrun n (5 marks)
Answer: (Guid
A des to solutio
ons)
(i) (Ref to
o Slides 39 and 40 in notess of Lecture N
Notes 1, and the illustration
n below)
The coore in the cyylindrical cavvity around ttends to resiist the contrraction of the
castin
ng during solidification. TThe casting sstarts to solidify from far LHS towards
the RHHS where sp prue and gating system aare located. Also the run nner only
3

9 Test(1) Date 2018; For Odd
d Number seaats

conneected to the top of the casting meanns the refillin ng of material from the
pourinng cup only tto the top. HHence, the fiilling of material from th
he around
shrinkkage during ssolidification
n exhausts ccasting mateerials makingg insufficientt
materrials at these
e zone which h under the resistance to o shrink by tthe core mold
result in tearing o
off at such reegion

The possible
p proach is to place gate to the top
app p, middle, as well as to
o the
bottom.

(ii) (Ref to
o Slides 41 and
a 43 on Le ecture Notes 1, and Fig. bbelow): ‐ It iss holes on caasting
surface with a bit o of material covering on thhe top surfacce. They are mainly due tto the
air/gass bubbles en ntrapped between mold and casting interface, which preventts the
complete filling of material. How wever, the veenting hole aallows partial evacuation o of gas
and thhus some me elt filled to cover
c to the top. The irreegular bottom surface off hole
mainlyy due to the m material shrin nkage problem m. It could bee overcome iff proper ventting of
air/gass is facilitated
d from the cavvity of the moold.
(iii) (refer to Slides 41 aand 42 on Leccture Notes 11, and figure b below):‐ Wassh is the additional

castingg material onn casting surfaace closer to the gate entrry. It is somettimes appearring in
sand casting
c and iss likely resultted from thee turbulent fllow of melt washing awaay the
sand around
a the gate entry wh here subsequuently being ffilled with thhe liquid metal. To
minimize its occurrrence, properr design of gaating and running systemss is necessaryy so as
to promote laminarr flow during filling of liquiid metal.
(iiv) (Refer to Slides 41 aand 43 on Leccture Notes 11, and Figure below) :‐ Cold d shut. Whenn the

cavity of a mold is ffilled by two o
or more streaams and the ttemperature of the melt iss not
sufficie
ently high, the flow front oof the stream
ms likely reachhes the freezing temperatu ure of
the me elt before mixxing each othher. The interfface of the sttreams is thuss not properlyy
fused ttogether and thus became e the weak pl ane of the caasting. To oveercome such
defectt, suitably insu
ulating the ch
hannel surfac e so as to red duce cooling rrate, and/or
suitably raising the temperature e of melt befoore pouring are necessary..

4

9 Test(1) Date 2018; For Odd
d Number seaats

4) Fiig. 4 is cross‐‐sectional view of a pair oof sand castinng mold. Describe the purrpose of indivvidual
fe
eatures. Discu uss why the in ndividual feattures are so aarranged and designed.
(18 marks))

Figg. 4: The desiggn of a pair off sand castingg mold.

Answer: (Guid
A des to solutio on)
(RRef to Slide 4 in Lecture No ote 2, and Figg. 4 above) : ‐ The designed d features of a sand mold for
saand casting (FFig. 4 above) mainlyt consiists two half m mold which iss mainly made of sand in
metallic flask f
m for easy handling and stren ngthening. Caavity of a castting and its asssociated riseers,
gaating and runnner system are made from m or along pa rting line. Do ownwardly tapping sprue
promotes lamiinate flow and prevent enttrapment of aair/gas to forrm oxide impu urities. The saank
well at the end
w d of sprue me eans to gather initially form med oxides so o as to purify to certain exxtent
melt into mold
m d cavity. Runn ner channel allows melt floowing through to cavity. The middle bliind
riser connectin ng the top surrface of runne er serves to ( i) trapping air/gas from up pstream, (ii)
skkimming impu ure oxides at its LHS corne er, (iii) trappinng excessive m
melt to ensurre complete ffilling,
(ivv) modifying temperature distribution of mold so thhat filled meltt freezing from m far LHS sidee of
mold to RHS, a
m and (v) refillin
ng melt to occcupy space le ft in shrinkagge cavity. The vent assists tthe
veenting off inittial air/gas in cavity. The open riser alsoo assists air/ggas venting an nd complete ffilling
off cavity. The ssand core clamped in the m middle of cavvity means to prevent meltt filling up thee
position so thaat a hole can be produced in the castingg.
Inn Sand Castingg, the top hallf mold is normally named COPE while iits bottom co ounterpart is
teermed DRAG

5

9 Test(1) Date 2018; For Odd d Number seaats

5) Describe with the aid of ske etches the settup features aand operatio nal principless of (i)
Seemicentrifugaal casting and
d (ii) centrifugging casting. G
Give reasons why semi‐cen ntrifugal casting is
named. Advise e how one can n use centrifu uging casting to purify the casting from lighter densiity
im
mpurities.
(25 marks)
Answer: ((Guides to solutions)
(i) SEMI‐CEN
NTRIFUGAL C
CASTING (Refe
er to Slides199 in Lecture N
Note 2 and thee sketched Figure
below)): ‐

Sketched figure to sho
ow the setup features of seemi‐centrifuggal casting pro
ocess

Setup featu ures of semi‐ccentrifugal casting (see: Thhe above sketched figure) consists of:
For (i) a sand mould iin a flask thatt is fastened tto a revolvingg table by somme holding fixxtures,
(ii) a casting cavity sittuated acrosss the central pportion of thee parting surffaces of the m
mold,
and (iii) a pouring bassin and gate ssystem at thee central portion and on th he top of the mold.
It shouldd be noted that the castingg is directly u nder the pou uring and gating system.
Its Operatioons are basiccally as:
In perforrming the cassting, the revo olving table iss rotating whilst molten caasting material is
being pooured from th he pouring baasin down thrrough sprue to the casting cavity, the sp pread
of materrial directly att the central portion is duee to the actio
on of pressuree in the pouring
basin, w
whilst those offf the center iis pushed by ccentrifugal foorce to fill resst portions of the
casting. Owing to the e reason that the internal fflow of castin ng is under the combined aaction
of centriifugal force and pressure h head in the poouring basin, the casting iss thus termed d
semi‐cenntrifugal casting.

(ii) CENTRIFUGING CASTIN NG (Refer to SSlide 19 and SSlide 20 in Leccture Note 2, and to the
sketched FFigure below))

Ske
etched figure shows a setuup of centrifugging casting
6

MBE3119 Test(1) Dated:6th March 2018; For Odd Number seats

Features (Ref to sketched Fig above):
The above sketched figure shows the features and operational principles of a typical
centrifuging casting process. Its configuration includes: (i) a circular mold with cavities of
castings situating at the periphery of mold, (ii) a runner and gating system situating in the
central portion of the mold where molten material can be filled in a pouring basin at the
center. The casting mold system is fastened to a revolving table.

Operations:
When molten material is poured into the pouring basin in the center of the casting
system, the combined action of pressure head and centrifugal force pushes the material
through the runner and gating system in the central portion to the cavities of castings
situating at the periphery of the circular mold. The equipment will still be revolved until
all the material casting cavities completely solidified. Because of the filling melt into the
casting cavities is entirely due to the action of centrifugal force, the process is thus called
centrifuging or spin casting. It is noted from the sketched figure that the bulk of a cavity
can be located at the outside portion of the periphery when this process is used.

Ref to the sketched figure for Semi‐centrifugal casting : ‐ Owing to the reason that the
internal flow of casting is under the combined action of centrifugal force and pressure head
in the pouring basin, the casting is thus termed semi‐centrifugal casting.

Technique to purify the casting from lighter density impurities : ‐ As centrifugal casting
normally involves with centrifugal force which is increasing with increase in the distance
away from the center, and higher the mass of casting tends to result in larger centrifugal
force to move faster. Hence, the lighter one normally tends to gather around the inner
cavity. Hence we can purify the casting if we design thicker for those features orientating
towards the center of the casting equipment, and subsequently machining off these
features off to the anticipated dimensions.
7

MBE3119
9 Test(1) 6 Maarch 2018 Forr Even Numbe er seats

MBBE 3119 – Maanufacturing TTechnology
Test 1 (Evven number sseats) Daate: 6 March 2018
Time alllowable: 1 hoour
Answe
er ALL questioons
1) Fiig. 1(a) showss a cooling curve of a pure metal. Fig. 11(b) illustratess the develop
pment of a
preferred texture at a cool mold wall.

(a) Co
ooling curve o
of a pure metaal ( b) Developm
ment of a prefferred texturee at a
cool moldd wall
Fig. 1:: Cooling curvve of parent m
metal and devvelopment off texture at a cool mold

(i) If a me
etal with high
her melting po
oint is alloyedd into melt off the pure meetal and both are
in sam
me temperature, which are e then allowedd to cooling. Describe with h suitable
reasonning which eleement in the alloy is likely
y to solidify firrst.
(5 marks)
er: (Guides to solutions)
Answe
Generally, the higher melting po oint temperatture will be reeached first d during coolingg.

Hence, the elementt with high m melting point i s solidified eaarlier than itss low melting point
element if the alloyy is well insulaated and coolled to a temp perature hommogenously.
Howevver, if the high melting poiint element iss evenly distrributed and att the vicinity of
almostt reaching its melting poin nt, it is generaally solidified first.
(ii) If Fig. 1
1(b) shows th he developmeent of texturee for the alloyy in (i), explain
n why the texxture
in chilll zone is as sh
hown. With ad
dequate reassoning, elucidate why the ccolumnar texxtures
can successfully gro ow toward to the core.
(6 marks)
er: (Guides to solution)
Answe
In view
w that high m
melting point is firstly reachhed and solidified during ccooling, and
undersstanding the temperature on inner surfface of mold is fluctuatingg about its aveerage
value, such element at the viciniity of the wal l where has ttemperature reaches the
1

MBE3119

freezin
ng temperatu ure is thus nuccleated. Its suurrounding ellements pass though it to
disperse away relattively quickerr, hence solidiified to enlargge the size off dendrite andd
successsfully growin
ng towards the core for forrming column nar textures. In the early stage
of suchh growing proocess, those eelements neigghboring to itts vicinity wall also become
nucleaated when tem mperature co ooled down too its freezing point. Their ssolidification
allowss them to groww around which are subseequently blocked by those pre‐successffully
growth h dendrites to
o form finer ggrain structurres. The layerr of such densse fine grain
structu
ures thus formms chilled zonne.
(iii) If Fig. 1
1(b) shows thhe developme ent of texturee for the alloyy in (i), with adequate
explan nation, anticip
pate which te
exture, e.g. thhe columnar o or the grain between two
neighb boring colum
mnar grains, closer to the coool mold wall is having higgher content of
high mmelting point aalloying metaal.
(9 marks)
Answe
er: (Guides to solutions)
In view ements to be early solidifieed closer to in
w that the ele nner wall are those with higher
meltinng point, as m
mentioned in ssub‐question (i), in the liqu uid alloy, also
o these firstly
nucleaated structurees are able to o grow successsfully toward ds the core off casting cavitty as
mentio oned in sub‐qquestion (ii), it can thus bee anticipated tthat those sm maller grains iin
betwe een each pair of successive e neighboringg columnar grrains are nucleeated at the llatter
stage tthan those suuccessfully gro ow toward thhe core. On th he growing naature of grain n
structuures as descriibed, it is posssible to envissaged that thee columnar n next to the innner
wall off the mold co
ontaining high her amount off high meltingg point elemeents than tho ose in
smalleer and finer grrains in the chhilled zone.
2) Fiig. 2 illustrate esign and its relevant systeems of (i) pou
es a casting de uring and gatting, and (ii) risers
within a pair o
w f casting molds. Specify th
he functions oof risers in cassting. With apppropriate
reeasoning, desscribe how the solidificatio on phenomenna likely to bee within the m mold cavity fo or the
caasting. From yyour afore‐de escription of ssolidification,, describe wh
hy the right haand side top rriser
iss as located.
(16 marks))
.
Fig. 2: Schematic illusstration of a ttypical rise‐gaated casting
2

MBE3119 Test(1) 6 March 2018 For Even Number seats

Answer: (Guides to solutions – Ref to Slide 30 to Slide 32 in Lecture Note 1, and Fig. 2 in the test
paper)

Functions of risers (Slide 31, Lecture Note 1)
The risers in a sand mold play the following roles
1) Ensuring the complete filling of casting cavity
2) Entrapping air/gas from its upstream so as to minimize air/gas bubbles in casting
3) Modifying the temperature distribution around the casting cavity so as to promote possible
directional solidification
4) Refilling liquid metal to the space left due to material shrinkage at some positions next or
closer to the riser.

Solidification Phenomena and why the right hand riser on the top of RHS side bulk (Slide 32,
Lecture Note 1)
Assuming the design of gating system without the top riser at the largest bulk at RHS and the
side at far LHS, the temperature distribution in the middle of the two end bulks is generally the
lowest and solidification starts at this plane. The solidified plane blocks off the remaining liquid
metal at either bulk. However, shrinkage of solidified material at LHS may be refilled by liquid
metal in gating system. However, the blocking of solidified plane tends to result in shrinkage
cavity in the middle of RHS bulk.

• With the introduction of the two risers as shown, it modifies the temperature distribution in the
mold wall and provides sufficient time to fill the possible space left due to shrinkage during
solidification. Furthermore, the liquid in the RHS top riser can flow back to refill the shrinkage
cavity at the larger bulk underneath. As a consequence, the quality of the casting can be
ensured.

The reason why the right hand side riser is on the top of the RHS bulk is partly taking advantage
of those heat released from the riser during the cooling so that it heats up the middle section of
the mold to make the temperature more even. This facilitates the melt in casting cavity almost
cooling down in the same pace as possible. By doing so, the excessive melt in the two risers can
fill the space at the top layer of cavity due to the shrinkage of solidified liquid metal originally in
the cavity.

3) Describe with the aid of sketches the features and causing mechanisms of following defects
likely to be seen in casting. Suggest also the possible way to minimize their corresponding cause.

i) Blow, and scar (7 marks)
ii) Scab (5 marks)
iii) Cold shut (5 marks)
3

MBE3119

Answer: (Guides to solution
ns – Refer to SSlides 39 to 444 in Lecture Note 1 for deefects)
(i) Refer tto Slides 41 and 42 in Lectture Note 1
Sketch
hes of feature es as below
Both bblow and scarr are holes on n the skin of aa casting as seeen in the skeetches (a) and d (b),

respecctively. They aare both formmed due to thhe pressurized d air/gas entrrapped betweeen
the intterface of inner mold surfaace and outerr surface of a casting. Blow w is hole with h
regular curving surfface at the boottom and is ccommonly fo ound on the to op of curving
surface casting. The e uniform currvature on thee bottom imp plies it is merely formed due to
the airr/gas bubble. Scar is also h
hole which is hhaving irregu ular bottom su urface. It is
formed by air/gas b bubble at site
e and by non‐ uniform shrin nkage of the m material arou und it.

Both bblow and scarr can be eliminated if propper venting ho oles are situatted around
castingg cavity, or slo
ow down relaatively the fillling speed of melt into cavvity so as to
furnishh with sufficie
ent time to evvacuate the aair/gas.

(ii) Scab (R
Refer to Slide
e 41 and Slide
e 42 in Lecturee Note 1, and
d following skketch)
The ke
etch of featurres is as show
wn below.

Sketched FFigure to sho w the featurees of scab
As seen in the sketch, Scab is incomplete fillingg or hole(s) ju ust beneath th he surface of a

casting. It is mainly due to the evo olution of gas//air from melt during solid dification is sllower
than the
e surface solid dification ratee, thus causinng the air/gas entrapment.. To minimizee its
causes, iit may requiree raising suitaably the moldd temperaturee to certain leevel so as to
prevent the pre‐matu ure solidificattion prior to tthe surfacing off all the air/gas from thee
central rregions of thee casting.

(iiii) Cold-sshut (Refer to
o Slides 41 and 42 in Lectuure Note 1, annd the followiing sketch)
ketch of cold-shut features is as shown bbelow.
The sk
Sketched Figure to shoow the featurees of scab
4

MBE3119
9 Test(1) 6 Maarch 2018 Forr Even Numbe
er seats

• Cold shuut. As seen from the above sketch, its ffeatures are ggenerally relaated to meltss from
two oppposite stream
ms in a thin channel
c with wide surfacee. The two sttreams meetts and
their solidified front and thus form ms creak‐linee vertically across the chan nnel as seen in the
sketch above.
•
• When th he cavity of aa mold is filleed by two or more stream ms and the teemperature o of the
melt is not sufficiently high, thee flow front of the streams likely reaaches the freeezing
temperaature of the melt
m before mixing each other. The in nterface of thhe streams iss thus
not propperly fused to ogether and th hus became tthe weak plan ne of the castting.

It is possible to minimize the taking
t place of cold‐shu ut by: (i) raising up the melt
temperaature before it is filling in
nto cavity; annd (ii) suitably insulating tthe surface o
of the
channel wall so as to reduce amount of heat trransferred aw way prior to tthe meeting o of the
streams..

4) Fiig. 3 is a pair oof casting moolds which are e individuallyy filled with th he melt of a m metal. Fig. 3(aa)
illlustrates the filled mold haas been overtturned and pooured away rremaining liqu uid metal afteer 1
minute and Fig
m g. 3(b) has been done after 6 minutes. TThe correspo onding solidified shell is theen
reemoved from the mold cavvity, which is then bisectedd to give solid dified cast skiin as shown.

(a) (b)
dified skin on a steel castin
Fig. 3: Solid ng
i) Elu
ucidate why tthe inner corn ner A is thinn er than the o
outer corner B B in Fig. 3(a).
(6 marks)

ii) Fro
om the reduccing of emptyy space from tthe bottom to o the top in the solidified skin
as shown in Figg. 3(a), and the cross‐sectioon at the top being is fullyy solidified whhilst
the middle secttion is almostt completely ssolidified andd large amoun nt of liquid metal
at the bottom ssection is pouured away, ass seen in Fig. 33(b), elaboratte what facto ors
on time of a casting is depeending on and explain the relevant reasons.
the solidificatio
(8 marks)

iii) What consideraations can you deduce, froom (i) and (ii) above, on deesigning a cassting
wiith high produuction througghput and goood quality?
(6 marks)
5


Answer: (Guides to solutions – Refer to Slides 35, 36, 37 and 46 in Lecture Note 1)
(i) (Ref to Slide 37 in Lecture Note 1): ‐ The solidification skin of the bisected shell in Fig. 3(a)
at inner corner A to be thinner than its counterpart at outer corner B, this mainly
because heat received by mold material at A is much higher due to their transmission
from its vertical wall and its horizontal wall, which is accumulated to increase
temperature at A. However, the heat received from B is only through the vertical wall
and tends to be diverged outwardly. As a result, TB<<TA. Furthermore, the heat transfer
surface with element of equal height x at B is much larger than at A. Summative of the
above two factors thus makes the solidification of melt within cavity at A slower than
that at B. The faster solidification thus results in thicker shall skin at B than at A.
(ii) Fig. 3(a) shows the solidified skin of the shell along larger cavity is averagely thinker than
those along smaller cavity. As the larger cavity has larger surface area, it means that the
solidification time is inversely proportional to the surface area of a cavity. Fig. 3(b)
illustrates that all melts in the smallest cavity are in solidified state, and larger the cavity
tends to have larger empty space left. As larger cavity contains more melt than its small
counterpart, which takes longer time to cool down to their complete frozen state, it
suggests that solidification time is directionally proportional to the volume of melts
since larger the cavity contains more melts. This is the experiment which is normally
performed to verify the Chvorinov’s rule, which states the solidification time of a casting
needed is directionally proportional to its volume and inversely proportional to its
surface area (ref to Slide 28 in Lecture Note 1).

(iii) The phenomena observed and analyses of (i) and (ii) indicate that the promotion of
production throughput requires designing casting which can be quickly solidified so as to
promote production rate. Design of casting to eliminate accumulation of heat around
the mold is essential. The achievement of this requires the prevention or reduction of
surface features with lesser interfacing of vertical wall and horizontal walls, so as to
form inner corner like A in Fig. 3(a) and promote outer corner like B in Fig. 3(b).
Furthermore, the result from Fig. 3(b) suggests that the use of uniform cross sections in
various features if possible. This also surely maintains good quality of casting since it
would not result any remaining melt to solidify at latter stage, which susceptibly forms
shrinkage cavity. In addition, implementation of risers should always locate at larger
cross sectional regions/bulk features since they are prone to forming shrinkage cavity.
5) Sand mold is a crucial component in sand casting. Describe with the aid of sketches: (i) how a
pair of sand molds of a pattern can be made?; (ii) what considerations a casting designer should
bear in mind so that pattern can be easily removed from the molds?; and (iii) how blind hole and
though hole can be cast in a pair of sand molds? (27 marks)
6

MBE31199 Test(1) 6 Maarch 2018 Forr Even Numbe er seats

Answer: (Guides to Solution ns – Refer to Slide 5 to Slidde 7 in Lecturre Note 2)
(i) Ref to Slide 5 and sketch below: ‐
The skketch of patte
ern plate

A patttern plate for making two halves of castting cavity in mold
The skketch above sshows a patte ern for makinng two halvess of casting ccavity in a mo old. In

buildinng up such mold halves, itt involves firs tly setting reegister pins/points on the plate.
The prre‐fabricated half pattern is thus fixed in related to o the registerred positions,, then
those patterns for (i) are situatted (if it is m aking cope) aaround the h
half pattern ((Note:
the paatterns for (ii) are distribu
uted around the bottom half of pattern initially lo ocated
accord ding to the pre‐set regisstered pins/ppoints for m making drag).. In addition n, the
patterns of sprue, rrunner and gating system s are placed around the top half patteern on
the paattern plate. TThen, flask is placed arounnd the properly laid patterns on the ho olding
plate, and fixed in n relation to o all the pre‐‐set registeriing points. SSubsequently,, it is
followed by depositting the pre‐m mixed sands oonto the pattterns and com mpacted denssely in
the flaask. A holdingg flat plate su ubsequently pplaces on thee top and thee complete syystem
is turn
ned over, wh hich, after the e removal off pattern plaate, is placed on the top of its
counte erpart system m and thus reaadily for fillingg melt.

(iii) Refer tto Slide 6 and
d sketch below
w
The skketches indicaating modificaation of straigght rib pattern to tapped p
pattern
Sketches to illustrate the modification

m oof pattern forr removal from
m sand mold

nd mold is maade of sands which are agggregation of loosening sand grains, alsso the
As san
cavity in a pair of ssand mold is meant to filll with melt, w which is the p
product to bee cast
7

MBE3119

after itts solidificatio
on. If the sannd mold is bu ilt for small b batch producttion, it is gen nerally
expectted that there is not any d distortion of the mold aftter retrieving of the produ uct. In
additioon, the buildiing up of individual half m mold requiress the retrievin ng of pattern n from
the mold halves. In n view that straight
s long rib/leg (LHS of the above sketched figure)
gives large contact area with the aggregatedd sands in san nd mold. The large contactt area
betwe een them resu ults in higher interfacial frriction to resist the removval of pattern plate
out from the mold d. Such difficculty may daamage the ssand mold. TTo overcome such
probleem, taper or d draft angle iss often applieed so that it ggives amble cclearance bettween
the paattern and mold
m cavity when the formmer is just liffted up slighttly. This easees the
removval of both pattern
p and casting from mold with any detrimeental damagin ng. In
designning the draft angle onto the rib/leg, th e width of tip p is taken as tthe specified value
of the rib/leg, and it is widened d upwards wiith an equal d draft angle on each edge.. Such
extra wwidth on castting is generally machined off.
(iii) Producction of blind
d hole in castting (Ref to SSlide 7 in Lecture Note 2, and the follo
owing
sketch
hed figure)
The se
etup features of a pair of saand mold witth core for production of b
blind hole

Sketch of setup feattures of a paiir of mold forr casting blind
d hole’
Hole inn a casting noormally mean ns that it is a hhollow region n and such ho ollow feature is not

passing through fro om one side o of the castingg to another.. Hence, the rregion wheree such
w region need
hollow ds to be occu upied by a soolid core rigid dly clamped. For casting a blind
hole, tthe core cann not be clamp ped in the pa rting line in ttwo end prints. This is because
there are materialss in one end of the end o f the hollow.. Hence, one end of the ccore is
n the cavity. TThis forms caantilever beam
free in m system, wh hich is weakeest support and its
free ennd tends to resume largesst deflection dduring filling of melt. The deflection crreates
probleem of retrievval of the corre from cast casting, and such hole d does not meeet the
specifiication of design specifications in engineering drawing. To o overcome such
deflecttion, chaplet of casting maaterial is usedd to clamp an nd support th he free end of core
(see: The
T above skketched figure e). As the m aterial of chaaplet is the ccasting materrial, it
acts ass a seed or chill to carry aaway heat raapidly, hence it becomes p part of the caasting
after complete off solidificatio on. After thhe casting, tthe mold m may be destroyed
8


completely, the part of chaplets which inserts into cope and drag of the sand mold pair
needs to be machined off accordingly.
9

Test 2(a) M
Manufacturin materials; 27 th April 2018
ng technologies for metal m

Test 2
MB
BE 3119 – Mannufacturing TTechnologies
Allowable Tim
A me: 1 hour 355 minutes
27th April, 20118
Date: 2
Answer ALL Questions
1) If the machine ed surface in tthe corner of a part as shoown Fig. 1 is eend milled, sp
pecify with thee aid
off sketches to illustrate andd with suitable reasoning w whether (i) ho orizontal milling machine oor (ii)
veertical millingg machine beiing appropriaate for perfor ming the macchining task. Give reasons why
th
he milling machine which yyou are not selected is nott adequate fo or such type oof milling.
(20 marks)

Fig. 1: Th
he first pass o
of end milled surface on a “l” long planee block whichh is moved at
longitud dinal and trannsverse velocities “v” and ““w”, respectivvely, to the m
milling cutter

Answers: (Guid
A ons – Ref to SSlides 17, 18,119, 20 and 211 in Lecture Note 6)
des to Solutio

(aa) Schematic illustration of setup features of
a horizontal millingg machine (b) Setup featurees of a verticaal milling macchine

(c) Mountingg of cutter in horizontal miilling (d) Mountingg of cutter in vvertical millin
ng
mach hine and in op perations machine and in opeerations
((f) Illustration
n of cutter in vertical millin
ng
(e) Cutter off horizontal m
milling machin
ne in
machine in operation fo or end milling
operationns

Fig. A1: Com
mparison of ho
orizontal and/or vertical m
milling machin
ne setup and their operations
1

Test 2(a) Manufacturing technologies for metal materials; 27th April 2018

Fig. A1(a) is the schematic illustration of a horizontal‐spindle column‐and‐knee type milling
machine (An arbor bridges the column and the mounting block at the free end of overarm, with
cutter to be fastened through the arbor). Fig. A1(b) shows a vertical‐spindle column‐and‐knee
type milling machine (Cutter is mounted into spindle in the head and spins to cut workpiece
mounted on the mounting table). Due to the approach of mounting cutter (cf. Fig. A1(c) and Fig.
A1(d)), the cutter blade can be vertically upward to generate vertically cut wall in any place
within cutting path for the vertical milling machine (Fig. A1(d)). However, the cutting zone (Fig.
A1(e)) of horizontal milling machine tends to create some slope along the cutting front and the
cutting teethes of cutter likely result in the unsmooth surface. Hence, the accessibility and the
free intermittence nature of end milling, as shown in Fig A1(f), suggest that the operation can
be performed using the vertical milling machine mounted with cutter having constant diameter,
from the bottom to top, which is mounted to the chuck of vertical spindle of the vertical milling
machine. By doing so, the depth and dimensions of end milling can be achievable by
progressively increasing the penetration of cutter into materials roughly, which is following by
final cut to achieve the proper depth and dimensions. Noting that the round corner of the end
milling is mainly as a result of cutter diameter (since smaller cutter diameter reduces its rigidity
and strength so that it is susceptible to break, certain level of round corner is usually allowed in
end milling).

2) A manufacturing engineer is finding a press with suitable tonnage to blank a L peripheral length
off a sheet metal with T thickness and ultimate tensile stress UTS.

i) Adviser him/her how to estimate the maximum punch force
(2 marks)

ii) Suggest 2 feasible approaches to reduce the required punch force so that a pressure
with lower tonnage output can be used for the execution of blanking. Describe the
setup features and operational principles of individual approaches. With the aid of
sketches, comment on the quality of blanked pieces to be achievable.
(18 marks)
Answers: (Guides to solutions – Slides 7 and 8 in Lecture Note 5)
(i) The maximum punch force F can be expressed as F= 0.7 T L (UTS) in which T is the thickness
of sheet metal, L is the periphery of workpiece to be punched out from worksheet, UTS is
the ultimate tensile stress of the workpiece.
(ii) From the mathematical expression for maximum force calculation, the values of T and UTS
are the parameters of sheet metal which are not changeable. Hence, the reduction of the
punch force can be achieved by suitably decreasing the instantaneous L during punching or
blanking. The most popular approaches for the reduction of F is either (i) implementing
shearing (or bevel shear onto the bottom of punch with flat die surface (Fig. A2(a)) or (ii)
implementing bevel on die surface to generate convex shear with bottom flat punch surface
(Fig. A2(b)).
2

Test 2(a) M

(a) Bevel shear on pu
unch (b) Beevel shear on die
o configuratio
Fig. A2: Two ons of punch‐ die pair for reeducing puncch force

(a) Setup features of b
bevel shear on
n punch (b) Setup
p features of bevel shear o
on die
Fig. A3
3: The setup ffeatures and resulted pun ch‐piece quality of (a) bevvel shear on p
punch
and (b) bevel shear onn die with theeir respective counterpart kept flat
Setup features: ‐
For setup of Fig. A3(a): ‐ A blank pie ece is placed on the top off flat die and the bevel sheared
punch is properly
p mouunted onto to o the bottomm of top platform so that the central liine of
both botto om die hole and top bevel shear punch is aligned pro operly.

For setup of Fig. A3(b):: ‐ Similarly, aa blank piece is placed on the top of bevel shear die and
the flat puunch is prope erly mounted onto to the bottom of to op platform sso that the ceentral
line of both bottom die e hole and top p punch is aliggned properlyy.

Operational principles: ‐
For setup of Fig. A3(a): ‐ When the top punch is lowering dow wn with the m moving down nward
ess platform, the tip of be
of top pre evel will peneetrate to sheear those region in touch.. Such
penetratio on creates strretching phen nomena to oother the parrts where aree still not tou
uching
with the bevel
b on pun
nch. Such pro ogressively inncreasing of bbevel contactt with blank piece
limits the instantaneou us L and hencce reduces th e punch force magnitude until all periphery
under the punch rim is i completelyy shorn off. D Due to the sstretching acttion, the punnched
piece givess dark shape as shown in the bottom oof Fig. A3(a). Due to the p probable disto ortion
of the punched piece shape, such h method m ay not be appropriate to use in blaanking
although itt is ok for she
earing processses.
3

Test 2(a) M

For setup in Fig. A3(b): ‐ After the p placing sheet blank flat (w with additionaal fixture) ontto the

bevel sheaar bottom die surface, thhe flat bottom m surface puunch is moun nted onto th
he top
platform o of press with proper alignm ment of the ceentral line of bottom holee in die and to op flat
punch. The e lowering of punch to the e sheet blank on the tip off top bevel bo ottom die resu ults in
localized shearing
s withh the other unshorn
u zonee shifting down in paralleel until the p
punch
completelyy penetrates through the sheet thickn ess; hence th here is not an ny stretching likely
to take plaace. Due to lo ocally shearin ng and the syynchronizing movement o of punch and sheet
metal, it creates
c no an nd thus givess a punched piece
ny stretchingg effect in th e process an
almost witthout distortiion (as shown in the botttom of Fig. A A3(b)). Subseq quently, this setup
and operation are suitaable for blankking off workppieces instead d.

3) Fiig. 2 shows the featuress of a thread d. As its threeaded sectioon can be prroduced by eeither
machining or r
m rolling, mention with adeq quate explanaations and skeetches how to distinguish if the
th
hread is prod duced by rolling. Describee with the aidd of sketchess the likely setup featurees and
operational principles of rolling thread ssection on a ccylindrical soliid rod.
(18 marks)

drical solid rod
Fig. 2: Illusstration of threaded sectioon on a cylind

Answers: (Guid
A des to solutio ons – Slides 20, 21, 22, andd 23 in Lecturre Note 4)
When
W one givven a bolt or stud with th hreaded sectiion on to ideentify whetheer the thread ds are
machined or r
m olled, it is poossible by simply seeing if the shank is equal to the major diameeter of
thhe threads. Iff it is smallerr, the threads are rolled. It is machined if they arre both equal. The
reeasons are th hat: (i) the materials
m t section oof thread reggion on a rod material w
in the will be
reemoved awayy to give valleys while th he peaks aree still remaining the samee diameter aas the
original rod (ass seen in Fig. A4(a)); and ((ii) the materrials in the pro otrusion regio ons of the forming
toool in rolling w will penetrate e into the rod d surface (for forming valleeys of the thrreads) and squeeze
thhe materials tto fill the cavities in the to ool (for forminng peaks of the threads) –– such squeezzed to
fill results in major
m diametter larger thaan that of thhe original ro
od (the shank of threads)) (Fig.
A4(b)). Due to o difference in processingg, the grain structure in the bisected d threads ressumes
parallel fiberss while those e with rolled d have curviing fibers beending into the tip peakks, as
illlustrated in Fig. A4(a) and Fig. A4(b), re espectively.

A4: The fiber o
Fig. A orientation of threads prooduced by maachining and//or rolling
4

Test 2(a) M

4) Describe with the aid of skketches the fe
eatures of thee likely defecct of laps in finished forgin
ng, its
caausing mechaanisms and ap pproach in deesign forging bblank for min
nimizing its occcurrence.
(6 marks)
Answers: (Guid
A des to solutio
ons – Slide 30
0, Lecture Notte 3)
Fig. A5
5: Schematic illustration off forming deffect of laps
Fiig. A5(1) show ws a blocker forging with bulk of mateerials accumu ulated at eithher ends whicch are

coonnected witth a thin web. When succh blocker is placed in a die pair for further forgiing as
shhown in Fig A A5(2), the commpression on the two bulk ends is pushing down maaterials to flow w into
both sides of e each bulk. The e inwardly floowing of mateerial towardss the central p portion of diees and
suuch action re
esults in compression to buckle
b the thhin web (Fig. A5(3)). Such
h buckled cenntre is
foolded and the e material is not hot enou ugh to defusee, thus formiing laps as sh hown in Fig. A A5(4).
Elliminating succh defect is ppossible by inccrease in webb thicknesses.

5) Describe with the aid of skketches the setup
s featurees and opera tional princip ples of hydro
ostatic
exxtrusion process. Briefly mention itts advantagees and limitaations comp paring with direct
exxtrusion proccess. Fig. 3 illu
ustrates the m metal flow paattern under high friction o or cooling of outer
reegion of the bbillet in a dire
ect extrusion chamber, in which a squaare die is situaated at one eend of
thhe opening off chamber. Prior to the exxtruding of soolid rod, it is bisected, grid dded with un niform
sqquared meshes, and joine ed. The rejoin
ned rod is exxtruded half w
way in chamber, which iss then
taaken off fromm chamber and disjoined. It gave ddistorted meshes as show wn. Elucidate the
im
mplications of the distorte ed meshes just in or at reear of die opeening. Describe with the aid of
skketches the fe eatures of exttrusion defecct of central bburst. Correlate the metal flow pattern in Fig.
3 with the possible causing mechanisms of central buurst.
(36 marks)

Fig. 3: Metal flow pattern in and beforee die openingg in direct exttrusion with ssquare die (un
nder
high friction or co
ooling of outeer region of th
he billet)

5

Test 2(a) M

Answers: (Guid
A des to solutio
ons – Slides 36 and 37, 41 ‐ 43, and 54 aand 55 in Lectture Note 4)
Fig. A6: Setup featurres of hydrosttatic extrusion processes
Se
etup features and operattion principle n:‐ (Slides 36
es of hydrostaatic extrusion 6 and 37 in Leecture
Note 4)
Fiig. A6 shows tthe design features of hyd drostatic extruusion have baasic componeents almost siimilar
too direct extrusion except that (i) the container liner ffor the setup p of direct exttrusion is replaced
byy fluid (lubriccant/grease) ssurrounding tthe billet and there is not aany direct con ntact betweeen
coontainer inne er wall and billlet outer surfface; and (ii) tthere are seaals replacing tthe dummy block
on pressing ste em of the dire ect extrusion system and bbetween com mponents wheere leaking off fluid
would likely be
w e resulted froom the system m. By doing soo, the floor off working placce may not be
eaasily wetted tto create safe ety hazards. H However, fluidd is allowed tto be dragged d out through h the
in
nterface of die e opening and d the billet so
o as to reducee significantlyy interfacial frriction.
Fuurthermore, tthe fluid surro ounding the b billet may appply fluid pres sure to deforrm the billet
hyydraulically b before it is exttruded out fro om fluid cham mber. In hydrrostatic extrusion, the forcce
frrom pressing stem is transmitted through fluid to deeform firstly tthe billet hydrraulically and d to
push the billett out from the e die openingg.

Advantages off the hydraulicc extrusion in n comparing w with direct exxtrusion proceess are: (i) it
reeduces surfacce friction aro ound billet sin nce does not hhave any inteerfacial contact with contaainer;
(ii) fluid flows tthrough interrface between opening an d extruded b billet and acts a lubricant to o
minimize furth
m her the friction, and smootthen the surfaace of extrusion; (iii) it preedeforms the billet
byy surroundingg fluid before extruded out;; and (iv) releease of wear o
e the billet is e of chamber
suurface so thatt inner liner m may not be ussed.

Liimitations of the hydraulicc extrusion in comparison w with direct exxtrusion: (i) P
Proper sealingg of
fluid from leakking is necessaary, which maay make com mpressive stem m system hard to design and
reelatively more e expensive; ((ii) leaking of fluid to the sshopfloor creaates safety haazard to workkers;
an nd (iii) the maachine may b be more expensive.

6

Test 2(a) M

hematic illustrration of form
Fig. A7: Sch ming center bust in extrusion

Ellucidation of the implicattion and distoortion of messhes just or wwithin the oppening: ‐ (Slid
des 41
– 43, Lecture N
Note 4)
Fiig. 3 shows m
material flow ppatterns within or at viciniity of die opening in a squaare die. Its deead
zoone indicates sufficient maaterials accummulating in thhe corners of chamber and d die, which resists
thhe materials ffrom upstreamm to fill and cchanges the fflow direction
n due to increeasing reductaant
flow. The absoorption of succh dead zone is to implemeent of die anggle along the outermost
envelope of thhe squeezed rrigid body where the meshh lines are squ ueezed closelly together. D Due to
thhe mesh liness are squeezed together fo orming rigid bbody compresssing the matterials in betw ween,
thhe materials u
under compre ession squeezzed to flow b ackwards to rresist the upccoming flow o of
upstream materials. This ad dds those materials in the middle to bee squeezed flo owing forwards,
crreating tensile stressing co
ondition for thhe materials in between. TThis subsequeently likely crreates
devastation off materials in the region an nd thus pronee to the formation of centeer bust.

Chevron crackking (Central bust) and correlation to fflow pattern in Fig. 3: (Reef to slides 54 4 – 55,
Leecture Note 44)
Ref to the desccription for Fiig. 3 above, th he formation of severe an nd large squeeezing zone clo oser

too the die open ning usually leads to the severe tensile strain in the middle zone,, which resultts in
thhe formation of central burst (Chevron Cracking – N ote: Chevron n is an engineeering scientisst
who firstly disc
w covered the eexistence of ssuch crack) if tthere is any b
buried hard im mpurity or tensile
sttrain is so largge to reach itss fracture lim
mit. Such phennomenon resu ults in some ccrack occurreence
in
n the cross‐se ection of an exxtruded circular solid bar aas illustrated in Fig. A7. Geenerally, incoming
material flows
m horizontally from the bacck of containeer and hits on n the inclined die wall at w
where
it changes dire ection to movve along the d die surface. Suuch change of direction blocks and changes
thhe material flowing from the back which subsequen tly forms the rigid zone ass shaded in Fig. 3.
If this shaded zzone is small, material san ndwiched in bbetween in larrge and the squeezing effeect
becomes insignificant (i.e. tthe tensile strrain is small aand can be pu ushed through h the die opeening
byy the incomin ng material frrom the back unsuccessful ly). Under such circumstance, the centtral
burst may not occur. When n the rigid zonne is so large tthat they tou
uch each otheer at the centeer of
thhe die openin ng, the central burst is also o successfully suppressed. However, wh hen the rigid zzone
iss ranging betw ween the former two cond material at thee central coree not touching
ditions, the m
eaach other and d also not too
o much, the squeezing of tthe rigid zonee creates suffiiciently large
teensile train reeaching the frracture limit o or the existennce of hard im
mpurity to creeate material
seeparation takking place, cen ntral burst thus appears.
7

uring technologies for mettallic materia ls; 27th April 22018
Test 2(b) on manufactu

Test 2(b)
MB
BE3119 – Man nufacturing TTechnologies
27th April, 20118
Date: 2
Allowable Tim
A me: 1 hour 355 minutes

Answer ALL Questions

1) Describe with the aid of ske etches to illusstrate the set up features aand operation nal principles of
tuurning. If a so
olid rod is turn
ned with longgitudinal feed f by a cuttingg tool having nose radius o of R,
exxpress its achhievable arithmetic surface e finish Ra in tterms of f and R. With suittable sketchees and
description, illustrate that ssuch mathem matic relationsship holds tru uth to its physsical
reepresentation ns.
(20 marks)

Answers: (Guid
A des to Solutioons – Ref to SSlides 5, 6 andd 7 in Lecturee Note 6)

Fig. A1: Schem matic illustraation of Setuup features o of turning prrocess

Setup
S featuures: Fig. A11 schematically illustrattes the mou
unting/clamp ping of a cirrcular
rood in turningg lathe, Cuttter mountingg/supportingg seat (blue color) moveed along a gguide‐
sllide rod on tthe lathe, cu utter (red coolor) mounteed on the to ool support seat or tooll post
on a compound rest on carriage whicch is connec ted to Apron n, which is d
designed to m move
trransversely aand/or longiitudinally in relative to tthe cylindricaal sold workkpiece.

Operationa
O l Principles: After the e proper moounting of rrod piece on
nto spindle (with
taailstock quill to center aand steady its end if neecessary) an nd setting off the toolingg, the
powering on the lathe tu urns the guid de‐slide rod which drivees the carriagge with tool‐post
moving forwa
m ards to the spindle. By suitable settting of feed d (mm/rev) aand depth o of cut
(mmm) with thhe use of adequate geometry of ccutter, it alllows the forming of vaarious
feeature profiles on the cyylindrical solid rod piece
1
1
Page
1


(a) Too
ol with large
e radius (b) Tool with smallerr radius
Fig. A2: Exaaggerated tu urned marks on lathed suurfaces with h same depth of cut

Fig. A2 sketch hes the exagggerated surfface profile on both turn ned rod surffaces, using (a)
cuutter with laarge radius aand/or (b) cu utter with sm maller radiuss, under sam me depth of ccut
and rotationaal speed. It illlustrates the marks left on the surfaace varies w with the effecctive
cuutting zone o of the cutter and the feeed in relation to the cuttting edge an ngle. As the
coombined efffect of the saame (i) depth of cut andd (ii) longitud dinal feed off cut gives
different tracces of spiral ccut path on workpiece ssurface, its reesulted turn ned traces afffect
thhe surface finishing. Oth her influentiaal factor dettermining the turned surrface is the n nose
of the cutter. According tto the sketch hes in Fig A22(a), which h has been pro oduced by: (ii)
firstly drawing the originaal outer diam meter of rodd surface; (ii)) drawing strraight line
thhrough the p peak of cut aand trough the bottom vvalleys, respectively, as shown in Figg.
A2(a); (iii) dra
A awing a straiight line, perrpendicular to the verticcal straight line of the
unturned reggion, half waay though th he top peak aand bottom valley, whicch is taken as
mean value. I
m Its arithmetiic surface ro
oughness Ra along a scan nning length h La can be
exxpressed as

Ra ∑ i/La (Eq. 1)

In
n Fig. A2(b), the sketched lathed surrface has beeen drawn on n Fig A2(a) w
with cutter having
smmaller radiu us. It is draw
wn by: (i) extending the original rod d surface ovver the com mplete
le
ength; (ii) drawing the base surface after depth of cut; (iii) u using the avverage value of (i)
and (ii) as ce t cutting trace of cuttter with a set radius aand the con
enter draw the nstant
vaalue of deptth of cut; (iv)) drawing straight line thhrough tip p peak of cut ttrace; (v) draawing
sttraight line through the e bottom off cut valleyss; (vi) drawing straight line through h the
avveraging (iv)) and (v), and marking th he corresponding xi within the La; aand (vii) usin ng Eq.
1 to calculate e Ra, which o obviously givves large Ra for Fig A2(b) than that ffor Fig A2(a).
From Fig A2((a) and Fig. A2(b), it ob bviously ind icates that the physicaal cut trace, with
coonstant rotaational speed and feed, gives smalller variation n in Ra valuee over a scaanned
le
ength La with h larger tooll nose radiuss, as lesser cchange withiin the measu urable region can
be detected. Hence, those replicated marks connstituting off finer surfaace roughness on
2
2
thhe cut rod.
Page
2


2) Fiig. 1 shows a forging proce ess at its initiaal setup featuures and its finishing stagee. Describe the
reelevant deficiencies of thiss process. Sugggest how to minimize theese deficienciees by suitablyy
describing and d sketching thhe modificatio ons accordinggly. Mention h how your mo odifications caan
reelease those ddeficiencies in
n the processs as shown in Fig. 1.
(18 marks)

(a) Design
ns and at the initiation of pprocess (b)) Conditions a at the finishin
ng stage of pr ocess

Fig. 1: Featuress of a forging process at it s initial and finishing condditions

Answers: (Guid des to Solutio ons – Ref to sllide 27 in Lectture Notes 3))
As shown in Fig. 1(b), the problem with tthe setup feaatures in Fig. 11(a) tends to create flashees
which flow out
w t from cavity to the land re egions into guutter if the orriginal shape of blank is noot
properly deignned even‐thou ugh the blankk volume mayy be the samee as that of th he cavity. Thee
foormation of fllash out from m the cavity re equires additiional trimmin ng process to remove them m,
which involves
w s with the setup of trimmin ng tools and eequipment, aand with additional processsing
times. In addittional, the trim mmed materiials are also cconsidered ass waste. To minimize the
geeneration of fflash, it is posssible by entrapping the deeforming matterials within the anticipatted
geeometry of a cavity which takes the shaape of the forrging. Typically, the two do ownwards sid de
toongues on the e upper die (FFig. 1(a)) can be removed aand the two u upwardly pointed tonguess of
thhe lower die ((Fig. 1(a) can be suitably exxtended to suufficient height (or replacing these two o side
toongues by two straight upw wards walls – – As shown inn Fig. A3(a)) so o that it can aadequately
suurround the uupper die mid ddle tongue w with suitable wwidth when itt is lowering down to defo orm
thhe blank mate erials as illusttrated in Fig. A
A3 below.

(b) Final stage oof the modifieed top and bo ottom
(a) Initial setup features dies in p
producing flasshless forgingg
(c)
Fig. A3: Modifications of tthe die setupss for formingg flashless forgging
3
3

Page
3


Generally, the modified die es, as shown in Fig. A3(a), aallow the uppper die squeezing to deform
thhe blank unde er the protrud ding tongue w which deform ms and displayys the materials sideway to o fill
thhe cavities captured within n the light blu oundaries. As the tall wall of
ue tall walls a nd the die bo
thhe die pair surrounds completely the caavity and relaatively tight cllearance betw ween the die
moving parts a
m and wall prevents the infilttration of ma terials, hencee materials arre captured w within
thhe cavity and it thus formss flashless forging as show n in Fig. A3(b b).

3) Describe with the aid of sketches the setup featurees and workiing principless of deep draawing
process in con nverting circular sheet blan nks to circulaar cans for co
oca cola soft ddrink. Mentio on the
coonsequences likely to occu ur if the die and/or punch are incorrecttly designed.
(16 marks)

Answers: (Guid
A des to solutioons – Ref to Slides 18 and 220, Lecture N Note 5)

Fig. A4: Setup features (LH
HS of Central Line) and a ffinishing stagee (RHS of central line) of d
deep
drawing

Se etup features: ‐ The LHS at central lin
ne of Fig. A4 shows the s etup features of deep draawing
process, which h consists of bottom die having hole ddiameter of Dd and flat b blank diameter Do
laaying on the ttop. A blank h holder is then n placed ontoo the top of b blank, which is then presssed to
position by a ppressure plate e. A punch with outer diam meter equal to the die ho ole diameter m minus
twwice of sheett thickness is suitably mou unted into th e mounting m mechanisms of top platfo orm of
thhe press.

Operational p
O rinciples: ‐ A circular sheet blank witth a diamete er Do and thiickness to is
ner radius Rd. The blankk is held in place with a
placed over aa die openingg with a corn
blankholder, or hold‐dowwn ring, withh a certain foorce. A punch with a diameter Dp an nd a
orner radiuss Rp movers downwardss and pushess the blank in
co nto the die ccavity, thus
fo
orming a cupp, as shown in the RHS aat central line of Fig. A4.

Coonsequence to occur witth incorrect design
d of diee and/or punnch: ‐ (Ref to
o Slide 20, Leecture
Note 5) Generrally, the incorrect design o of die and/orr punch includ des: (i) too naarrow of cleaarance
between them m; (ii) too large of clearance between thhem; (iii) too sharp on the corner of thee hole
in
n die; and (iv)) too sharp on n the bottom edge cornerr of punch. In (i), the setup p may not perform
thhe deep draw wing but blannking operation instead. In (ii), the d
deep drawingg results in ssevere
sttretching bettween the clearance zone which seriiously jeoparrdizes the qu uality of the deep
drawing. In case of (iii), it rresults in the pre=mature cracking alon ng the edge o of flange as sshown
4
in
n Fig. A5(a). Inn case of (iv), it leads to th
he early crackk of the botto om edge of deep drawing.. Both
4
Page
(iii) and (iv) are
e mainly due to the stress concentratioon.
4


Fig. A5: Problem of d
deep drawn p
pieces with shharp edge corrner of die an
nd/or punch

4) Fiig. 2 shows the
t outer pro ofile and inne
er profile of an annular rring which is enlarged fro
om an
prefabricated small diameter flat and th hick ring. Sugggest a processs which can b be used to en nlarge
both inner an nd outer diam
meters. Desccribe with thhe aid of skeetches the seetup features and
operational prrinciples of yo our suggested process. M Mention how you can use the setup to o form
he flat profiles of the ring w
th with the proffiles of both oouter and inneer surfaces ass shown in Figg. 2.
(18 marks)

Outer profiile

Inner profiile

oduced on th e inner and o
he shape proffiles to be pro
Fig. 2: Th outer surface of a flat ring

Answers: (Guid
des to solutio
ons – ref to Slides 16 and 117 in Lecture Note 4)

Fig, A6: Setup features of r ing rolling pro
ocess

Seetup featuress: ‐ Ring rollin ng process is n
normally to c hange the dim mensions of aa ring producced by
otther process. Its setup mainly consists o of (i) a main rroll which is p
powered to ro otate; (ii) a
roounding roll w
which is free aand likely set at position w where controlls the outer d diameter of th he
finishing ring; (iii) an idler ro
oll which can be freely rottated and also o can be shiftted to press a ring
in
n the system aagainst the ro ounding roll aand the main roll as shown n in Fig. A6; and (iv) a pair of
coonical edging rolls mounte ed oppositely to the main rroll.

Operational P
O rinciples: ‐
5
5
Inn the ring‐rollling process, a pre‐fabricated thick ringg is placed between main rroll and idler roll.
Page
Thhe driven main roll drives the ring to ro otate when thhe idler roll sq queezes it agaainst both maain
5


rooll and rounding roll. Such squeezing exxpands the rinng with a largge diameter aand reducing
crross‐section b
by thinning thhe annular with closer disttance betweeen idler roll an nd main roll, aand
thhat with rounding roll. Sincce the volume deformation, the
e of the ring rremains consstant during d
reeduction in th
hickness is compensated b by the increasse in the ring’s diameter an nd the depth of
annnular. To control such deepth, the pair of edging rollls is achievingg such
taask when the expanded rin ng is passing tthrough theirr set distance.

Top surface of rolling ringg (Flange thicckness to, prootrusion lengtth from outsid
de diameter D Do)
Outer surface
O of annular waall Inner surface of an
nnular wall (D
Diameter at to op DT,
at botttom Db)
Bottom m surface of rrolling ring

Fig. A7: P Proper orientaation of Fig. 22

Foorming flat innner and oute er surfaces to o the profiless as illustrated in Fig. 2: ‐
With this ring
W rolling processs, it is possib ble to fabricatte various shaapes on both inner and outer
roolled flat surfaaces on the aannular. The p production off by suitable ccombination of shaped idler
annd rounding rrolls, and can be carried out at room teemperature o or at elevated temperaturee.
Due to revolvin ng roll body hhas a continuous surface, tthe discontinuous surface of the flangee and
thhe profile on tthe surface oof outer annullar wall is harrd to roll, it is thus anticipaated that the
profile shown in Fig. 2 shou uld have orien ntation as shoown in Fig. A77. Thus, the tyypical ring‐rolling
off the profile o
on the external surface me eans that the rounding roll should be sh haped as shown in
Fiig A8(a) whilee the idler roll should be sh haped as show wn in Fig A8(b) for the pro
ofiling of interrnal
suurface of the rolled ring.

(a) Sketcch of shape d
design on rounding (b) Sketch
h of shape deesign on idler roll
ro
oll

Fig. A8: The
e sketches of possible roll designs for a chieving the anticipated shapes on outter
surface and/o
s or inner surfacce of annularr wall
6
6

Page
6


5) With
W the aid of o rough skeetches, contraast the differrent setup feeatures of bo
oth vertical m
milling
machine
m and horizontal milling
m machhine. Commeent on which h milling maachine is suitable
peripheral shaaping of flat ssurfaces on a bulk of mechhanical workpiece. If you are ask to m mill a T
slot in the flat mechanicall workpiece, describe witth suitable reeasoning whiich type of m milling
machine is mo
m ore appropriately to use. PPlease specifyy the operatio onal sequencce involved in the T
slot machiningg.
(28 marks)

Answers: (Guid
A des to solutio
ons – Ref to slides 17, 18, 119, 20, and 233 in Lecture N Note 6)

(a) Setup o
of horizontal m
milling machine
(b) Setup of vertical millling machine

(c) Cutter mo
( unted onto aarbor in horizo
ontal (d ) Mounting o
of cutter bladee in sprindle o
of a
milling mach
hine verticcal milling maachine

(e) Illustratio
on of cutter in
n operation fo
or a (f) TTool mounting and cuttingg steps in milling T
horizzontal milling machine slot with vvertical millin
ng machine

Fig. A9: Settup features oof horizontal and/or verticcal milling maachines, theirr mounting annd
operationns

Fig A9(a) is the schemaatic illustratio
on of a horizontal‐spindle ccolumn‐and‐kknee type millling machinee (An
arbor brid dges the colummn and the m mounting blocck at the free end of overaarm. Cutter iss fastened thrrough
the arbor) (Fig. A9(c)) aand Fig. A9(b) is that of ve
ertical‐spindlee column‐and‐knee type m milling machin
ne
(Cutter is mounted into o spindle in the head and spins to cut w workpiece (Figg. A9(d))). The nature of cutter
mountingg allows verticcal milling maachine to cut non‐through slot from thee end of a wo orkpiece and
pauses the cut anywhe ere in the milling region, tyypically the e nd milling as shown in Fig. A9(d).

For Fig. A99(a), the cutter is mounted d onto the hoorizontal arboor with diameeter of cuttingg blade in verrtical
7
7
plane. Although the de esign and mounting of Fig. A9(a) providde rigidity, it cconstrains cerrtain materials
Page
removal o operations.
7

Test 2(b) on manufacturing technologies for metallic materials; 27th April 2018

For Fig. A9(b), the cutter is mounted into the vertical chuck in head, forming a free end cantilever
system. Hence, its rigidity is relatively poorer than that for Fig. A9(a)

Since the cutter wheel in horizontal milling machine is mounted onto the built‐in arbor (Fig. A9(c)) which
provides sufficiently high rigidity, its deflection due to reaction force from workpiece can be absorbed
more easily and it also provides higher removal rate with higher accuracy. As a result, horizontal milling
machine is suitable to be used for heavy peripheral shaping of mechanical workpiece in generating flat
surface. It is normally unable to mill any feature with vertical wall around it. This can be seen in the
illustration in Fig. A9(e) that the mounting of cutter results in the last few blade teethes which are into
the materials and not easily stopped without any piercing marks, slope, or rough finishing surface.

For the production of T‐slot, vertical milling machine is generally used. This is because the mounting of
cutter in the chuck of spindle allows the cutting blades orientating vertically. It may be firstly cut to the
total slot depth with the smaller diameter cutter first (see the 2D green illustration in Fig. A9(f)), which is
followed by changing the cutter with mounting feature as show in the Grey illustration at far LHS of Fig.
A9 with a cutting wheel (Brown color cutting wheel in the far RHS in Fig. A9(f)) having outer diameter of
the head width of the T. The passing through of the milling cutter in grey color mounting fixture from
the end edge to the other end edge in the milled narrow slot allows the completion of T‐slot milling. As
shown in the green 3D milled part in Fig. A9(f).

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Guides To Solutions: (Ref To Slides 3 and 5 in Notes "Machining (2) "

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Sampling questions on Manufacturing processes (1)

MBE 3119 Manufacturing Technology

1) Fig, 1(a) shows the configuration structure of a horizontal milling

(a) horizontal milling (b) vertical milling (c) Peripheral milling

Guides to Solutions: (Ref to Slides 3 and 5 in notes “Machining (2)”

Cutting with cutter on horizontal

The rigidity of the horizontal

For vertical milling machine, the mounting of cutter into the

2) Fig. 2 shows a milled T-slot in a block of workpiece. From the milling

Fig. 2: A milled T-slot in a block of workpiece

Guides to solutions: (Ref to Slides 9, 3, and 5 in notes “Machining (2)”)

(c) The cutter mounted

Fig. G2: Cutting tool and sequence for milling T-slot

3) The complexity of a casting varies with the fluidity of melt. Describe

In foundry, the device, as sketched in Fig G3, is normally used to

Fig. G3: A device for comparing fluidity of metallic melts

The setup feature consists of a pouring cup connected to a well or

4) The bisected shell wall (Fig. 3) of casting, which is formed by pouring

Guides to solutions: (Ref to Slide 9 in notes of “Manufacturing Processes

Guides to solutions: (refer to Slide 6 in notes “Manufacturing

The problem clearly indicates that utilizing risers to modify the

6) Briefly mention the sequence of operations of sand casting process.

Fig. 5: The inner wall pattern of a rolled ring

Guides to solutions: (Ref to Slide 10 in notes “Manufacturing

Fig. G4: Setup of a ring rolling process

Operational Principles: After the setting of the rolling system as

Inner wall pattern of the rolled ring, as shown in Fig. 5, is achievable

(a) Upsetting a billet from ho to h1 (b) Cogging of a workpiece

Fig. 6: Two upsetting processes in reducing height of workpiece

Guides to solutions: (Refer to Slides 14 and 15 in notes

Fig. 7: Stages of pre-forming involved in converting a cylindrical rod

Guides to solutions: (Ref to Slide 17 in notes “Manufacturing

Fig. G5: Two processes to displace and/or to accumulate materials

Fig. G5(a) is a fullering process and its setup consists of a pair of

Fig. G5(b) is an edging process and its setup consists of a pair of

Guides to solutions: (Refer to Slides 22 and 25 in notes

(a) Direct extrusion (b) Tube drawing

Fig. G6: Illustration of extrusion and/or drawing processes

Direction Extrusion Process:

Operational principles: After setting up the system, a workpiece is

Tube drawing process:

Operational principles: A tube which is pre-fabricated by other

Contrasting the two processes:

Th he top curve

(iii) (refer to Slides 41 aand 42 on Leccture Notes 11, and figure b below):‐ Wassh is the additional

(iiv) (Refer to Slides 41 aand 43 on Leccture Notes 11, and Figure below) :‐ Cold d shut. Whenn the

Generally, the higher melting po oint temperatture will be reeached first d during coolingg.

Both bblow and scarr are holes on n the skin of aa casting as seeen in the skeetches (a) and d (b),

As seen in the sketch, Scab is incomplete fillingg or hole(s) ju ust beneath th he surface of a

Sketched Figure to shoow the featurees of scab

The skketch above sshows a patte ern for makinng two halvess of casting ccavity in a mo old. In

Sketches to illustrate the modification

Hole inn a casting noormally mean ns that it is a hhollow region n and such ho ollow feature is not

For setup in Fig. A3(b): ‐ After the p placing sheet blank flat (w with additionaal fixture) ontto the

Fiig. A5(1) show ws a blocker forging with bulk of mateerials accumu ulated at eithher ends whicch are

Ref to the desccription for Fiig. 3 above, th he formation of severe an nd large squeeezing zone clo oser

Thhe driven main roll drives the ring to ro otate when thhe idler roll sq queezes it agaainst both maain

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