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Set 315: Material Forming Question Paper

Set 315: Material Forming

Course:Manufacturing Engineering

Institution: Kenyatta University question papers

Exam Year:2008

KENYATTA UNIVERSITY
UNIVERSITY EXAMINATIONS 2007/2008
SECOND SEMESTER EXAMINATION FOR THE DEGREE OF BACHELOR
OF SCIENCE IN MANUFACTURING ENGINEERING
SET 315: MATERIAL FORMING

DATE: Tuesday 6th May 2008

TIME: 8.00 – 10.00 am

INSTRUCTIONS:
1.
This paper contains FIVE questions.
2.
You are required to answer question ONE, and any other TWO questions.
3.
Question ONE carries 30 marks while each of the others carry 20 marks.
4.
All answered questions should be on the answer book.
5.
Make your work neat and visible.
6.
Mobile phone and any extra reading materials is not permitted in the
examination room.

QUESTION 1
a)
Differentiate between hot rolling and cold rolling processes of metal forming.
Give examples of each?
b)
(i)
Describe each of the following methods of blow molding:
(i)
Injection blow molding (IBM)
(ii)
Stretch blow molding (SBM)
(iii)
Extrusion blow molding (EBM)
Give example of materials formed by each of the processes/methods.
c)
(i)
Parts made from thermoplastic and thermosetting plastic materials in
production undergo which type of manufacturing technique? Describe
this type of technique?

2

(ii)
By the use of well labeled diagram, describe the stages of injection
moulding?

QUESTION 2
a)
Describe and differentiate between the following methods of material forming:
(i)
Blow moulding
(ii)
Casting
(iii)
Die manufacturing
(iv)
Injection moulding
b)
Explain the following terms as applied in hot rolling process.
(i)
Bending and flanging
(ii)
Stretching
(iii)
Drawing and Deep drawing
(iv)
Cutting

QUESTION 3
a)
Explain the terms Expandable and non-expandable materials as applied in
castings. Describe each by indicating 3 methods that depend on Expandable and
other 3 that relay on non-expandables. Also give examples of products formed by
each method.
b)
Prior to continuous technology, ingots were rolled approximately 200mm in
thickness in form of a “slab” or “bloom mill”. Describe what “bloom mill” and
“slab mill” are, in reference to the types of rolling mills.

QUESTION 4
a)
Differentiate between shell moulding and sand casting as applied in materials
castings. State the advantages and disadvantages of each process.
b)
(i)
Describe the terms, stretching, cutting and deep drawing? Give examples
of products formed by each of the method.
(ii)
What does the following statement mean, “Degree of Cold Work”, as
applied in cold rolling process? Explain by use of an example.

3

QUESTION FIVE
a)
(i)
Explain the following term as applied in Deep drawing process
-
“Draw reduction”
(ii)
Describe the physical metallurgy of cold rolling.
b)
(i)
Explain the injection moulding cycle.
(ii)
Describe the following moulding defects, stating their alternative names,
descriptions and causes:
(i)
Blister
(ii)
Burn marks
(iii)
Colour streaks

……………………..

Set 315: Material Forming Question Paper

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