Engineering Exam: Manufacturing Engineering and Material Science, Exams of Manufacturing Systems Design

Download Engineering Exam: Manufacturing Engineering and Material Science and more Exams Manufacturing Systems Design in PDF only on Docsity! Cork Institute of Technology Bachelor of Engineering (Honours) in Mechanical Engineering – Award (NFO-Level 8) Autumn 2007 Manufacturing Engineering Time: 3 Hours Instructions: Answer FOUR questions Answer ONE from each Section Use a separate answer book for each section Examiners: Mr. M. P. O’Mahony Mr. M. Uhlemann Dr. M. Woods Mr. P. Clarke Prof. M. Gilchrist Section A Q1 (a) EDM has been widely adopted by toolmakers; Wire EMD for Press Tools, Ram EDM for Plastic injection moulding tools. Discuss the reasons for this and highlight issues that may need to be taken into consideration (9 Marks) (b) What are the relative merits of the two main spark generation circuits used in EDM (4 marks) Compare ElectoChemical Grinding to conventional grinding, explaining the reasons why ECG is the preferred choice for certain processes & why it is unsuitable for others. (12 Marks) Q2 (a) Laser cutting is increasing being used by industry to make parts from sheet metal. Discuss the reasons for this (12 Marks) (b) In what circumstances would Abrasive Water Jet cutting be used instead of Laser cutting (5 Marks) (c) In the context of Electron Beam Welding (EBW) discuss the benefits and limitations of using EBW-NV (No Vacuum) compared with EBW-HV (High Vacuum) (8 Marks) Section B Q3 (a) (i) Sketch a labelled electron energy level diagram for the generation of Auger electrons from a solid surface using a primary electron beam of energy Ep. Hence describe the two-step process for the generation of Auger electrons. [7 marks] (ii) State the equation for the kinetic energy [Ek] of the emitted Auger electrons. [2 marks] (iii)Explain why Auger Electron Spectroscopy is surface sensitive. [2 marks] (b) A nickel super-alloy turbine blade is to be chemically analysed after operation at high temperatures by Auger Electron Spectroscopy and Scanning Auger Spectroscopy . (i) State TWO typical experimental AES primary beam settings from the following list of THREE parameters: beam energy, beam current, beam incidence angle on the sample surface. [2 marks] (ii) Sketch a labelled diagram of the experimental set-up for Auger Electron Spectroscopy. [3 marks] (iii) What is different about the Auger electrons from different elements? How is the analyser operated to detect this difference and to detect the elements present at the turbine blade surface? [3 marks] (iv) State TWO limitations in terms of either elements detected, or % concentration detected (sensitivity), which may affect the analysis of the turbine blade. [2 marks] (v) What is Scanning Auger Microscopy [SAM]? How might SAM be applied to study the turbine blade? [4 marks] Q4 (a) Sketch a labelled diagram of the optical detection system of a scanned force microscope and briefly explain how it operates to detect changes in height on a materials surface. [6 marks] (b) Describe ONE type of imaging artefact associated with scanned force microscopy. [4 marks] (c) A glass fibre epoxy laminate material is to be imaged by the lateral force microscopy and force modulation microscopy techniques using a scanned force microscope. Describe with the aid of labelled diagrams the principles of operation of BOTH techniques to image the fibres and matrix of the composite laminate. [15 marks]