Manufacturing Process 1 Question Paper

Manufacturing Process 1

Course:Bachelor Of Science In Manufacturing Engineering And Technology

Institution: Kenyatta University question papers

Exam Year:2008

KENYATTA UNIVERSITY
UNIVERSITY EXAMINATIONS 2008/2009
FIRST SEMESTER EXAMINATION FOR THE DEGREE OF
BACHELOR OF SCIENCE (MANUFACTURING)
SET 412: MANUFACTURING PROCESSES I

DATE: Friday 28th November 2008

TIME:8.00 a.m.-10.00.a.m.

INSTRUCTIONS:
? All questions carry equal marks
? Answer any THREE Questions

1
a)
Discuss briefly, with aid of sketches, how you would make a mould using a shell moulding process.(10marks)
b)
What factors would you consider in selection of a furnace? (5marks)
c)
Distinguish between primary and seconcary crystallization. (3marks)
d)
Why do we refine metals? (2marks)

2.
a)
How does the size, shape and distribution of sand grains relate to moulding sand properties? (10marks)
b)
What are the advantages of shell moulding over green sand would? (7marks)
c)
List three methods of cleaning castings. (3marks)

3.
a)
What should the gating system be designed to accomplish? (8marks)
b)
What factors influence the rate of solidification of a casting? (6marks)
c)
What are the advantages of lost wax process over green sand moulding process? (6marks)

4.
a)
What are the causes of blow holes and gas holes? (8marks)
b)
What are the main difficulties in melting aluminum and how can we overcome them? (4marks)
c)
Why is the cupola widely used in melting cast iron? (3marks)
d)
Describe the process of annealing. What is it supposed to accomplish? (5marks)

5.
a)
Describe the process of solution treatment of aluminum-copper alloys.
(4marks)
b)
Outline the sources of melting losses.
(4marks)
c)
What are the causes of shrinkage cavities?
(3marks)
e)
What are the functions of the following features in a casting process?
i)
riser
ii)
chill
e)
What is the purpose of melt treatment? Give examples.
(5marks)

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