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23-Ind-B2 Manufacturing Processes: December 2016

Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)

  1. Question 1 Non-Ferrous Alloy Characteristics, Plastics vs. Metals, and Trends in Plastics Development
  2. Question 2 Casting Process Selection, S​hell-Molding, and Permanent-Mold Casting
  3. Question 3 Metal Chip Types, Built-Up Edge, and the Orthogonal-Cutting Shear Angle
  4. Question 4 Factors in Metal Cutting, Tool Wear/Finish/Machinability, and Current Trends
  5. Question 5 Grinding Operation Characteristics, Design Considerations, and the Economics of Surface Finish/Accuracy
  6. Question 6 Residual Stress in Welding, Joint/Process Selection Factors, and Future Trends in Welding
  7. Question 7 Statistical Process Control, Acceptance Sampling/AQL, and the Deming and Taguchi Methods

Start with Question 1 →

National Exams — December 2016 — 98-Ind-B2 Manufacturing Processes. Closed book; Casio or Sharp approved calculators only. Any five of the seven questions constitute a complete paper; all questions are of equal value (20 marks each). Answers are written in point form but fully, with all calculations shown, as instructed. Complete answers to all seven questions follow.

Reference texts: Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 6th ed. — material selection, casting, metal-cutting theory, welding processes, polymer processing, statistical process control; Montgomery, Introduction to Statistical Quality Control, 8th ed. — acceptance sampling, control charts, the Deming/Taguchi quality philosophies.

Q2 = December 2013 Q2 (casting process factors, s​hell molding, permanent-mold casting); Q3 = December 2013 / May 2015 Q3 (metal chip types, built-up edge, orthogonal-cutting shear-angle calculation); Q4 = December 2013 / May 2015 Q4 (factors in metal cutting, tool wear/surface finish/machinability, cutting trends); Q5 = December 2014 Q5 (grinding operation characteristics, design considerations, economics of finish/accuracy); Q6 = December 2014 / December 2015 Q6 (residual stress in welding, joint/process selection, welding trends); Q7 = December 2013 / December 2015 Q7 (statistical process control, acceptance sampling/AQL, Deming and Taguchi methods).