UNIVERSITY OF SOUTH AFRICA

SCHOOL OF ENGINEERING
CONTINUOUS ASSESSMENT

MEMO ASSIGNMENT NO: 1

Semester Course

MTC1501

MANUFACTURING TECHNOLOGY I
60 Marks

Duration: --

Examiner: Mr I MABUDA

Moderator: Ms. LB MATHEBELA

Weight of Assessment: 10%

NB: Take note most of the guidance regarding this assignment is from the study guide,
other sources and textbooks.

This paper consists of 3 pages including the cover page.

INSTRUCTIONS:

1. Answer all the questions.

2. Show all calculations.

3. In the event of uncertainties, state your assumptions clearly and carry on.

4. Please indicate the method of submission, platform for submission and honor pledge

5. Strictly submission on Moodle (Assessment 1) and no emails

6. Use SI units on your readings.

7. Start each new question on a new page.

1. Health and safety in an engineering environment

1.1. Identify at least five potential safety hazards and their sources in your own environment. (5)
 Refer to table 1.1 on your study guide for answers.
1.2. Give six reasons why accidents happen in the workplace. (6)
 Refer to section 4.1.3. (Accidents in the workplace) on your study guide for answers
1.3. Make a list of five general safety measures that must be taken when working in machining
operations. (5)
 Refer to section 4.1.5.1 and 4.1.5.2 (GENERAL SAFETY GUIDELINES) on your study
guide for possible answers.
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2. Engineering Materials
2.1. What are the four (amongst others) critical decisions to be taken when selecting
an engineering material for an application? (2)

 Can the material be recycled?

 Can the material or its manufacture cause environmental problems? Is it biodegradable?
 Is the material readily available?
 Can the material consistently be formed into the correct shape and does it meet
dimensional tolerance requirements?
 Can the material maintain the correct shape during its intended use?
 Is it possible to achieve the required properties and maintain those properties during its
intended use?
 Cost of the material.

2.2. What are the four critical decisions in the selection of engineering materials? A hammer(4)
Material requirements-objective of a hammer
 Durable
 Less maintenance
 Cost effective.
 Tough and ductile material
 Withstand impact load.
 Less electrical conductivity
Finding possible materials
 The most popular steel types used to make hammers are 4340, 4140, and 1045–1060 steels.
Hammers may be constructed from a wide variety of steel kinds. In comparison to their
rivals, certain types of steel are more suitable for hammers in terms of hardness, weldability,
and overall appropriateness.

Make a choice
 Hammers are often made of 4140, 4340, and 1045 steel. Because of its ease of use and
simplicity, 1045 steel is a good choice if you're forging a hammer. However, you may
choose to utilize 4340 or 4140 if you're seeking for a steel that will produce a solid and
long-lasting hammer. Make your hammer out of 4140 steel at the best pricing and finest
quality possible.
Metals manufacturing -Iron and steel production
2.3. Differentiate between the various types of heat treatment processes.
2.3.1. Annealing (2)
 Steel is heated to a temperature at or near the critical temperature range (500–600 OC)
and then cooled at a predetermined rate. Relatively slow cooling is usually employed.
 Annealing is often done to reduce hardness, improve machinability and remove
 internal stresses.
2.3.2. Tempering (2)
 The process of reducing the hardness in steel is referred to as tempering. During the
tempering process, the hardened steel is heated to a temperature below the critical
temperature, held at that temperature for a specified time and then slowly cooled.
 The use of hardened steels is undesirable in many applications; for example, fully
hardened steel is unable to withstand impact loads, then tempering is done.
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3. Checking workpieces for accuracy
3.1. Name the two differences between micrometers and vernier scales.
(2)
A vernier caliper is a measuring instrument used for measurements of less
precision when compared to micrometer instruments.
 Micrometer comes in two sets, internal and external micrometer, whereas a
vernier is a combination which in one can do internal and external measurements.
3.2. Which two safety precautions would you take to ensure that a vernier scale
is not damaged?
(2)
 Never use vernier caliper jaws as markers.
 After using the vernier caliper put it back to its cover.

3.3. Take readings and show calculations from the Vernier and micrometer scale
provided below.

3.3.1………range (50-75 mm) 3.3.2. …………….. (2)

(2)

12+0.5+49 (0.01) =12.99 19+20(0.02) =19.4

50 +12.99 = 62.99

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4. Fitting using hand tools

4.1. Name the four tools commonly used by fitters and describe how they are used. (2)

 Refer to unit 4.7. (Fitting using hand tools) on your study guide for answers.

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5. Drilling operations, milling machines, Turning operations on the Centre lathe & Cutting Tools
5.1. What are four functions of cutting fluids? (2)
 Refer to section 4.8.8. (Cutting fluids) on your study guide for answers.
5.2. What do you understand by tool geometry? (2)
  Refer to section 4.8.6. (Tool Geometry) on your study guide for answers.
5.3. The top surface of a rectangular work part is machined in a peripheral milling
operation. The work part is 735 mm long by 50 mm wide by 95 mm thick. The milling cutter,
which is 65 mm in diameter and has five teeth, overhangs the width of the part equally on
both sides. Cutting speed = 60 m/min, chip load = 0.20 mm/tooth, and depth of cut = 7.5 mm.
Determine the time required to make one pass across the surface, given that the setup and
machine settings provide an approach distance of 5 mm before actual cutting begins and an
overtravel distance of 25 mm after actual cutting has finished. (3)
N = v/πD = 60(103) mm/65 = 293.8 rev/min

fr = Nntf = 293.8(5)(0.20) = 293.8 mm/min

A = (d(D-d))0.5 = (7.5(65-7.5))0.5 = 20.8 mm

Tm = (735 + 5 + 20.8 + 25)/293.8 = 2.67 min

5.4. An engine lathe is used to turn a cylindrical work part 150 mm in diameter by (5)
500 mm long. Cutting speed = 2.50 m/s, feed = 0.30 mm/rev, and depth of
cut = 3.0 mm. Determine:
5.4.1. Cutting time
N = v/(πD) = (2.50 m/s)/0.15 = 5.31 rev/s

fr = Nf = 6.757(.30) = 1.6 mm/s

Tm = L/fr = 500/1.6 = 313 s = 5.3 min

5.4.2. Metal removal rate

RMR = vfd = 2.5 x1000 x 0.3x 3 = 2250 mm3/s
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6. Additive manufacturing
6.1. Mention four benefits of AM (2)
 AM is now widely referred to as one of a number of disruptive technologies that are
transforming the way we build goods and launch new enterprises.
 The use of computers throughout the product development process greatly speeds up the
process.
 Because 3D CAD is employed as the beginning point and the transition to AM is very smooth,
there is significantly less concern about data translation or interpretation of design intent.
 The decrease in process stages is also evidence of the seamlessness.
 Building in an AM machine is often done in a single step, regardless of the intricacy of the
pieces to be created.
 As a result, additive manufacturing (AM) may be viewed as a technique to more accurately
forecast the amount of time required to build models, independent of what changes are
performed during this formative period of product development.
 Similarly, the number of processes and resources required can be significantly reduced when
using AM.
 CNC machining requires careful planning and a sequential approach that may also require
construction of fixtures before the part itself can be made. AM can be used to remove or at
least simplify many of these multistage processes.
 6.2. Describe and explain the AM Processes below; (10)
6.2.1. Extrusion-Based Systems
 By layer-by-layer selective material dispensing through an aperture or nozzle at the
macro, meso, and micro scales, extrusion-based additive manufacturing (AM) enables
the production of three-dimensional objects with complex cellular topologies.
6.2.2. Material Jetting
 The 3D printing technique known as material jetting (MJ) is exceedingly accurate and
effective. UV light is used in this printer to turn liquid photopolymers into solid objects.
Due to the fact that MJ sprayed the photopolymer resin in droplets prior to its
solidification, it was commonly compared to the 2D inkjet technique.
6.2.3. Binder Jetting
 A liquid-based binding agent is used in the additive manufacturing method known as
"binder jetting" to selectively combine materials in a powder bed. It can create intricately
formed components out of a range of materials, such as metals, ceramics, and polymers.
6.2.4. Directed Energy Deposition Processes
 By melting the material while it is being deposited using focussed thermal energy like a
laser, electron beam, or plasma arc, DED creates 3D objects. A gantry system or robotic
arm is used to control the energy source and the material feed nozzle.
6.2.5. Sheet Lamination Processes
 Stacking and laminating thin sheets of material to create a three-dimensional item.
Laser cutting or CNC machining can be used to obtain the final shape while bonding,
ultrasonic welding, or brazing can be used for lamination.
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TOTAL MARKS: 60 marks

© UNISA 2023

1. Gibson, I., D. Rosen, and B. Stucker, Additive Manufacturing Technologies. 3D Printing, Rapid
Prototyping, and Direct Digital Manufacturing. 2015. second.
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