ME 2653 Test 5-7-15
the range of rise per tooth for internal broaching is ___ to ___ inches/tooth
.001 .0025
the range of rise per tooth for external broaching is ___ to ___ inches/tooth
.003 .006
up milling: the mill cutter rotates ___ the direction of feed
against
tapered end mills are used for
finish cutting on molds to produce a desired angle
the saddle provides ___ movement on the knee ways
transverse (y-axis)
centerless grinding is a process that is performed quickly t/f
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 t/f
true
more flat surfaces are produced by the milling process than any other machining process t/f
true
the filing process is used to remove small amounts of material from a part t/f
true
the truing of a grinding wheel is a process performed to restore the desired shape to the wheel t/f
true
a requirement of broaching is that ___ teeth be in contact with the workpiece
two
up milling: in slab milling operations, the direction of the cutting force is ___
up
the most common type of broaching machine construction is ___
vertical
the knee provides ___ movement on the column ways
vertical (z-axis)
end milling, drilling, and boring is typically performed using what type of knee-and-column milling machine
vertical milling machine
down milling: in slab milling operations, the direction of the cutting force is ___
vertically down
down milling: the mill cutter rotates ___ the direction of the feed
with
what type of milling is used to mill a semi-circular keyway in a shaft used in power transmission equipment?
woodruff keyseat milling cutter
the milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches
150
the surface finish obtained from the broaching process has a surface finish measurement of ___ to ___ microinches
32 125
vertical broaching machines are usually limited to strokes of ___ inches due to height and load considerations
72
which of the following is not a common material used for the teeth of a band saw blade?
CBN
the milling machine was invented in approximately 1816 by ___
Simeon North
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 workpiece
a diving 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
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
horizontal milling: 45 degree, v-shaped groove in the surface of a flat bar
angle cutter
vertical milling: producing a groove with a 1/8" diameter concave bottom
ball end mill
the most common type of sawing machine for cutting metal is ___
bandsaw
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 is the most frequently used mounting system for abrasives?
bonded
the teeth of an end mill cutter are located on the ___
circumference and the face of the cutter
what type of grinding machining would be used for the grinding of camshafts and crankshafts?
cylindrical external
attrition refers to the material property regarding the wearing action of the abrasive, resulting in ___ edges and ___ of the abrasive grit
dull flattening
vertical milling: deep slots with straight side walls
end mill
vertical milling: producing a flat-bottom groove in the surface of a part
end mill
vertical milling: producing a pocket in a work piece
end mill
vertical milling: finishing the top surface of a work piece
face mill
broaching is a process that can be used only in mass-production t/f
false
dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened t/f
false
for grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles t/f
false
high ductile materials (i.e. aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth t/f
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 t/f
false
horizontal milling: 1/4" radius, convex shape along the edge of the part
form cutter
horizontal milling: milling wood to produce wood trim
form cutter
vertical milling: bearing pocket in gearbox housing
form cutter
friability refers to the ability of the abrasive material to ___
fracture, producing new, sharp edges
by using extremely ___ materials for abrasives, it is possible to machine hardened steel, ___, ___, and ___
hard ceramics carbides glass
slab milling is typically performed using what type of knee-and-column milling machine
horizontal milling machine
which of the following is not a type of broach construction?
insert tooth
broaching was originally developed for the production of ___
internal keyways
the slot cut in the material by a saw blade is called ___
kerf
the table has ___ movement on the saddle ways
longitudinal (x-axis)
in the abrasive machining process, ___ edges are cutting simulatenously resulting in a(n) ___ surface finish
many excellent
down milling: the chip thickness is a ___ at the beginning of the chip formation
maximum
up milling: the chip thickness is a ___ as the end of the chip formation as the tool exits the work piece
maximum
down milling: the chip thickness is a ___ at the end of the chip formation as the tool exits the work piece
minimum
up milling: the chip thickness is a ___ at the beginning of the chip formation
minimum
which of the following is not a type of mounting method that is used with the abrasive machining process?
mounted
the milling process uses ___ and involves ___ cutting
multi-tooth cutter interrupted
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)
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
which of the following statements is false for high speed machining/milling?
one or more axes are always accelerating in a 3-D cut
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
in face milling, most of the cutting occurs at what areas of the cutter?
peripheral edge
horizontal milling: finishing the top surface of a flat bar
plain cutter
the abrasive machining process is a mixture of three processes; ___ moves material, ___ causes friction and ___ forms chips
plowing rubbing cutting
a CNC milling machine ___
provides for machining of more complex parts than a manual milling machine
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
the pattern used to offset the saw blade teeth from the centerline 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 ___ process using a ___ tooth cutter to remove material with roughing and finishing operations performed in ___ of the cutter
single-stroke multi a single pass
horizontal milling: deep, straight walled, narrow slots
slitting saw cutter
which of the following is not a common tooth form for saw blades?
square
horizontal milling: deep slots in a work piece
staggered-tooth cutter
what is the milling of two parallel surfaces with side cutters called?
straddle milling
plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter
straight helical
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
the structure of a grinding wheel refers to ___
the spacing of the abrasive grit in the wheel
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
up milling: the direction of the cutting forces are ___
toward the part