IntroToManufactoring_Test 3
In surface roughness measurement, the standard cut-off length is ____.
0.030"
A micrometer has a measurement range of ____ between it's anvils
1"
A spade drill is used for what drilling application?
1" and larger holes in thick materials
Which machining process has generally replaced shaping?
Milling
Which of the following functions are performed by the headstock
housing and speed selection for the spindle
Accuracy is the ________ spread in measurements made of slide movement during successive runs at a set of target points along an axis of the machine or tool.
maximum
The undesired but permissible deviation from a desired dimension is called _______.
tolerance
Which of the following is NOT a base for machinability?
tool temperature
Material removal rate is defined as ____.
volume of material cut/cutting time
From the following list, select four reasons for machining a part.
1. To produce unique features; i.e. threads, o-ring gooves, sharp edges, grooves in a part. 2. To produce a prototype of a part. 3. To produce flat, smooth surfaces for mating parts so that they can seal. 4. To make a finished hole in a part that is true along an axis.
Select the three variables that are normally controlled in the machining process.
1. speed 2. feed rate 3. depth of cut
In the inspection process, the measurement instrument should be ___ times more precise than the tolerance to be measured.
10
The point angle is most often ground at an angle of ____ degrees.
118
A point angle of ____ degrees is often used to drill more ductile materials.
135
A major contribution to the lathe was the slide carriage in _______.
1800
Coated carbides have an increased tool life of ____.
200-300%
Drilling makes up about ___ % of all machining operations.
25%
With PCBN tooling, cutting speeds and therefore MRR can be ____ times greater than a cemented carbide tooling
5
What percentage of the total energy of the machining process goes into the shearing process?
60-70%
Approximately ____ % of carbide tools are coated, commonly by the ____ vapor deposition process.
85 to 90, chemical
Which of the following statements is false regarding drilling and hole making related processes
A hole produced by a twist drill bit will be concentric
Rough cutting on the lathe involves cutting with
A large depth of cut and a slow feed rate
Machinery used for drilling holes in structural steel is
Beam drill line
Which of the following processes cannot be performed on a lathe? (mark all that apply)
Broaching, Gear hobbing
Which of the following is NOT used to hold parts in the lathe?
C-clamp
Which of the following is not a machining process?
Casting
Which of the following is not correct for coated carbide tooling?
Coated carbides are used only in turning operations.
The machine used to reverse engineer parts and perform inspection of parts in 3-D space is ____.
Coordinate measurement machine
A hole saw would not be used in which of the following applications?
Drill a blind, 2" diameter hole in steel.
By mounting a ___ in the lathe tailstock, holes can be produced in the part.
Drill bit
A gun drill is used for what applications?
Drilling deep holes
Which of the following is not an item produced by a screw machine as listed on the website:
Engine piston pin
Turning is a machining operation that rotates the work piece about an axis and material is removed from the _____________ of the part.
External surface
What is the process called that produces a flat surface perpendicular to the axis of rotation of the work piece?
Facing
___ is an operation that produces a flat surface by feeding a tool across the end of the work piece
Facing
Collets have a wide range of sizes that they can hold.
False
The compound rest can be used on the lathe to produce long tapers in the turning and boring of parts.
False
With a horizontal boring machine, the part and the tooling are rotated around a horizontal axis simultaneously.
False
The body of the drill contains two or more helical gooves call _____ for chip removal.
Flutes
For the oblique machining process, match the listed forces and descriptions.
Force acting in the direction of the tool feed- feed force Force acting perpendicular to the machined surface.- radial force Force acting in the direction of the cutting velocity vector- primary cutting force
Power for the lead screw and the feed rod are provided by the ___.
Gearbox
Identify for each of the following whether the device is used for measurement or gaging. Be careful - the name does not always tell you.
Go/No-Go Plug gage- gaging Dial Caliper- measurement Tool makers microscope- measurement Screw thread pitch gage- gaging Height Gage- measurement Surface roughness instrument- measurement micrometer- measurement
Which of the following is not a material for drill bits?
HSS with Al2O3 coating
Tools made from high-speed tool steel are generally used for what type of machining operations?
Hand tools and low-volume machining operations
The angle that the flutes make with the center line of the drill is called:
Helix Angle
What type of machine would be used to do boring on large parts that cannot be turned in an engine lathe?
Horizontal boring machine
Specific horsepower can be defined as ____.
Horsepower/MRR
which of the following statements applies to the conventional chisel edge of a twist drill
If forms a small hole at the center of the hole location as part of the hole drilling operation
Which of the following is not a method to decrease or eliminate the formation of a built-up edge from a cutting tool?
Increasing the depth of the cut
which of the following statements applies to the carriage of an engine lathe
It is an H-shaped casting which travels on the lathe ways, the apron is mounted to it, it provides motion to the tooling along the axis of rotation for the lathe
Which of the following statements is false for producing holes by trepanning?
It is used only in mass-production operations.
Select the statement that is false for the chisel edge of a twist drill.
It tends to be self centering
What is the process called that produces a raised diamond pattern on the surface of the part by a cold forming process?
Knurling
The accurate longitudinal feed of the tooling for threading operations is provided by ?
Lead screw
During the drilling operation, the drill is guided in the hole by the _____ rubbing against the walls of the hole.
Margins
What is a the name of a drilling machine with multiple spindles that produces multiple holes simultaneously in a work piece?
Multispindle Drill Head
What is the process in which a thin tool is fed perpendicular to the axis of rotation of the work piece to remove the completed part from the stock?
Parting off
What is the process called where the drill is fed into the work, removed slightly, fed again and the cycle repeated until the hole is finished?
Peck drilling
A machine used to drill holes in large, heavy parts in low volume operations is a
Radial arm drill press
Collets are used to hold____ in a lathe.
Smooth parts
The twist drill was invented in 1863 by whom?
Stephen Morse
What types of machines should be used for the turning of small, long slender parts?
Swiss screw machine, Brown and Sharpe screw machine
Measurement is a process by which calibrated instruments are used to determine what?
The actual dimensions of the completed part
ANSI's guide for specifying allowance and tolerance assumes______.
The hole size is considered as base.
Which of the following statements is false for the reaming process?
The process will make the hole concentric with an axis of rotation.
PCBN and diamonds are extremely hard but brittle materials, placing new demands on machine tools and machining processes. These demands include the following.
The use of more ____ machine tools. (Rigid) Machining practices involving ____ entry and exit of the cut to prevent microchipping of the tool material. (Gentle) The use of ____ machine tools, because these tool materials are capable of producing higher quality finishes and machining to greater accuracy. (precision) The use of machine tools with high power, because these tool materials are capable of higher MRR and higher _____. (spindle speeds)
Which of the following statements is false for discontinuous chips?
They are formed when machining at high cutting speeds and fine feed rates.
A vertical boring machine is typically used with large parts, and the part is rotated around a vertical axis.
True
The carriage on the lathe is an H-shaped casting which provides motion for the tooling.
True
The centerline of the tailstock quill is adjustable relative to the lathe centerline.
True
The cutting tool is the most critical part of the machining process.
True
The drill process is has a high MRR.
True
Typically collets provide more accurate centering than a 3-jaw chuck.
True
What is the most common type of drill bit?
Twist Drill
What machine should be used for the boring of large, short parts?
Vertical boring machine
The _______ are hardened, precision ground steel rails that run longitudinally along the top of the lathe bed.
Ways
What is the center column or backbone of a twist drill called?
Web
To hold odd-shaped parts, a face plate or ____ would be used.
a 4 jaw chuck
The desired difference between the dimensions of two mating parts is called ____.
allowance
The tailstock moves [x] and the [y] is housed in the upper casting of the tailstock and moves [z] to the bed with a handwheel.
along the ways, quill, longitudinally
With continuous chips, ____ in the work, heat generation, and temperature is experienced.
an increase
What is the 3rd step in the four steps needed to obtain an accurate hole in a workpiece?
boring
The tooling for the lathe is mounted on the tool post, which mounts on the ____, which is mounted to the _____, which is part of the carriage assembly.
compound rest, cross slide
Cutting fluids are used primarily as ____
coolants
Using a taper attachment to produce a taper causes the [x] to move transversely as a guide shoe moves on the [y].
cross slide, ways
The surface roughness from a part produced in a lathe can be decreased by ___.
decreasing the tool feed rate and increasing the tool corner radius.
In boring operations, compared to turning operations, the
depth of cut and the feed rates are lower
Which of the following is not a basic chip type?
discontinuous with built-up edge
The size of a lathe is specified by two parameters, which are ____ and ____.
distance between centers, swings
Cermets are a new class of tool materials best suited for what type of operations?
finish machining
The purpose of a counterboring operation is to produce a ____.
flat bottom recess for a bolt head or nut.
What is the process called that uses fixed size instruments to determine if a part has been machined within tolerance?
gaging
To drill very deep holes in a part, which type of drill should be used
gun drill
High speed steel is used in which of the following applications
hand tools, low speed and low volumes, and complex tooling shapes
Polycrystalline Cubic Boron Nitrides are used for machining what types of materials?
hardened steels and superalloys
Which of the following materials typically is used for gage blocks?
hardened, ground steel
The typical twist drill is comprised of a shank, cutting edges, chisel edge, and
helical flutes along a long, slightly flexible rod
Continuous chips are formed with _____ ductile materials.
high
The spindle is a [x] which supplies the rotational motion to the [y].
hollow shaft, workpiece
For the boring of large parts which cannot be turned in a lathe, what type of machine should be used?
horizontal boring machine
The lathe head stock provides ____ and ____
housing for the spindle, speed selection for the spindle
Continuous chips remain in contact with the tool face longer, causing ___.
increased frictional heating, temperature and tool wear
The bed of the lathe
is the base of the lathe on which other components of the lathe mount
Which of the following statements does not apply to the reaming process?
it will make the hole concentric with an axis of rotation
The direction of the predominant surface pattern produced by the machining process.
lay
Cutting fluids are used secondarily as _____.
lubricants
New tooling machines are placing new requirements upon machining and machining processes, including
machining procedures with gentle tool entry and exit from the cut
The function of the ___ is to guide the bit inside the drilled hole
margin
Cermets are a _____ material in a _____ binder
metal, ceramic
Turret lathes hold tooling in tool turrets so that
more tools can be set up machining, thereby decreasing setup time and increasing machine productivity
A drilling machine used in mass production operations to drill several holes simultaneously is a
multiple spindle drilling machine
Most parts manufactured are a collection of geometric shapes; therefore, their dimensions have a(n) ____ distribution.
normal
Most machining occurs at ____ angles
oblique
Which of the following materials is NOT used for gage blocks?
polished stainless steel
Taylor's equation is used to
predict the life of a cutting tool based upon cutting speed
Machining operations are performed on a part for the following reasons:
produce threads, produce flat sealing surfaces, produce a mold for injection molding, to produce one of an item
Traditional machining is the process of ____.
removing unwanted material from a part in the form of chips
Specific horsepower correlates well with
shear strength
Chip formation involves a localized [x] process with [y] strains and high strain rate plastic deformations in a radial [z] region that progresses ahead of the tool.
shearing, high, compression
The ____ has the lathe bed rotated 45 to 60 degrees, typically has a tool turret, and is a type of construction often used for a CNC lathe
slant bed lathe
Precision of a machine tool can be defined as
spread of the normal curve at the tangent point with the largest value
The mathematical quanity associated with precision for a device is _____.
standard deviation
When machining long, slender parts to reduce the deflection of the work piece a ___ and a ____ can be used to support the part.
steady rest, follow rest
Tool failure can be classified into two categories: _____ death and _____ death
sudden, slow
Finely-spaced surface irregularity from the machining operations.
surface roughness
Which of the following processes are gage blocks not used for?
surface roughness measurement
In surface roughness measurement, the term surface roughness means
the finely-spaced surface irregularities produced by the machining process
The current design practice is to specify tolerance with a base dimension and +0.000x/-0.0000 or +0.0000/-0.000x. This is called ____ tolerance.
unilateral
The turning of a taper can be accomplished by
using a taper attachment, offsetting the centers, programming in a CNC lathe, using the compound rest
Material removal rate is defined as
volume of material removed / cutting time
Surface irregularity of a wide spacing, generally due to warping, vibrations, or deflection duringthe machining process.
waviness
Gage blocks are assembled by being ______ together to create various dimensional sizes.
wrung