Tolerance - Materials and Manufacturing Process - Exam, Exams of Materials science

Download Tolerance - Materials and Manufacturing Process - Exam and more Exams Materials science in PDF only on Docsity! Cork Institute of Technology Bachelor of Engineering in Biomedical Engineering – Stage 1 (NFQ Level 7) Summer 2007 Materials & Manufacturing Process (Time: 3 Hours) Instructions Answer One question, from Section A and Two questions from Section B. Use separate answer books for each Section. Examiners: Mr. D.Sullivan Mr. T. Kelly Mr. M. Murphy Mr. P. McHugh Section A (20 marks) Answer 1 Question Q1. (a) With the aid of a diagram sketch how you might align a set of pulleys on two parallel shafts one meter apart. (8 marks) (b) 4 matched vee belts drive a machine, if one breaks, should you replace just one or all four? Why? (4 marks) (c) A gear has a Pitch Circle Diameter of 180 millimeters and a module of 3 millimeters, how many teeth does the gear have? (4 marks) (d) Name three different types of gears. Make a sketch of one. (4 marks) Q2. (a) Describe 3 different types of maintenance and give one example of each type. (9 marks) (b) What is Condition Based Maintenance? (3 marks) (c) List three different types of Condition Monitoring. (3 marks) (d) In a pneumatic system what does the abbreviation F.R.L stand for? (2 marks) (e) Break the following sequence up into groups A+B+B-A-C+C- What is the least amount of groups needed? (3 marks) 2 Section B (55 marks) Answer 2 Questions Q3. (a) In an exercise to measure the included angle of an Internal Taper using precision spheres and a depth micrometer, the following information was obtained. D = 40 mm (Diameter of the Larger sphere) d = 8 mm (diameter of the smaller sphere) h = 3 mm (refer to Figure Q3 (a) attached) H = 85 mm. Calculate the included angle of the taper. (10 marks) (b) Define the following terms as used in BS4500 - Limits and Fits i. Nominal Size ii. Limits of Size iii. Tolerance (6 marks) (c) When using slip gauges, certain rules must be observed to ensure maximum accuracy. What are these rules? (5 marks) (d) State clearly the slip gauges required to make a stack of 63.8275mm using a standard Metric Set. Two 2.5mm protector slips must be included in your stack. Refer to figure Q3(d) attached. (6.5 marks) Q4. (a) A lathe running at 2000rpm is used to reduce a bar of diameter 30mm to a diameter of 29mm. The force on the cutting tool is 350N at a feedrate of 0.05mm/rev. Calculate: (i) Power Consumption during the operation. (ii) Rate of Metal Removal. (8 marks) (b) Describe the forces acting on a single point cutting tool during a cutting operation. State clearly how each force relates to the power consumption as cutting proceeds. (9 marks) (c) Sketch a graph to illustrate the relationship between force, power consumption and cutting speed during a typical machining operation. Comment on your graph. (6 marks) (d) What is the main limitation of Diamond as a cutting tool material? (4.5 marks)