IME 330 Quizzes 2

Microsystem technology is concerned with products and components whose feature sizes are measured in microns. A micron is equal to which one of the following:

10^-4

Which one of the following is closest to the temperatures used in plasma arc cutting:

11,000ºC

In preparing a CNC path you need to trace the part detailing the X,Y coordinate dimensions. Based on the image below, determine the X,Y coordinates of point 3 and point 12 based on an absolute position from 0,0. Note that each answer corresponds to only one point location. Assume the part is symmetrical.

3 - 2.75, 1.5; 12 - 1.5, 2.75

Martensite can be defined as which one of the following:

A phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived

Match each sand-casting defect with the appropriate description. (Matching) Balloon Pin Holes Penetration Mold shift

Balloon: other Pin Holes: consist of many small gas cavities formed at or slightly below the surface of the casting Penetration: refers to a surface defect that occurs when the fluidity of the liquid metal is high and it penetrates into the sand mold... Mold shift: sidewise displacement of the mold cope

Of the following quenching media, which one produces the most rapid cooling rate:

Brine

The chemical formula for acetylene is which one of the following:

C2H2

Which one of the following plating metals produces the hardest surface on a metallic substrate:

Chromium

Which one of the following processes would be appropriate to drill a hole with a square cross section, 6mm (0.25 in) on a side and 25mm (1 in) deep in a steel workpiece:

EDM

Which one of the following arc welding processes uses an electrode consisting of continuous consumable tubing containing flux and other ingredients in its core:

FCAW

MIG welding is a term sometimes applied to which one of the following processes:

GMAW

Which one of the following arc welding processes has the lowest heat transfer factor:

GTAW

Which one of the following processes uses a thick rubber pad to form sheet metal over a positive form block:

Guerin Process

Tempering is a heat treatment applied to hardened steels that is best defined as which one of the following:

Heating and soaking at a temperature below the austenitizing level followed by slow cooling

A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the arc center axes?

I,j,k

The rate fo heat energy supplied in a resistance spot welding operation is determined by which one of the following equations, where RH=rate of heat energy, E=voltage, I=current, R=resistance, and t=time:

I^2R

The time-temperature-transformation curve (TTT curve) for steel can best be described by which one of the following:

Indicates how cooling rate affects the transformation of austenite into various possible phases

Match the following casting defects with their definitions. (Matching)

Misruns: Casting that solidify before completely filling the mold cavity Cold Shuts: Occurs when two portions of the metal flow together but there is a lack of fusion between them due to premature freezing Cold Shots: Results from splattering during pouring, causing the formation of solid globules of metal that become entrapped in the casting Shrinkage Cavity: A depression in the surface or an internal void in the casting caused by a restriction in the amount of molten metal available to the last region of the cavity Microporosity: A network of small voids throughout the casting caused by localized solidification and shrinkage of the final molten metal in the dendritic structure

What are the three main factors to successfully pouring molten metal?

Pouring temperature, pouring rate and turbulence

"Stick" welding is a term sometimes applied when referring to whcih one of the following processes:

SMAW

In sand blasting, which one of the following blast media is used:

SiO2

Silica sand has which one of the following compositions:

SiO2

Match each mold property to its definition. (Matching)

Strength: to maintain shape and resist erosion Collapsibility: ability to give way and allow casting to shrink without cracking the casting Thermal Stability: to resist craving on contact with hot metal Permeability: to allow hot air and gases to pass through voids in sand

A cupola is a vertical, cylindrical furnace equipped with a tapping spout near its base.

True

A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the incremental or secondary axes?

U,V,W

Which of the following steel parts will cool from the austenite region most quickly:

a cylinder 4 meters long

In casting, the term chaplet has multiple meanings. One use of the term refers to _____.

a support made of a metal having a higher temperature than the casting metal

A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the rotary axes?

a,b,c

A stepper motor is which one of the following types of devices?

actuator

In abraisive water jet cutting, the abrasive particles are added to the water stream:

after it exits the nozzle

In precipitation hardening, the hardening and strengthening of the metal occurs in which one of the following steps:

aging

The cleaning fluids in ultrasonic cleaning are generally aqueous solutions containing which of the following types of chemicals:

alkaline detergents

Calorizing is the same as which one of the following surface processes:

aluminizing

Electroslag welding uses an arc as in arc welding to initiate welding but is not classified as an arc welding process for which one of the following reasons:

an arc is not used during welding

In anodizing, the work part to be coated is which one of the following during the electrolytic process:

anode

A SCARA robot is normally associated with which one of the following applications:

assembly

A contact input interface is a device that reads which one of the following types of data:

binary

Flash welding is normally used to weld which one of the following joint types:

butt

The typical application of friction stir welding is which one of the following joint types:

butt

Which one of the following surface-hardening treatments is the most common:

carburizing

The standard coordinate system for numerical control machine tools is based on which one of the following:

cartesian coordinates

The standard coordinate system for numerical control machine tools is based on which one of the following?

cartesian coordinates

Which one of the following casting metals is most important commercially:

cast iron

Shell molding is best described by which one of the following:

casting process in which the mold is a thin shell of sand bonded by a thermosetting resin

Most sheet metalworking operations are performed as:

cold working

A stamping die that performs two or more operations on a sheet-metal coil at two or more stations with each press stroke is called which one of the following:

combination die? NOT! maybe progressive die?F

Which one of the following is not one of the major components of a PLC:

control console

The ability of a positioning system to return to a previously defined location is measured by which one of the following terms?

control resolution - wrong, accuracy -wrong repeatability?

In which of the following spinning processes does the thickness of the starting sheet-metal blank remain unchanged after the process:

conventional spinning

Which one of the following is the name of the resistance welding process widely used to produce welded wire products such as wire fence and shopping carts:

cross-wire welding

An indirect fuel-fired furnace is an alternative name for which one of the following furnace types:

crucible

The liquid used to create the discharge path between the tool and the work in electric discharge machining is called which of the following:

dielectric fluid - wrong (but should be according to slides) electrolyte - actual

Laser metal deposition is classified into which one of the following AM process categories:

directed energy deposition

A control system in which multiple computers are used to share the process control workload is called which one of the following:

distributed process control

Ballistic-particle manufacturing is another name for which one of the following RP technologies?

droplet deposition manufacturing

Springback in a sheet-metal bending operation is the result of which one of the following:

elastic recovery of the metal

Electroplating is also known as which one of the following:

electrochemical plating

Which one of the following is used to create indentations in sheet metal, such as raised letter or strengthening ribs:

embossing

Fused deposition modeling uses which one of the following layer-forming techniques in the layer-by-layer construction of a three-dimensional part:

extruder heads

Rapid tool making (RTM) applications divide into two approaches: Direct RTM and indirect RTM. Direct RTM refers to which of the following:

fabrication of the tool itself

The crystal structure of austenite is which one of the following:

face centered cubic

In the context of rapid prototyping and additive manufacturing, tessellation refers to the process of slicing the CAD model of the part into layers: (a) true or (b) false?

false

Machining is never used for rapid prototyping because it takes too long: (a) true or (b) false?

false

The three basic types of automated systems used in manufacturing are fixed automation, programmable automation, and flexible automation. Programmable automation is an extension of flexible automation in which there is virtually no lost production time for setup changes or reprogramming.

false

Soaking is a term that refers to which one of the following:

heating the metal to a suitable temperature and holding at that temperature for a certain time

The aspect ratio in microsystem technology is best defined by which one of the following:

height-to-width ratio of the fabricated features

Tungsten is the preferred nonconsumable electrode metal in GTAW for which one of the following reasons:

high melting temperature

In a blanking operation, as the hardness of the sheet metal increases, the clearance between punch and die should be:

increased

As the ratio of tube diameter over wall thickness increases, the tendency for a tube to collapse and fold during bending:

increases

A positioning system in which the next work head position is defined with respect to the previous position is called which one of the following:

incremental positioning

Which one of the following expendable mold processes is known as a precision-casting process:

investment casting

In ion implantation, the concentration of the impregnated element in the substrate is greatest

just below the surface

Which one of the following RP technologies uses solid sheet stock as the starting material?

laminated-object manufacturing

Resistance spot welding is most widely used for which one of the following joint types:

lap

The typical application of ultrasonic welding is which one of the following joint types:

lap

Which one of the following processes would be appropriate for cutting a hole of 0.075mm (0.003 in) diameter through a plate of aluminum that is 1.6mm (1/16 in) thick:

laser beam machining

Stereolithography uses which one of the following layer-forming techniques in the layer-by-layer construction of a three-dimensional part:

lasers

The linear velocity of a worktable driven by a leadscrew equals which one of the following:

leadscrew pitch multiplied by leadscrew rotational speed

Which of the following is the best definition of bend allowance:

length before bending of the straight sheet-metal section to be bent

In die casting, the term flash means _____.

liquid metal under high pressure squeezes into the small space between the die halves at the parting line

In the LIGA process, the letters LIGA stand for which one of the following:

lithography, electroplating, and plastic molding

Investment casting is also known by which one of the following names:

lost-wax process

Surface finish in EDM is best under which one of the following combinations of process parameters:

low discharge current and high frequency

The method of NC part programming in which the machine operator enters the part program into the machine control unit is called which one of the following:

manual data input

A misrun is which one of the following defects in casting:

metal solidifies before filling the cavity

Which one of the following is not considered a category of devices associated with microsystem technology:

microscopic biological entities

For which one of the following reasons is a green mold named:

moisture is contained in the mold

Stereolithography uses which one of the scanning modes in the layer-by-layer construction of a three-dimensional part:

moving-spot mode

Which of the following are characteristics of work situations that tend to promote the substitution of a robot in place of a human worker (three best answers)?

multiple work shifts, hazardous work environment, repetitive work cycle

A sheet-metal cutting operation that cuts out a portion of metal from the side of a sheet or strip is called which one of the following

notching

In CNC programming the term "modal" is often used to describe the state of variables. What does this mean?

once a variable is set, it remains constant until it is changed

Which one of the following press type is associated with the highest production rates in the sheet-metal-stamping operations:

open-backed inclinable

Which one of the following is not an advantage of laser-beam welding over electron-beam welding:

optical lenses and mirrors can be used - wrong...deeper welds are possible?-correct

Which of the following are problems with the current rapid prototyping and additive manufacturing technologies (three best answers)?

part accuracy limited material variety part shrinkage

Which of the following are examples of appropriate applications of additive manufacturing in the actual production of parts and products (three best answers)?

parts with intricate and/or complex geometries customized one-of-a-kind parts plastic parts in small batch sizes

Steel car bodies are commonly conversion coated with which one of the following thin films in preparation for painting:

phosphate

Typical sheet-metal thicknesses are between 0.4 mm (1/64 in) and 6 mm (1/4 in). When thickness exceeds the upper limit of this range, the stock is usually referred to as which one of the following:

plate

The polymer used to make compact discs (CDs) and digital versatile discs (DVDs) is which one of the following:

polycarbonate

The common resist material used in LIGA is which one of the following:

polymethylmethylacrylate

The arm‑and‑body of a robot manipulator generally performs which one of the following functions in an application:

positions the wrist within the work volume

When a control box is used in leadthrough programming to move the manipulator to a desired position in the work volume, the programming method is called which one of the following:

powered leadthrough

The quenching step in precipitation hardening results in which one of the following effects:

precipitation of fine particles that strengthen the alloy - wrong formation of martensite- wrong

A device that converts a series of pulses from an external source into a digital value is which one of the following:

pulse counter

In the sheared edge of a sheet-metal part, the depression made by the punch prior to actual cutting is called which one of the following:

rollover

How can you produce multiple etches with a single mask?

rotating the mask

Which one of the casting processes is the most widely used?

sand casting

Which of the following RP technologies uses powders as the starting material (two correct answers)?

selective laser sintering and three-dimensional printing

A sheet-metal cutting operation that cuts out a portion of metal from the interior of a sheet or strip that will become part of the outline of the blanking is called which one of the following:

seminotching

The cutting force in a sheet-metal blanking operation depends on which mechanical property of the metal:

shear strength

The most common work material used in microsystem technology is which one of the following:

silicon

The data contained in a compact disc are coded as which one of the following:

small pits in a helical track

Vapor degreasing is a form of which one of the following:

solvent cleaning - wrong, but should be emulsion cleaning - right

In water jet cutting and abrasive water jet cutting, the separation between the nozzle opening and the work surface is called which one of the following:

standoff distance

Shot peening uses a high-velocity stream of which one of the following media:

steel pellets

Which one of the following rapid prototyping processes uses a photosensitive liquid polymer as the starting material?

stereolithography

Which of the following RP technologies uses molten material as the starting material (two correct answers)?

stereolithography droplet deposition manufacturing....1 of these is correct not sure which one is wrong

The advantage of reactive ion etching is

straight walls can be produced

To reduce residual stresses and warping in long seam welds, the parts are sometimes welded at multiple points along their lengths prior to continuous seam welding; this is called which one fo the following:

tack welding

The treatment in which the brittleness of martensite is reduced is called which one of the following:

tempering

Overcut in EDM is defined as which one of the following:

the distance by which the machined cavity in the work part exceeds the size of the tool on each side

In a blanking die, the device that clears the sheet metal from the punch after blanking is called which one of the following:

the stripper

Which one of the following is not a physical form of the starting material in additive manufacturing:

three-dimensional volumes

In an organic coating process, the proportion of paint supplied to the process that is actually deposited onto the work surface is called which one of the following:

transfer efficiency

A manufacturing system can be defined as a collection of integrated equipment and human resources that performs one or more processing and/or assembly operations on a starting work material, part, or set of parts.

true

Numerical control is a form of programmable automation in which the mechanical actions of a piece of equipment are controlled by a program containing coded alphanumeric data, the data representing relative positions between a work head and a work part.

true

Rapid prototyping and additive manufacturing are two terms that refer to fabrication technologies that add layers of material to an existing part or substrate: (a) true or (b) false?

true

Which one of the following is the name of the casting process in which molten metal is poured into a rotating mold to produce a tubular part:

true centrifugal casting

Tumbling is a mass finishing process that is also known by which one of the following names:

tumble finishing - wrong... barrel finishing?-correct

As work material hardness increases, material removal rates in ECM are

unaffected

Along the penetration into the work, etching also occurs sideways under the protective coating; this is called which one of the following:

undercut

Physical vapor deposition must be carried out in which one of the following types of equipment:

vacuum chamber

The fused zone between the two parts in a resistance spot weld is called which one of the following:

weld nugget

Which one of the following plating metals is associated with the term galvanizing?

zinc

Which one of the following metals has the lowest melting point:

zinc?-wrong!