Question 1: Describe why glasses typically have relatively low strength (2) Properties of Polymers vs.

Properties of Polymers vs. Metals: Polymers have lower density, are generally less stiff, have
Glasses have an amorphous structure, lacking the orderly atomic arrangement of crystalline better corrosion resistance, and are more flexible, while metals are denser, stronger, more
materials.
This structure makes them prone to brittle failure as they cannot redistribute stress
ductile, and exhibit good thermal and electrical conductivity. 2. Polymer Types Not Considered
effectively, causing cracks to propagate easily. (2) Plastics: (c) Elastomers. 3. Polymer Types Without Cross-Linking: (a) Thermoplastics. 4. Branched
Question 2: 2) Describe 2 main manufacturing methods used to make glass bottles and the key differences between vs. Linear Molecular Structure: (a) True; branched structures are stronger in solid state and more
them (3)
Blow and Blow Method:
viscous in molten state. 5. Atomic Bonding in Ceramics: Ionic and covalent bonding. 6. Primary
Molten glass is blown into a parison mold to form a rough shape, then reheated and blown Mineral for Glass Products: (e) Silica. 7. Properties of Ceramic Materials: General physical
again into a final mold. properties include high hardness, brittleness, and low thermal and electrical conductivity, while
Common for narrow-neck bottles.
Press and Blow Method:
mechanical properties feature high compressive strength, low tensile strength, and good wear
Molten glass is first pressed into a parison mold using a plunger to form the shape, then resistance. 8. Composite Material Definition: A material made from two or more constituent
blown into the final mold. materials with different physical or chemical properties, creating a new material with improved
Used for wide-mouth containers; more control over wall thickness. characteristics. 9. Meaning of Anisotropic: (c) Properties vary depending on the direction in
Key Differences: Blow and Blow is for narrow-neck bottles, while Press and Blow is for
wide-mouth containers. which they are measured. 10. Materials That Are Not Composites: (d) Portland cement and (g)
Press and Blow offers better control of wall thickness. (3) 1020 steel.
Question 3: Why are the processes of annealing and swabbing used in the manufacture of glass bottles? (2)
Annealing: Used to relieve internal stresses in glass bottles by slowly cooling them,
preventing cracks and improving durability. Increase in Cutting Force: The cutting force, Fc, increases with greater depth of cut due to the
Swabbing: A lubrication process that applies a protective coating to the molds, ensuring larger volume of material being removed and decreases rake angle increases resistance to
smooth glass flow and preventing defects during bottle formation. (2) cutting, leading to higher cutting forces. 2. Effects of Dull and Sharp Tool Tips: A dull tool tip
Question 4: 4Describe what types or categories of defects can occur in the manufacture of glass bottles, and what to
check to determine their cause during the manufacturing process. (4) results in increased cutting forces, poor surface finish, and greater tool wear, while a very sharp
Surface Defects: Includes scratches, cracks, and chips. Check for poor handling or tip decreases cutting forces, improves surface finish, and reduces tool wear. 3. Easy Machining of
improper annealing during the cooling phase. Aluminum and Copper: Pure aluminum and copper are easy to machine because they are
Dimensional Defects: Incorrect size or shape of the bottle. Check mold alignment or
temperature variations during forming. relatively soft, have high thermal conductivity, and good ductility, which facilitates easier chip
Inclusions: Foreign materials like bubbles or stones inside the glass. Check for formation and heat dissipation during machining. 4. Effects of Orthogonal Cutting Wood: Cutting
contaminants in the raw materials or issues with melting. wood at different angles to the grain affects chip formation; cutting parallel to the grain results in
Thickness Defects: Uneven wall thickness. Check the blow and press operations for
improper timing or mold issues. (4) smooth cuts, while cutting against the grain can lead to tearing and splintering. 5. Percentage
Question 5: Give an example of a major type of ceramic, giving their important properties and what uses they have Increase in Chip Thickness: When the coefficient of friction is doubled from 0.15, the percentage
based on these. (3) increase in chip thickness is 12%. 6. Data from Orthogonal Cutting: Given depth of cut = 0.13 mm,
Porcelain: Important Properties: High strength and hardness. Excellent thermal stability
and chemical resistance. Low porosity, making it less absorbent. width of cut = 2.5 mm, rake angle = -5°, and cutting speed = 2 m/s, calculate the shear angle φ,
Uses: Widely used in tableware (dishes and mugs) due to its aesthetic appeal and durability. friction coefficient μ using F/N, shear stress τ on the shear plane, chip velocity, and shear velocity
Commonly used in insulators for electrical applications and dental crowns in dentistry from the provided equations and data.
because of its strength and biocompatibility. (3)
Question 6: Explain the differences between thermoplastics and thermosets, in terms of their chemical structure and
their physical properties. Give examples of a type of thermoset and a type of thermoplastic. (6) Suitable Manufacturing Method: A suitable manufacturing method for ‘glassing’ surfboards is
Thermoplastics: Chemical Structure: Made of linear or branched polymer chains that can hand lay-up or vacuum bagging. Glassing is important because it provides structural integrity and
slide past each other. These chains do not chemically bond during heating.
Physical Properties: Can be repeatedly melted and reformed without significant degradation. Generally have enhances durability by protecting the foam core from moisture and damage. 2. Challenges in
lower strength and higher flexibility compared to thermosets. Robotic Cell for Carbon Fiber Layup: Challenges include ensuring precise alignment of the carbon
Example: Polyethylene (used in plastic bags and containers). Thermosets: Chemical Structure: omposed of cross- fiber layers, maintaining consistent temperature during curing, and handling the material
linked polymer chains that form a rigid network. These chains chemically bond during curing, making them
permanently hard. Physical Properties: Cannot be remelted or reshaped after curing; they are heat-resistant and without causing defects. 3. Questions Before Replacing Metal Gears with Plastic: Considerations
have greater dimensional stability. Typically exhibit higher strength and rigidity compared to thermoplastics. include: what load and stress conditions will the gears face? What are the wear characteristics of
Example: Epoxy resin (used in adhesives and coatings). (6) plastic compared to metal? What is the cost difference? How will it affect the overall
Question 7: In polymer manufacture, what are some of the roles of additives (3)
Enhancers: Plasticizers improve flexibility and workability, making the polymer easier to performance and longevity of the product? 4. Advantages of Traditional Metalworking
process and more versatile in applications. Techniques for Plastics: Traditional metalworking techniques can enhance the precision, surface
Stabilizers: UV stabilizers and antioxidants protect the polymer from degradation due to finish, and dimensional accuracy when forming plastics. 5. Concerns with Using Rapid-Prototyped
exposure to light and heat, enhancing longevity and performance.
Fillers: Materials like calcium carbonate or talc are added to improve mechanical properties, Parts for Stress Analysis: Concerns include potential differences in material properties between
reduce costs, and enhance specific characteristics like strength or thermal resistance. (3) the prototypes and final parts, dimensional inaccuracies, and the need for thorough validation.
Question 8: What causes residual stresses in an injection moulded thermoplastic part? (1) Address these by conducting comparative testing and ensuring prototypes closely mimic the final
Residual stresses in an injection-moulded thermoplastic part are primarily caused by rapid
cooling and uneven temperature distribution during the solidification process. When the materials. 6. Time Estimate for Stereolithography: To cure a 40-mm circle with a line width of
molten plastic fills the mold, it cools quickly, leading to differential shrinkage between the 0.20 mm and 10% overlap at a traverse rate of 0.25 m/s, the estimated time is 28 seconds. 7.
outer and inner layers, which creates internal stresses as the material solidifies. (1) Time Estimate for Fabricating a Square Tube: The estimated time to build a tube with specified
Question 9: Why would one select a powder metal processing technique over other manufacturing methods? (2)
Complex Shapes and Fine Tolerances: Powder metal processing allows for the production of
dimensions and 10 seconds lost per layer for platform lowering is 5.6 hours. 8. Three Main
intricate shapes and components with high dimensional accuracy and fine tolerances, which can be difficult to Classes of Polymers: The three classes are thermoplastics (melt upon heating and solidify when
achieve with traditional methods. cooled), thermosets (harden permanently after curing), and elastomers (stretchable and flexible).
Material Efficiency: This technique generates less waste compared to machining, as it utilizes
the raw powder material more effectively, making it a cost-effective option for producing parts with minimal scrap. 9. Main Categories of Plastics Shaping Processes: Categories include extrusion, injection molding,
(2) blow molding, and compression molding. 10. Recommended Manufacturing Process for Water
Question 10: State some challenges associated with powder metal processes (3) Tanks: Rotational molding is recommended for polypropylene water tanks due to its ability to
Density and Strength Variation: Achieving uniform density and strength throughout the part
can be challenging, as inconsistencies in powder distribution can lead to weak spots.
create hollow parts with uniform wall thickness. Die swell occurs when a polymer melt expands
Limited Material Selection: Not all materials are suitable for powder processing, limiting the upon exiting a die due to pressure release; it can be minimized by controlling melt temperature
choice of alloys and compositions that can be used for specific applications. and die design. 11. Steps to Reduce Post-Moulding Shrinkage: Techniques include using proper
Sintering Issues: Proper sintering is critical, and difficulties such as incomplete sintering or grain growth can lead
to defects, impacting the mechanical properties of the final product. (3)
cooling rates, designing molds to accommodate shrinkage, and selecting materials with low
Question 11: Label on Row 2 the following common defects found in fused-deposition modeling (FDM) shown shrinkage rates. 12. Viscosity Parameters: Viscosity depends on temperature, molecular weight,
below in Row 1. Write down a possible cause (on row 3) and remedy (row 4) for each. (½ mark x 4 x 3 = 6 total) shear rate, and polymer concentration. 13. Meaning of Viscoelasticity: Viscoelasticity refers to a
Defect Cause Remedy polymer melt's ability to exhibit both viscous and elastic behavior when deformed. 14. Steps in
Adjust retraction distance and Processing Ceramics: Steps include mixing raw materials, shaping, drying, and firing. 15.
Stringing Inadequate retraction settings
speed Precautions to Avoid Distortion During Drying: To prevent warping, control drying rates and
Layer Adhesion Issues Low print temperature Increase the printing temperature humidity levels. 16. Important Parameters in Drying Ceramic Products: Important parameters
include temperature, humidity, airflow, and drying time.
Rapid cooling or temperature Use a heated bed and control
Warpage
fluctuations ambient temp
Clogged nozzle or insufficient Clean the nozzle and ensure
Under-extrusion
filament flow proper filament feed

Question 12: What is the major difference between a Multijet and Polyjet 3D printer (1)
The major difference between a Multijet and Polyjet 3D printer lies in their printing technology:
Multijet 3D printers use multiple jets to deposit layers of liquid material that are then cured
layer by layer, often with ultraviolet (UV) light.
Polyjet 3D printers, on the other hand, utilize a similar jetting method but can print with
multiple materials simultaneously, allowing for more complex multi-material parts with
varying properties and colors. (1)
Question 13: Compare and contrast laser beam machining with traditional punching and stamping of sheet metals (4)
Laser Beam Machining (LBM) Precision: Offers high precision and intricate detail, allowing for complex shapes
and fine features without the need for secondary processes.
Material Flexibility: Can cut through a variety of materials, including metals, plastics, and
composites, with minimal material waste.
Thermal Effects: Generates heat during the process, which can affect the heat-affected zone
(HAZ) and lead to thermal distortion in some materials.
Traditional Punching and Stamping Speed and Efficiency: Generally faster for high-volume production of simple
shapes, as multiple parts can be processed simultaneously using dies.
Tooling Costs: Requires specific tooling and dies for each part, leading to higher initial setup
costs but lower per-part costs in mass production.
Material Limitations: Primarily suitable for sheet metals and may struggle with thicker
materials compared to laser cutting.
Comparison Precision: LBM provides greater precision compared to traditional punching and stamping.
Setup and Tooling: LBM has lower setup costs as it does not require specialized tooling,
while punching and stamping need custom dies.
Production Speed: Traditional methods can be faster for mass production of simple shapes,
whereas LBM is better for complex geometries.
Heat Effects: LBM can induce thermal effects that may require additional finishing, while
traditional methods typically do not affect the material structure significantly. (4)
Question 14: During cutting with laser-beam machining, what parameters are important to consider? (4)
Laser Power: The amount of power used directly affects the cutting speed and quality; higher
power typically allows for faster cutting through thicker materials.
Cutting Speed: The speed at which the laser moves across the material influences the quality
of the cut; too fast may result in incomplete cuts, while too slow can cause excessive heat and
melting.
Focal Point Position: Proper positioning of the laser beam's focal point is crucial for
achieving optimal cutting quality and thickness; an incorrectly positioned focal point can lead
to poor cutting performance.