22-Mec-A4 Design and Manufacture of Machine Elements, December 2017: worked solutions

Paper format. National Examinations, December 2017 — 16-Mec-A4, Design and Manufacture of Machine Elements. Three hours, open book, non-communicating calculator permitted. Six questions divided into Part A (Q1–Q3, manufacturing processes) and Part B (Q4–Q6, machine-element statics); candidates answer two from each part, and all questions carry equal value (25 %). All six questions are solved here.

Reference texts.

S. Kalpakjian and S. R. Schmid, Manufacturing Engineering and Technology — sheet-metal forming, welding metallurgy, polymer processing.
M. P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes and Systems — drawing, moulding and tooling design rules.
R. G. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design — columns, welded joints, static failure theories.
R. C. Hibbeler, Mechanics of Materials — free-body diagrams, buckling.

Note on units and material data. The paper is metric throughout. Where a property is needed but not printed on the exam (the modulus of elasticity of steel, the reduction of area of 1015 steel, the minimum yield strength of E60 filler metal), the standard handbook value is used and flagged at the point of use, as the paper's own Note 1 invites.

22-Mec-A4 Design and Manufacture of Machine Elements: December 2017