IntroToManufactoring_Test4

The milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches.

150

2) finishing the top surface of a work piece

2) face mill

2) finishing the top surface of a flat bar

2) plain cutter

In the design of fixtures/jigs the principle of 3-2-1 uses location points to define:

3 perpendicular planes

3) producing a groove with a 1/8" diameter concave bottom

3) ball end mill

3) deep, straight walled, narrow slots

3) slitting saw cutter

The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.

30 to 40

A good design consideration is to limit operator force in operating clamping mechanisms to ___ lbs

30-40

The surface finish obtained from the broaching process has a surface finish measurement of [x] to [y] micro inches.

32 to 125

The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.

False

The honing process used stones with a grit size of 1200 or more particles per inch.

False

The cutting process during the milling operation is a(n)___ process

Interrupted

Which of the following is a correct statement for rapid prototyping?

Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.

In centerless grinding, the ___ controls the rotation and longitudinal motion of the workpiece

Regulating wheel

The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.

True

The filing process is used to remove small amounts of material from a part.

True

The blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade

radius

"Power filing" is frequently performed with ___.

rotary burrs

Powered filing is most frequently performed with

rotary burrs

The pattern used to offset the saw blade teeth from the center-line of the blade is called ___.

set

The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?

sewing machines

The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter.

single stroke multi a single pass

What is used to produce internal threads?

taps

The accuracy that can be expected from the milling process is:

.0005 inches

The range of rise per tooth for *internal* broaching is [x] to [y] inches/tooth.

.001 to .0025

CNC milling machines are used in machining operations becase

1. the part geometry can be more complex and 3D compound curves are possible 2. the part can be machined more accurately 3. the part can be machined faster

4) Bearing pocket in gearbox housing

4) end mill

The milling process typically involves

A non-rotating part and a rotating cutter

The broaching process can be described as

A single- stroke process using a multi-toothed cutter to remove small amounts of material with roughing and finishing operations performed in the single pass of the cutter

Which of the following statements for Electical Discharge Machining is incorrect?

A very specialzied process for machining developed for machining parts for NASA rocket engine parts.

Which of the following is not an advantage of plasma arc cutting?

Can be used for cutting metal based composite materials

The teeth of an end mill cutter are located on the ___.

Circumference and the face of the cutter

The lapping process must be performed only by hand without machinery.

False

____ is the property referring to the ability of the abrasive material to fracture producing new, sharp edges

Friability

which of the following statements applies to centerless grinding

Heavy cuts and accurate size control is possible because the workpiece is supported at the grinding location

The most common type of surface grinding machine.

Horizontal spindle, reciprocating table

The slot cut in the material by a saw blade is called ____.

Kerf

Which of the following applies to plasma arc cutting?

Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

In centerless grinding, the regulating wheel controls _____ in the grinding process.

Rotating speed and axial feed of the work piece

What device is used to produce external threads with lathes, screw machines, and threading machines?

Self-opening die head

The milling machine was invented in approximately 1816 by ___.

Simeon North

What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ?

T-slot milling cutter

Which of the following statements correctly describes the purpose of the mask in chemical machining?

The mask is applied to the area of the part that is is desired to not remove material from the part

Which of the following statements is false regarding the thread rolling process?

Thread rolling is a hot forming process

A fixture/jig should be designed to tolerate variations in the workpiece.

True

Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.

True

Centerless grinding is a process that is performed quickly.

True

Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.

True

Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs.

True

More flat surfaces are produced by the milling process than any other machining process

True

The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.

True

Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.

True

The honing process is not used for which of the following:

Truing of holes

3) In slab milling operations, the direction of the cutting force is _____.

Up

End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?

Vertical milling machine

Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.

Vertical spindle, rotary table

The surface finish of a mold or plastic injection molding can be damaged by

a finger print

A dividing head is an accessory used with a milling machine primarily to provide what operation?

accurate rotation of the work piece through any desired arc of rotation

1) The mill cutter rotates ___ the direction of feed.

against

Which of the following is not an abrasive material used in commercial cleaning applications?

aluminum chips

What is the most common material used for abrasives?

aluminum oxide

The chips formed during the broaching process

are trapped in the gullet until the cutting edge exits the workpiece

In mass-production operations, a milling machine capable of making heavy cuts, having 1,2, or 3 spindles, and without vertical tale motion is often used. This is a

bed milling machine

Which is the most frequently used mounting system for abrasives?

bonded

Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material.

charged

The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole?

crosshatch

The abrasive machining process is a mixture of processes, which of the processes produces the *chips* are formed by the grit?

cutting

Clamping forces must be greater than what four (4) forces?

cutting, gravity, inertial, and centrifugal

Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit.

dull flattening

You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice?

electrostatic chuch

Broaching is a process that can be used only in mass-production.

false

For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.

false

The ability to load a part into a fixture only one way is called?

fool proofing

Friability refers to the ability of the abrasive material to ____.

fracture, producing new, sharp edges

By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics

hard glass, ceramics, carbides

Synthetic abrasive materials are commonly used in manufacturing instead of natural abrasive materials because synthetic materials

have more uniform physical properties

Bandsaw blades are frequently made with teeth of what material

high speed steel

A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.

holds size

The soft material used in the lapping process is called _______.

lap

A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.

location

3) The chip thickness is a ___ at the beginning of the chip formation.

maximum

5) The chip thickness is a ___ as the end of the chip formation as the tool exits the work piece

maximum

4) The chip thickness is a ___ at the beginning of the chip formation.

minimum

4) The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.

minimum

Loading and unloading of a fixture will often abuse the fixture ____ .

more than the machining operation

The milling process uses __ and involves __ cutting

multi-tooth cutter interrupted

A plain arbor helical-toothed cutter is preferred over straight-toothed cutters because

multiple teeth contact the work during the milling operation

Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter.

negative 3 to 5

In face milling, most of the cutting occurs at what area of the cutter?

peripheral edge

In _____ products, threads are frequently produced by casting.

plastic

The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips.

plowing rubbing cutting

To thread a blind hole the threes types of taps used, in order are [x], [y], and [z].

taper plug bottom

In the equation fm=ftNn, n refers to

the number of teeth on the cutter

2) The direction of the cutting forces are ____.

toward the part

The saddle provides ___ movement on the knee ways

transverse (Y-axis)

A requirement for broaching is that ___ teeth be in contact with the work piece.

two

The most common type of broaching machine construction is ____.

vertical

2) In slab milling operations, the direction of the cutting force is ____.

vertically down

What is the typical MRR for electrochemical machining?

0.1 in^3/min/1000 amps

The amount of material removed in lapping is usually less than _____

0.001"

1) Deep slots with straight side walls

1) end mill

6) Deep slots in a work piece

6) Staggered- tooth cutter

Which of the following is a function of the dielectric in the electrical discharge machining process?

Flushing agent

What is the milling of two parallel surfaces with side cutters called ?

Straddle milling

Magnetic chucks are commonly used on what type of machinery?

Surface grinders

Which of the following statements is false for clamping forces?

The clamping forces should be spread over a small area

Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)

True

For the honing process the amount of material removed is less than 0.005" from the surface.

True

In centerless grinding, the work piece must be round and not include flats or keyways.

True

The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.

True

Surface grinding machine used in production operations.

Vertical spindle, rotary table

Which of the following describes the ultrasonic machining process?

A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

Which of the following is not an application for laser beam machining?

Cutting thick materials

What device is used to manually produce external theads?

Die

The most common type of sawing machine for cutting metal is____.

bandsaw

in up milling, the chip starts out ___ and is ____ as the tool exists the workpeice

thin/thick

The range of rise per tooth for *external* broaching is [x] to [y] inches/tooth

.003 to .006

1) 45 degree, V shaped groove in the surface of a flat bar

1) angle cutter

The broaching processes is used in the manufacturing of

1. Pipe wrench jaw teeth 2. internal keyways 3. dovetail for a turbine blade 4. internal splines

Non-Traditional Machining produces parts by which of the following (mark all that apply)?

1. Removing material from a base using chemicals 2. Removing material from a base using a tool vibrated at ultrasonic frequencies 3. Removing material using ultra-high pressure water 4. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. 5. By an additive process where small, precise amounts of materaisl are built-up into a shape

Modular fixturing is frequently used ...

1. for prototyping and small jobs 2. because standard parts can be used to construct the fixture 3. to lower costs

The abrasive machining process is used for which of the following?

1. improving the surface finish of a part 2. accurately machining a part to a finished size with an excellent surface finish 3. cleaning the particle 4. Part seperation

4) 1/4" radius, convex shape along the edge of the part

4) form cutter

5) Producing a flat-bottom groove in the surface of a part

5) end mill

5) milling wood to produce wood trim

5) form cutter

Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations.

72

What percentage of EDM is used to produce tool and die sets?

80-90%

The honing process is a finishing process typically used to produce

A cross-hatch pattern on an internal cylindrical surface

The milling process is characterized by

A high MRR, a good surface finish, and is used in mass production

Which of the following best describes the tool and workpiece movement for the milling process?

A process involving a rotating tool and X-Y-Z linear movement of the work piece

Which of the following statements applies to creep feed grinding?

A process with very slow t able feeds and deep depth-of-cut compared to conventional surface grinding

Which of the following materials is not commonly used as a lap?

Aluminum

In mass-production operations, a milling machine with the capability of making heavy cuts, having 1,2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine?

Bed milling machine

Which of the following is not a common material used for the teeth of a band saw blade?

CBN

What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.

Cylindrical external

Identify the type of cutter that would be used to machine a 12" wide, 48" long aluminum bar stock to produce a flat, smooth, and an excellent finish on the 12" wide surface of t he bare using a *vertical* knee-and- column milling machine

Face mill

A fixture/jig should be design using the least number of standard elements as possible.

False

Centerless grinding is a process that must be performed manually by the machinist.

False

Centerless grinding requires lots of operator skill to operate the machine.

False

Centerless grinding requires that small grinding wheels be used in the grinding process.

False

Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.

False

Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.

False

Electrochemical Machining is a deplating process using high DC voltage, high current for the process.

False

High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.

False

In centerless grinding deep cuts are not possible due to the work support.

False

The milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass-production, tool and die work, and prototype work.

False

With centerless grinding tubes will automatically have concentric inside and outside diameters.

False

Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.

False

Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.

False (Water jets are used to cut non-metal materials. To cut metals, an abrasive is added to the water stream)

Tapered end mills are used for ____

Finish cutting on molds to produce a desired angle

Slab milling is typically performed using what type of knee-and-column milling machine?

Horizontal milling machine

Surface grinder not typically used due to limited type of work which it will accommodate.

Horizontal spindle, reciprocating table

The most common type of surface grinder is a

Horizontal spindle, reciprocating table

The milling machine was invented in approximately 1816 by Simeon North to machine

Interchangeable parts for rifles for the US Gov.

The table has ___ movement on the saddle ways.

Longitudinal (X- axis)

Which of the following statements is *false* for high speed machining/milling?

One or more axes are always accelerating in a 3-D cut.

Which of the following statements is false regarding thread grinding?

Only course threads can be produced

In face milling, most of the cutting process occurs at the ___ portion of the cutter

Peripheral

Identify the type of cutter that would be used to mill deep narrow slots in a part using a *horizontal* knee-and-column milling machine

Slitting saw cutter

Which of the following statements is false for rolled threads?

The threads produced by thread rolling have a lower strenghth than cut threads

The chemical machining process is used in mass-production of parts.

True

The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.

True

The operator should not have to reach past the tool to load/unload parts for machining.

True

With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions.

True

Surface grinder where the wheel diameter must exceed the width of the part being ground

Vertical spindle, reciprocating table

A surface grinder that can be equipped with multiple heads, ad automatic loading, and unloading is a

Vertical spindle, rotary table

In up milling, the cutter rotates ___ the direction of the feed

against

Which of the following materials is not used a a carrier to charge the lap with abrasive particles?

air

The most common sawing machine is

band saw

In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish.

few excellent

A fixture is a special workholding device that ___ during machining or assembly operations

holds the workpiece and determines size demensions

Superfinishing is a variation of what process to finish flat surfaces.

honing

Which of the following is not a type of broach construction?

insert tooth

Broaching was orginally developed for the production of ____.

internal keyways

Which of the following is NOT a type of mounting method that is used with the abrasive machining process?

mounted

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface.

multiple teeth less smoother (lower surface roughness value)

Mill cutters manufacturing from carbide and ceramic have a ____ rake angle

negative

In the slab milling process, the finished surface is _____ to the axis of rotation of the cutter and is normally performed on a ____ spindle milling machine.

parallel horizontal

A CNC milling machine ___.

provides for machining of more complex parts than a manual milling machine

The blade width determines the minimum ___ that can be cut with a bandsaw for contour cutting

radius

Which of the the following is not a common tooth form for saw blades?

square

Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter.

straight helical

The coarseness of a file is determined by

the pattern of cut and length of the file

The structure of a grinding wheel refers to ___.

the spacing of the abrasive grit in the wheel

The structure of a grinding wheel refers to

the spacing of the abrasive particles

The grade of a grinding wheel refers to ___.

the strength of the bonds between the abrasive grits

For American pattern files, the coarseness of the file cut is given by:

the tooth pattern and the length of the file

The process for machining threads which requires a CNC machining center capable of circular interpolation is ___.

thread milling

The principle of 3-2-1 uses location points to define ___.

three (3) perpendicular planes

The knee provides ____ movement on the column ways.

vertical (z-axis)

Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.

vise chuch

1) The mill cutter rotates ____ the direction of feed.

with

What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment?

woodruff keyseat milling cutter