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22-Mec-A4 Design and Manufacture of Machine Elements: May 2016

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

  1. Question 1 Cutting Fluids, Chatter and Turned Surface Finish
  2. Question 2 Casting — Freezing Range, As-Cast Skin and Hot Tearing
  3. Question 3 Sheet Forming — Pressing Failure, the Forming Limit Diagram, and Sheet Property Selection
  4. Question 4 Thermal Stress in a Magnesium Tube and Aluminium Rod Separated by a Gap
  5. Question 5 Continuous Shaft on Three Bearings — Reactions, Bending Moment Diagram, and a Settled Bearing
  6. Question 6 Bolt Cutter — Force on the Bolt, Pin Loads, and Lever Stresses

Start with Question 1 →

Paper format. National Examinations, May 2016 — 07-Mec-A4, Design and Manufacture of Machine Elements. Three hours, open book, any non-communicating calculator. Six questions in two parts: Part A (Q1–Q3, manufacturing-process theory) and Part B (Q4–Q6, machine-element analysis). Candidates answer two from Part A and two from Part B; four questions constitute a complete paper and all questions carry equal value (25 %). All six are solved here.

Reference texts. Kalpakjian & Schmid, Manufacturing Engineering and Technology (Part A); Groover, Fundamentals of Modern Manufacturing (Part A); Budynas & Nisbett, Shigley's Mechanical Engineering Design, 11th ed. (Part B); Hibbeler, Mechanics of Materials, 10th ed. (Q4, Q5); Norton, Machine Design: An Integrated Approach, 6th ed. (Q6).

Check: two corrections carried through Part B. (1) Q5 prints the shaft modulus as “E = 30 ksi”; a 30 ksi modulus is physically impossible for steel and would make the shaft a rubber band, so it is read as the standard E = 30 × 106 psi (30 Mpsi). (2) Q6 supplies the linkage dimensions but not the cross-section of the levers, so the stress in members 2 and 3 is worked for an explicitly stated assumed section and the required section is also reported. Both readings are flagged where they are used, in the spirit of Note 1 on the cover page.