TECHNICAL UNIVERSITY OF MOMBASA
Faculty of Engineering and Technology
DEPARTMENT OF MECHANICAL AND AUTOMOTIVE ENGINEERING
UNIVERSITY EXAMINATIONS FOR DEGREE IN BACHELOR OF SCIENCE IN
MECHANICAL ENGINEERING
(BSME) Y3-S1
TMC 4312: MATERIAL PROCESSING 1
END OF SEMESTER EXAMINATIONS
SERIES: OCTOBER 2031
TIME: 2 HOURS
INSTRUCTIONS:
You should have; Answer booklet,; Drawing instruments and Scientific calculator
Attempt ALL questions.
This paper consists of THREE printed pages
QUESTION 1
a) (i) State THREE indicators of tool failure (1.5 marks)
(ii) State FOUR characteristics of orthogonal as opposed to oblique cutting (2 marks)
(iii) Working from first principles, establish Merchant’s shear angle expression (3 marks)
b) In an orthogonal cutting operation, the rake angle = -5°, chip thickness before the cut = 0.2 mm
and width of cut = 4.0 mm. The chip ratio = 0.4. Determine :
i) the chip thickness after the cut, (b) shear
ii) shear angle,
iii) friction angle,
iv) coefficient of friction, and
v) shear strain ( 13.5 marks)
QUESTION 2
a) Working from first principles, establish the draw stress expression for wire drawing a round bar
through conical dies. (15 marks)
b) Compare the force required to draw 25mm x 6mm to 45% reduction of area with that required for
an equal reduction on round bar of equal cross sectional area , using (i) 12o included angle dies
(ii) 30o included angle dies if µ=0.07
QUESTION3
c) With Working from first principles, establish the draw stress expression for strip drawing a flat
bar through wedge shaped dies dies. (15 marks)
QUESTION4
a) An end mill cutter of diameter 120mm is to face mill a workpiece 100mm wide. The optimum
power available is 4 kW, depth of cut is 3mm, cutting speed is 22m/minute and the cutter has
16teeth. If the material removal rate (K) is 25,000mm3/([Link]), determine the feed rate per
tooth. (5 marks)
b) A single-pass rolling operation reduces a 20 mm thick plate to 18 mm. The starting plate is 200
mm wide. Roll radius = 250 mm and rotational speed = 12 rev/min. The work material has a
strength coefficient = 600 MPa and a strength coefficient = 0.22. Determine :
i) roll force,
ii) roll torque, and
iii) power required for this operation
c) A hot upset forging operation is performed in an open die. The initial size of the workpart is: Do
= 25 mm, and ho = 50 mm. The part is upset to a diameter = 50 mm. The work metal at this
elevated temperature yields at 85 MPa (n = 0). Coefficient of friction at the die-work interface =
0.40. Determine
i) final height of the part, and
ii) maximum force in the operation.
QUESTION5
a) Working from first principles, establish Merchant’s shear angle expression (7 marks)
b) The power to cut a material under certain conditions is 2.6 W/mm3/s. A cut 5.2 mm deep x
0.22mm/rev feed is taken at a cutting speed of 18 m.p.m and the work cooled by a flow of 3.5
litres of coolant per minute, specific heat capacity 3.6 kJ/kg oC, which conducts away 82% of the
heat. The specific gravity of the coolant is 0.92. Determine:
i) the rise in temperature of the coolant due to this cut.
ii) If the cut was performed without coolant, on a metal of specific heat capacity 450
J kg-1 K-1 and specific gravity 8.4, and the chip took 90% of the heat, estimate the
chip exit temperature.
c) A billet that is 75 mm long with diameter = 35 mm is direct extruded to a diameter of 20 mm.
The extrusion die has a die angle = 75°. For the work metal, K = 600 MPa and n = 0.25. In the
Johnson extrusion strain equation, a = 0.8 and b = 1.4. Determine
i) extrusion ratio,
ii) true strain (homogeneous deformation),
iii) extrusion strain, and
iv) ram pressure and force at L = 70, 60, 50, 40, 30, 20, and 10 mm.
QUESTION 6 STUDY THOROUGHLY CHAPTER 19 , 20 & 21 OF MIKELL P
GROOVER