Materials of Manufacturing Exam Two
What is the range of carbon percentages which defines an iron-alloy as a steel?
0.02% to 2.11%
A lathe can be used to perform which of the following machining operations
(a) boring (c) drilling (f) turning
Which one of the following cutting tools cannot be used on a turret lathe
(a) broach
End milling is most similar to which one of the following
(a) face milling
Knurling is performed on a lathe, but it is not a metal cutting operation
(a) true
The twist drill is the most common type of drill bit
(a) true
Which of the following are the usual responsibilities of the manufacturing engineering department (four best answers): (a) advising on design for manufacturability, (b) facilities planning, (c) marketing the product, (d) plant management, (e) process improvement, (f) process planning, (g) product design, (h) solving technical problems in the production departments, and (i) supervision of production workers?
(a), (e), (f), and (h).
Which of the following are operations to enhance physical properties (three correct answers): (a) annealing, (b) anodizing, (c) die casting, (d) drilling, (e) electroplating, (f) rolling of nickel alloys, (g) sheet metal drawing, (h) sintering of pressed ceramic powders, (i) surface grinding of hardened steel, (j) tempering of martensitic steel, (k) turning, and (l) ultrasonic cleaning?
(a), (h), and (j).
In a turning operation, the change in diameter of the workpart is equal to which one of thefollowing
(b) 2 x depth of cut
Reaming is used for which of the following functions
(b) enlarge a drilled hole, (c) improve surface finish on a hole, (d) improve tolerance on hole diameter
A planing operation is best described by which one of the following
(d) a workpart moves linearly past a single-point tool
A tap is a cutting tool used to create which one of the following geometries
(d) internal threads
The manufacturing engineering department in an organization is best described as which one of the following: (a) branch of the sales department, (b) concurrent engineers, (c) management, (d) product designers, (e) production supervisors, or (f) technical staff function?
(f).
What is a precedence constraint in process planning?
A precedence constraint is a limitation on the order in which processing or assembly operations can be performed on a given workpart; for example, a hole must be drilled before it can be tapped.
What is a riser?
A reservoir of feeder of liquid metal used for prevention of excessive shrinkage in finished castings
What is a route sheet?
A route sheet is a listing of the production operations and their sequence required to make a given part. It also lists the equipment and special tooling that is required.
What is a cupola?
A vertical cylindrical furnace equipped with a tapping spout near its base. Used for melting cast irons.
Which one of the metallic elements is the most abundant on the earth: (a) aluminum, (b) copper, (c) iron, (d) magnesium, or (e) silicon?
Aluminum
In the make or buy decision, why is it that purchasing a component from a vendor may cost more than producing the component internally, even though the quoted price from the vendor is lower than the internal price?
Because purchasing the component may cause idle equipment and staff in the factory that the company must still pay for.
Which one of the following elements is the most important alloying ingredient in steel: (a) carbon, (b) chromium, (c) nickel, (d) molybdenum, or (e) vanadium?
Carbon
In the sand casting process, what are cores used to create?
Cavities in the cast part
Which of the following alloying elements are most commonly associated with stainless steel: (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e) tungsten?
Chromium and Nickel
What is concurrent engineering and what are its important components?
Concurrent engineering is an approach used by companies to reduce the time to bring a new product to market. It includes (1) design for manufacturability, (2) design for quality, (3) design for life cycle, and (4) design for cost. It also includes certain organizational changes that attempt to bring different functions in the company together during product design to consider all possible aspects of the product.
Which of the following metals is noted for its good electrical conductivity: (a) copper, (b) gold, (c) iron, (d) nickel, or (e) tungsten?
Copper
Traditional brass is an alloy of which of the following metallic elements (two correct answers): (a) aluminum, (b) copper, (c) gold, (d) tin, and (e) zinc?
Copper, Zinc
What is meant by the term design for life cycle?
Design for life cycle means that factors relating to the product after it has been manufactured should be taken into consideration in design. These factors include ease of installation, reliability, maintainability, serviceability, upgradeability, and disposability.
A particular composition in an alloy system for which the solidus and liquidus are at the same temperature is called
Eutectic
The predominant phase in the iron-carbon alloy system for a composition with 99% Fe at room temperature is which one of the following: (a) austenite, (b) cementite, (c) delta, (d) ferrite, or (e) gamma?
Ferrite
What is flash in die casting?
Flash is a thin portion of metal at the exterior of a casting that results from molten metal being squeezed into the spaces between the die halves of the mold at the parting line, or into the clearances around the cores and ejector pins.
A ___________________ is a wooden or metal frame in which a mold is made
Flask
Cold Shuts
General defect in a casting process Two portions of metal flow together but there is lack of fusion at the joint
Which of the following is the most important cast iron commercially: (a) ductile cast iron, (b) gray cast iron, (c) malleable iron, or (d) white cast iron?
Gray cast iron
Which of the following properties or characteristics are inconsistent with the metals (two correct answers): (a) good thermal conductivity, (b) high strength, (c) high electrical resistivity, (d) high stiffness, and (e) ionic bonding?
High electrical resistivity, ionic bonding
A steel with 1.0% carbon is known as which one of the following: (a) eutectoid, (b) hypoeutectoid, (c) hypereutectoid, or (d) wrought iron?
Hypereutectoid
The strength and hardness of steel increases as carbon content (a) increases or (b) decreases?
Increases
Which one of the following metals has the lowest density: (a) aluminum, (b) magnesium, (c) tin, or (d) titanium?
Magnesium
Define manufacturing engineering.
Manufacturing engineering is a technical staff department responsible for planning the manufacturing processes for a product and its components.
A _______________________ is a form used to prepare and produce a mold cavity
Pattern
The lost wax process for making precision castings utilizes an expendable ___________________
Pattern
11.11 The Antioch process is similar to plaster-mold casting but uses a mixture of sand and plaster to make the mold: (a) true or (b) false?
a
Which of the following metals has the highest density: (a) gold, (b) lead, (c) platinum, (d) silver, or (e) tungsten?
Platinum
What are the principal activities in manufacturing engineering?
Principal activities in manufacturing engineering are (1) process planning, (2) technical problem solving and continuous improvement, and (3) advising the product designers in design for manufacturability.
Identify some of the details and decisions that are included within the scope of process planning.
Table 40.1 lists the following details and decisions in process planning: (1) the processes required and the sequence in which they are performed; (2) equipment selection; (3) tools, dies, molds, fixtures, and gages that will be needed; (4) cutting tools and cutting conditions for machining operations; (5) methods for manual operations (e.g., assembly) and manual portions of machine cycles (e.g., loading and unloading a production machine); (6) time standards for each operation; and (7) estimates of production costs. Not all of these details and decisions are the exclusive responsibility of the manufacturing engineering department.
Name three of the general principles and guidelines in design for manufacturability.
Table 40.5 lists the following DFM principles and guidelines: (1) Minimize number of components. (2) Use standard commercially available components. (3) Use common parts across product lines. (4) Design for ease of part fabrication. (5) Design parts with tolerances that are within process capability. (6) Design the product to be foolproof during assembly. (7) Minimize flexible components. (8) Design for ease of assembly. (9) Use modular design. (10) Shape parts and products for ease of packaging. (11) Eliminate or reduce adjustment required.
Identify some of the important factors that should enter into the make or buy decision.
The factors in the make or buy decision include (1) cost, (2) whether the process is available internally, (3) production quantity, (4) product life, (5) whether or not the component is a standard commercially available hardware item, (6) supplier reliability, and (7) possible need for alternative sources.
Which one of the following metals has the lowest melting point: (a) aluminum, (b) lead, (c) magnesium, (d) tin, or (e) zinc?
Tin
Aluminum is noted for its low density and high thermal conductivity. True or false
True
Solid solution alloying is the principal strengthening mechanism in high-strength low-alloy (HSLA) steels: (a) true or (b) false?
True Solid solution alloying is the principal strengthening mechanism in high-strength low-alloy (HSLA) steels.
Which one of the following is not a common alloying ingredient in steel: (a) chromium, (b) manganese, (c) nickel, (d) vanadium, (e) zinc?
Zinc
10.1 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?
a
10.3 Sand casting is which of the following types of casting process: (a) expendable mold or (b) permanent mold?
a
11.2 In sand casting, the volumetric size of the pattern is (a) bigger than, (b) same size as, or (c) smaller than the cast part?
a
11.13 Which of the following are metals commonly cast in permanent mold casting (three best answers): (a) aluminum, (b) brass, (c) gold, (d) magnesium, (e) nickel, (f) steel, and (g) tungsten?
a,b,d
11.17 Which of the following are advantages of die casting over sand casting (four best answers): (a) better surface finish, (b) closer tolerances, (c) higher melting temperature metals can be cast, (d) higher production rates, (e) larger parts can be cast, and (f) mold can be reused?
a,b,d,f
10.11 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
10.20 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,c
Which of the following stress or strength parameters is used in the computation of rolling force
average flow stress
Which of the following stress or strength parameters is used in the computation of the force in an extrusion operation
average flow stress
10.14 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
Which of the following are alternative names for indirect extrusion (two correct answers)
backward extrusion, reverse extrusion
11.6 Which of the following casting processes are expendable mold operations (four correct answers): (a) centrifugal casting, (b) die casting, (c) investment casting, (d) low pressure casting, (e) sand casting, (f) shell molding, (g) slush casting, and (h) vacuum molding?
c,e,f,h
The maximum possible draft in a rolling operation depends on which of the following parameters (two correct answers)
coefficient of friction between roll and work, roll diameter
Which of the following operations are closely related to open-die forging (three best answers)
cogging, fullering, upsetting
Which of the following are classified as forging operations (four correct answers)
coining, fullering, swagging, upsetting
Most sheet metalworking operations are performed as which one of the following
cold working
Sheet-metal bending involves which of the following stresses and strains (two correct answers)
compressive, tensile
10.13 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
11.1 Which one of the following casting processes is the most widely used: (a) centrifugal casting, (b) die casting, (c) investment casting, (d) sand casting, or (e) shell casting
d
11.5 Given that Wm = weight of the molten metal displaced by a core and Wc = weight of the core, the buoyancy force is which one of the following: (a) downward force = Wm + Wc, (b) downward force = Wm - Wc, (c) upward force = Wm + Wc, or (d) upward force = Wm - Wc?
d
A circular sheet-metal slug produced in a hole punching operation will have the same diameter as the
die opening
In which of the following extrusion operations is friction a factor in determining the extrusion force
direct extrusion
Springback in a sheet-metal-bending operation is the result of which one of the following
elastic recovery of the metal
Which of the following processes are classified as high-energy-rate forming processes (two best answers)
electromagnetic forming, explosive forming
Johnson's formula is associated with which one of the four bulk deformation processes
extrusion
Production of pipes and tubes is associated with which of the following bulk deformation processes (three correct answers)
extrusion, roll piercing, tube sinking
10.15 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
Flash in impression die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming
false
The production of tubing is possible in indirect extrusion but not in direct extrusion
false
Which of the following stress or strength parameters is used in the computation of the maximum force in a forging operation
final flow stress
As sheet-metal stock hardness increases in a blanking operation, the clearance between punch and die should be
increased
Which of the following descriptions applies to a V-bending operation as compared to an edge- bending operation (two best answers)
inexpensive tooling, used for low production
Which one of the following is the best definition of bend allowance
length before bending of the straight sheet-metal section to be bent
The cutting force in a sheet-metal blanking operation depends on which mechanical property of the metal
modulus of elasticity
The starting workpiece in steel hot rolling of plate and sheet stock is which of the following
slab
In a sheet-metal-cutting operation used to produce a flat part with a hole in the center, the part itself is called a blank, and the scrap piece that was cut out to make the hole is called a slug
true
10.12 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
10.17 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?
a
10.4 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
10.6 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
10.7 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
10.8 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?
a
11.15 In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity: (a) true or (b) false?
a
11.8 The expanded polystyrene casting process uses a mold of sand packed around a polystyrene foam pattern that vaporizes when the molten metal is poured into the mold: (a) true or (b) false?
a
11.16 Which of the following metals would typically be used in die casting (three best answers): (a) aluminum, (b) cast iron, (c) steel, (d) tin, (e) tungsten, and (f) zinc?
a,d,f
11.14 Which of the following casting processes are permanent mold operations (two correct answers): (a) centrifugal casting, (b) expanded polystyrene process, (c) sand casting, (d) shell molding, (e) slush
a,e
11.4 For which one of the following reasons is a green mold named: (a) green is the color of the mold, (b) moisture is contained in the mold, (c) the mold is cured, or (d) the mold is dry?
b
11.7 Shell molding is best described by which one of the following: (a) casting operation in which the molten metal has been poured out after a thin shell has been solidified in the mold, (b) casting process in which the mold is a thin shell of sand bonded by a thermosetting resin, (c) sand-casting operation in which the pattern is a shell rather than a solid form, or (d) casting operation used to make artificial sea shells?
b
11.3 Silica sand has which one of the following compositions: (a) Al2O3, (b) SiO, (c) SiO2, or (d) SiSO4?
c
11.9 Investment casting is also known by which one of the following names: (a) fast-payback molding, (b) full-mold process, (c) lost-foam process, (d) lost-pattern process, or (e) lost-wax process?
e
Which of the following are variations of sheet-metal-bending operations (two best answers)
flanging, hemming
A broaching operation is best described by which one of the following
(b) a tool with multiple teeth moves linearly past a stationary workpart
The three basic types of sawing, according to type of blade motion involved, are
(b) bandsawing, (c) circular sawing (f) hacksawing
Which of the following are examples of generating the workpart geometry in machining, as opposed to forming the geometry
(b) contour turning (d) profile milling
The basic milling machine is which one of the following
(b) knee-and-column
A facing operation is normally performed on which one of the following machine tools
(b) lathe
Gear hobbing is a special form of which one of the following machining operations:
(b) milling
In a make or buy situation, the decision should always be to purchase the component if the vendor's quoted price is less than the in-house estimated cost of the component: (a) true or (b) false?
(b).
Which one of the following types of computer-aided process planning relies on parts classification and coding in group technology: (a) generative CAPP, (b) retrieval CAPP, (c) traditional process planning, or (d) none of the preceding?
(b).
Which one of the following turning machines permits very long bar stock to be used
(c) screw machine
Which of the following would be considered secondary processes, as opposed to basic processes (four correct answers): (a) annealing, (b) arc welding, (c) drilling, (d) electroplating, (e) extrusion to produce steel automotive components, (f) impression die forging, (g) painting, (h) plastic injection molding, (i) rolling of sheet steel, (j) sand casting, (k) sheet-metal stamping, (l) sintering of pressed ceramic powders, and (m) ultrasonic machining?
(c), (e), (k), and (m).
Which of the following are considered basic processes, as opposed to secondary processes (four correct answers): (a) annealing, (b) anodizing, (c) drilling, (d) electroplating, (e) forward hot extrusion to produce aluminum bar stock, (f) impression die forging, (g) rolling of sheet steel, (h) sand casting, (i) sheet-metal stamping, (j) spot welding, (k) surface grinding of hardened steel, (l) tempering of martensitic steel, and (m) turning?
(e), (f), (g), and (h).
A route sheet is a document whose principal function is which one of the following: (a) continuous improvement, (b) design for manufacturability, (c) provides authorization for material handlers to move the part, (d) quality inspection procedure, (e) specifies the process plan, or (f) specifies the detailed method for a given operation?
(e).
Identify the sources of contraction in a metal casting after pouring
- Contraction of the molten metal after pouring - Solidification shrinkage during transformation of state from liquid to solid - Thermal contraction in the solid state
What is a basic method by which metals can be strengthened?
-Alloying -Cold Working -Heat treatment
Name a basic method by which metals can be strengthened
-Alloying -Cold working -Heat treatment
Name the general defects encountered in casting processes
-Misruns -Cold shuts -Cold shots -Shrinkage cavity -Microporosity -Hot tearing
Plain carbon steels are designated in the AISI code system by which of the following: (a) 01XX, (b) 10XX, (c) 11XX, (d) 12XX, or (e) 30XX?
10XX
What is the difference between a basic process and a secondary process?
A basic process establishes the starting geometry of the work material; e.g., casting, rolled sheet metal, drawn metal bar. Secondary processes are used to refine the starting geometry and transform the material into final shape and size; machining and sheet metal pressworking are common secondary processes.
From which of the following ores is aluminum derived: (a) alumina, (b) bauxite, (c) cementite, (d) hematite, or (e) scheelite?
Bauxite
What is a factory that performs casting operations usually called?
Foundry
Hot Tearing
General defect in a casting process A crack in the casting caused by a mold that does not yield to the metal during the early stages of solidification shrinkage
Shrinkage Cavity
General defect in a casting process A depression on the casting surface or an internal void in the casting caused by solidification shrinkage
Microporosity
General defect in a casting process A network of small voids throughout the casting caused by localized solidification shrinkage
Cold Shots
General defect in a casting process Solid globules of cast metal become entrapped in the casting
Misruns
General defect in a casting process The casting solidifies before filling the mold cavity
10.2 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
10.5 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
11.10 In plaster mold casting, the mold is made of which one of the following materials: (a) Al2O3, (b) CaSO4-H2O, (c) SiC, or (d) SiO2?
b
11.12 Which of the following qualifies as a precision-casting process (two correct answers): (a) ingot casting, (b) investment casting, (c) plaster-mold casting, (d) sand casting, and (e) shell molding?
b
11.20 Cupolas are furnaces used to melt which of the following metals (one best answer): (a) aluminum, (b) cast iron, (c) steel, or (d) zinc?
b
10.16 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
10.19 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?
c
11.19 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: (a) centrifuge casting, (b) semicentrifugal casting, or (c) true centrifugal casting?
c
11.21 A misrun is which one of the following defects in casting: (a) globules of metal becoming entrapped in the casting, (b) metal is not properly poured into the downsprue, (c) metal solidifies before filling the cavity, (d) microporosity, and (e) "pipe" formation?
c
11.22 An irregularity in the surface of the casting caused by erosion of the sand during pouring is called which one of the following sand casting defects: (a) penetration, (b) sand blow, (c) sand wash, or (d) scabs?
c
11.23 Which one of the following casting metals is most important commercially: (a) aluminum and its alloys, (b) bronze, (c) cast iron, (d) cast steel, or (e) zinc alloys?
c
10.10 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
10.18 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
10.9 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 one of the following press types is usually associated with the highest production rates in sheet-metal-stamping operations
open back inclinable
11.18 Which of the following names are applied to a process in which a molten metal is poured into a heated lower die, and the upper die is closed to create the mold cavity only after solidification begins (two correct answers): (a) liquid-metal casting, (b) liquid-metal forging, (c) rheocasting, (d) squeeze casting, or (e) thixocasting?
b,d
Which one of the following stamping dies is the most complicated
progressive die