Manufacturing Final
A live center is one way of holding a workpiece in the headstock of a lathe, whereas a dead center is used to hold the work in the tailstock: (a) true or (b) false?
A
A photoresist is a masking material that is sensitive to light. (a)True (b) False
A
Desirable properties of a metal for resistance welding are high resistivity, low electrical and thermal conductivity, and low melting point. (a) true (b) false
A
In casting processes, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity, (b) worker who moves the molten metal to the mold, or (c) vertical channel into which molten metal is poured into the mold?
A
In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning: (a) depth of cut d, (b) feed f, or (c) speed v?
A
The twist drill is the most common type of drill bit: (a) true or (b) false
A
A vertical milling machine is more appropriate than a horizontal milling machine for performing which of the following types of operations (three best answers): (a) end milling, (b) face milling, (c) peripheral milling, (d) plain milling, (e) slab milling, and (f) surface contouring?
A, B & F
A lathe can be used to perform which of the following machining operations (three correct answers): (a) boring, (b) broaching, (c) drilling, (d) milling, (e) planing, and (f) turning?
A, C & F
2 Gear hobbing is a special form of which one of the following machining operations: (a) grinding, (b) milling, (c) planing, (d) shaping, or (e) turning?
B
A broaching operation is best described by which one of the following: (a) a rotating tool moves past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary workpart, (c) a workpart is fed past a rotating cutting tool, or (d) a workpart moves linearly past a stationary single-point tool?
B
A facing operation is normally performed on which one of the following machine tools: (a) drill press, (b) lathe, (c) milling machine, (d) planer, or (e) shaper?
B
The distinguishing feature between a drilling fixture and a drill jig is that the fixture provides a means of guiding the tool during the hole-making operation: (a) true or (b) false?
B
The empirical relationship that determines total solidification time in casting is known as which one of the following: (a) Bernoulli's theorem, (b) Chvorinov's rule, (c) continuity law, (d) flow curve, (e) Hooke's law, or (f) Ohm's law?
B
When the drill bit in a drilling operation exits the opposite side of the work, the resulting hole is called which one of the following: (a) a blind hole or (b) a through hole
B
Which of the following is the main function of a cutting fluid in machining? a. Improve surface finish on the workpiece c. Reduce forces and power required b. Reduce friction at the tool-chip interfaced d .Wash away chips
B
A roughing operation generally involves which one of the following combinations of cutting conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d, where v = cutting speed, f = feed, and d = depth of cut?
C
A single-point cutting tool is used for which one of the following operations: (a) drilling, (b) milling, or (c) turning?
C
Solidification shrinkage in casting is defined as which one of the following: (a) liquid contraction during cooling prior to solidification, (b) liquid contraction during cooling and solidification, (c) contraction during the phase change from liquid to solid, or (d) thermal contraction of the solidified casting during cooling to room temperature.?
C
The mechanism of chip formation in machining is best described by which one of the following: (a) compression, (b) fracture failure, (c) shear deformation, or (d) tensile failure?
C
The mechanism of chip formation in machining is best described by which one of the following: (a) compression, (b) fracture failure, (c) shear deformation, or (d) tensile failure
C
Which one is not a desirable characteristic of a brazing flux? a. low melting temperature, c. high viscosity when melted, b. promotes wetting of metal surfaces, d. protects the joint until solidification
C
Which one is not true about the disadvantages and limitations of brazing include a. the strength of the brazed joint is generally less than that of a welded joint, b. high service temperatures may weaken a brazed joint, c. dissimilar metal parts cannot be joined d. the color of the filler metal is often different than the color of the base metals.
C
Which one of the following turning machines permits very long bar stock to be used: (a) chucking machine, (b) engine lathe, (c) screw machine, (d) speed lathe, or (e) turret lathe?
C
All of the following issues define some of the problems introduced by machining dry, EXCEPT: a. Absence of chip removal benefits that are provided by cutting fluids in grinding and milling b. Operating at lower cutting speeds and production rates to prolong tool life c. Overheating the tool d. Reductions in defect rates for finished products
D
During solidification of an alloy when a mixture of solid and liquid metals is present, the solid‑liquid mixture is referred to as which one of the following: (a) eutectic composition, (b) ingot segregation, (c) liquidus, (d) mushy zone, or (e) solidus?
D
Which one is not a welding defect ? a. cracks, b. cavities, c. solid inclusions d. stress formation, e. incomplete fusion
D
A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, or (e) turning?
E
Which one is not included among the steps in chemical machining. a. cleaning, b. masking, c. etching, d. demasking e. Diffusing
E
According to the empirical relationship in the previous question, total solidification time is proportional to which one of the following quantities: (a) (A/V)n, (b) Hf, (c) Tm, (d) V, (e) V/A, or (f) (V/A)2; where A = surface area of casting, Hf = heat of fusion, Tm = melting temperature, and V = volume of casting?
F
Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity; the term casting also applies to the part that is made by this process: (a) true or (b) false?
True
Where the base metal has a rating = 1.0, a machinability rating greater than 1.0 indicates that the work material is ____________. u. Easier to machine than the base metal v. More difficult to machine than the base metal w. Has no difference with respect to machinability when compared to the base metal x. None of the above
U
Boring and reaming share the common feature that they are both used to enlarge an existing hole: (a) true or (b) false?
Un answered
In general, which of the following materials has the highest machinability? y. Aluminum and brass c. Cast iron and stainless steel z. Copper and titanium alloys d. Low carbon steel and brass
Y
All of the following techniques are alternative ways by which a cutting tool is held in place during machining, EXCEPT: f. Solid shank, in which the cutting edge is an integral part of the tool shank, an example being high speed steel tooling g. Brazed inserts, used for some cemented carbides h. Mechanically clamped inserts, used for most hard tool materials including cemented carbides, coated carbides, cermets, ceramics, SPD, and CBN i. Reinforced padded jigs, used to securely hold the cutting tool in place
idk
Overcut refers to the gap between the electrode (tool) in EDM on each side of the tool and the machined hole, cavity, or kerf (in wire EDM). (a)True (b) False
idk
The most important semiconductor material is silicon; others include germanium and gallium arsenide. (a)True (b) False
idk
Which one is not included in the group of fusion welding. a. resistance welding, c. diffusion welding, d. EBW and LBW, e. friction welding
E
Knurling is performed on a lathe, but it is not a metal cutting operation: (a) true or (b) false?
A
Most vertical boring machines are equipped for both turning and boring and are used for large, heavy work parts with large diameters: (a) true or (b) false?
A
Of the following cutting conditions, which one has the greatest effect on tool wear? a. Cutting speed b. Depth of cut c. Feed d. Materials used
A
Sand casting is which of the following types of casting process: (a) expendable mold or (b) permanent mold?
A
Specific energy in metal machining is a measure of the amount of energy required to remove a unit volume of material: (a) true or (b) false?
A
The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry: (a) true (b) false?
A
The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry: (a) true or (b) false?
A
The pattern that determines the geometry of the casting in expendable mold processes is usually made (a) oversized, (b) the same size, or (c) undersized relative to the dimensions of the casting?
A
The upper half of a sand-casting mold is called which one of the following: (a) cope, (b) drag, (c) flask, or (d) pattern?
A
Which of the following processes is/are used to provide the thin coatings on the surface of coated carbide inserts? a. Chemical vapor deposition c. Electroplating b. Pressing and sintering d. Spray painting
A
Which of the following riser types are completely enclosed within the sand mold and connected to the main cavity by a channel to feed the molten metal (two correct answers): (a) blind riser, (b) open riser, (c) side riser, and (d) top riser?
A
Which one of the following cutting conditions has the strongest effect on cutting temperature: (a) cutting speed, (b) depth of cut, or (b) feed?
A
Which one of the following cutting tools cannot be used on a turret lathe: (a) broach, (b) cutoff tool, (c) drill bit, (d) single-point turning tool, or (e) threading tool?
A
Which one of the following metals would usually have the lowest specific energy in a machining operation: (a) aluminum, (b) brass, (c) cast iron, or (d) steel?
A
With which one of the following geometric forms is the turning operation most closely associated: (a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads, or (e) sphere?
A
Two important relationships that determine the flow of molten metal in casting are which of the following (two correct answers): (a) Bernoulli's theorem, (b) Chvorinov's rule, (c) continuity law, (d) flow curve, (e) Hooke's law, or (f) Ohm's law?
A & C
What are the two joint types most commonly used in brazing? a. butt b. corner c. lap d. groove e. Tee
A & C
A factory that performs casting processes is called which of the following (one best answer): (a) casting plant, (b) foundry, (c) ingot-making plant, (d) metal working plant, or (e) molding plant?
B
An autogenous weld is a fusion weld made with the addition of filler metal. (a)True (b) False
B
As an alloying ingredient in high-speed steel, tungsten serves which of the following functions? a. Improves strength and hardness c. Increases corrosion resistance b. Increases hot hardness d. Increases toughness
B
As discharge current decreases, metal removal rate increases and surface finish is degraded (in wire EDM). (a)True (b) False
B
In a sand-casting mold, the V/A ratio of the riser should be (a) equal to, (b) greater than, or (c) smaller than the V/A ratio of the casting itself?
B
In a turning operation, the change in diameter of the workpart is equal to which one of the following: (a) 1 x depth of cut, (b) 2 x depth of cut, (c) 1 x feed, or (d) 2 x feed?
B
In brazing and soldering, a filler metal is not added, whereas in solid state welding filler metal is added. (a)True (b) False
B
Which one is the disadvantages of Electro- Chemical Machining (ECM) a. cost of high frequency oscillation tool, b. cost of disposal of electrolyte sludge. c. cost of abrasive material d. cost of cutting wire spool
B
Which one is the principal fuel used in oxyfuel cutting a. MAPP (methylacetylene propadiene), b. Acetylene c. propylene, d. propane,
B
Which one of the following terms is used for cutting external threads using self-opening threading dies: (a) tapping, (b) thread chasing, (c) thread forming, or (d) thread milling?
B
Typical operations performed on a machining center include which of the following (two best answers): (a) boring, (b) drilling, (c) milling, (d) sawing, and (e) turning?
B & C
According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers): (a) decrease in friction angle, (b) decrease in power requirements, (c) decrease in shear plane angle, (d) increase in cutting temperature, and (e) increase in shear plane angle?
B & E
Which of the following are examples of generating the workpart geometry in machining, as opposed to forming the geometry (two best answers): (a) broaching, (b) contour turning, (c) drilling, (d) profile milling, and (e) thread cutting?
B & E
Machining is noted for which of the following characteristics relative to other manufacturing processes (two best answers): (a) creates three-dimensional geometries, (b) good dimensional accuracy, (c) net shape process, (d) poor surface finish, (e) wasteful of energy, (f) wasteful of material?
B & F
Which of the following are classified as peripheral milling rather than face milling (three best answers): (a) end milling, (b) plain milling, (c) pocket milling, (d) slab milling, (e) straddle milling, and (f) surface contouring?
B , D & E
The three basic types of sawing, according to type of blade motion involved, are which of the following: (a) abrasive cutoff, (b) bandsawing, (c) circular sawing, (d) contouring, (e) friction sawing,(f) hacksawing, and (g) slotting.
B, C & F
Which of the following are the three most common machining operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, (e) planing, (f) shaping, or (g) turning?
B, D & G
A roughing operation generally involves which one of the following combinations of cutting conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d, where v = cutting speed, f = feed, and d = depth of cut?
C
Cast cobalt alloys typically contain which of the following main ingredients? a. Aluminum, Titanium, & Cobalt c. Cobalt, Chromium, & Tungsten b. Chromium, Iron, & Nickel d. Iron, Steel, & Cobalt
C
Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material: (a) continuous, (b) continuous with built‑up edge, (c) discontinuous, or (d) serrated?
C
Machined parts can be classified as rotational or nonrotational. Which of the following are examples of operations that create non-rotational geometries (two best answers): (a) boring, (b) drilling, (c) milling, (d) planing, and (e) turning?
C & D
Reaming is used for which of the following functions (three correct answers): (a) accurately locate a hole position, (b) create a stepped hole, (c) enlarge a drilled hole, (d) improve surface finish on a hole, (e) improve tolerance on hole diameter, and (f) provide an internal thread?
C, D & E
A planing operation is best described by which one of the following: (a) a single-point tool moves linearly past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary workpart, (c) a workpart is fed linearly past a rotating cutting tool, or (d) a workpart moves linearly past a single-point tool?
D
A tap is a cutting tool used to create which one of the following geometries: (a) external threads, (b) flat planar surfaces, (c) holes used in beer kegs, (d) internal threads, or (e) square holes?
D
Of the various methods for testing machinability, which of the following is the most important? t. Cutting forces b. Cutting temperature c. Horsepower consumed d. Tool life
D
The internal surfaces of a casting are determined during the casting process by means of which one of the following: (a) core, (b) gating system, (c) parting line, (d) pattern, or (e) sprue?
D
Which one is not the important factor for consideration of nontraditional material removal processes? a. the need to shape new metal alloys and non- metals that are difficult to machine by conventional processes; b. the requirement of unusual and complex work part geometries; and c. the need to avoid surface damage which is often associated with conventional machining. d. the need to increase the production volume.
D
Total solidification time is defined as which one of the following: (a) time between pouring and complete solidification, (b) time between pouring and cooling to room temperature, (c) time between solidification and cooling to room temperature, or (d) time to give up the heat of fusion?
A
Wave soldering involves the flow of molten solder onto the underside of a printed circuit board to provide soldered connections between the component leads that project through holes in the boards and the copper circuit lands on the board. (a)True (b) False
A
Which of the following is NOT a common ingredient in cemented carbide cutting tools? a. Al2O3 b. Co c. WC d. TiC
A
In brazing the filler metal melts at a temperature above 4500C (8400F). In soldering the filler metal melts at a temperature of 4500C or below. (a)True (b) False
B
In casting, a flask is which one of the following: (a) beverage bottle for workers who perform casting, (b) box which holds the cope and drag, (c) container for holding liquid metal, or (d) metal which extrudes between the mold halves?
B
In the heat affected zone (HAZ), while welding, no microstructural change occurs. (a)True (b) False
B
Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more rapidly than the surrounding sand are called which one of the following: (a) external chills, (b) internal chills, (c) pipes, or (d) sprues?
B
The basic milling machine is which one of the following: (a) bed type, (b) knee‑and‑column, (c) profiling mill, (d) ram mill, or (e) universal milling machine?
B
The chip thickness ratio in orthogonal cutting is which one of the following: (a) tc/to, (b) to/tc, (c) to/w, where tc = chip thickness after the cut, to = chip thickness before the cut, and w = width of cut?
B
The difference between up milling and down milling is that in down milling the direction of motion of the cutter teeth is opposite the feed direction when the teeth cut into the work: (a) true or (b) false?
B
Which of the following materials has the highest hardness? a. Aluminum oxide b. Cubic boron nitride c. Titanium carbide d. Tungsten carbide
B
Turbulence during pouring of the molten metal is undesirable for which of the following reasons (two best answers): (a) it causes discoloration of the mold surfaces, (b) it dissolves the binder used to hold together the sand mold, (c) it increases erosion of the mold surfaces, (d) it increases the formation of metallic oxides that can become entrapped during solidification, (e) it increases the mold filling time, and (f) it increases total solidification time?
C & D
A riser in casting is described by which of the following (three correct answers): (a) an insert in the casting that inhibits buoyancy of the core, (b) gating system in which the sprue feeds directly into the cavity, (c) metal that is not part of the casting, (d) source of molten metal to feed the casting and compensate for shrinkage during solidification, and (e) waste metal that is usually recycled?
C, D & E
All of the following criteria are used to assess machinability in a production machining operation, EXCEPT: a. Ease of chip disposal b. Surface finish c. Tool wear and tool life d. Voltage and Amperage
D
Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material: (a) continuous, (b) continuous with built up edge, (c) discontinuous, or (d) serrated
D
Which of the following are characteristics of the orthogonal cutting model (three best answers): (a) a circular cutting edge is used, (b) a multiple-cutting-edge tool is used, (c) a single-point tool is used, (d) only two dimensions play an active role in the analysis, (e) the cutting edge is parallel to the direction of cutting speed, (f) the cutting edge is perpendicular to the direction of cutting speed, and (g) the two elements of tool geometry are rake angle and relief angle?
D, F & G
Heating a metal from room temperature to pouring temperature in a casting operation depends on all of the following properties except which one: (a) density, (b) heat of fusion, (c) melting temperature, (d) specific heat, or (e) thermal expansion?
E
Which of the following manufacturing processes are classified as material removal processes (two correct answers): (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) molding, (h) pressworking, and (i) spinning?
E & F
Which of the following manufacturing processes are classified as material removal processes (two correct answers): (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) molding, (h) pressworking, and (i) spinning?
E & F
