ME2653 Final
broaching machine
-The total material removed in a single pass of the broach is the cumulative result of all the steps in the tool. -The speed motion is accomplished by the linear travel of the tool past the work surface. -The shape of the cut surface is determined by the contour of the cutting edges on the broach, particularly the final cutting edge.
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
Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations. A. 100 B. 72 C. 48 D. 60
72
grinding wheel what does bonding material do?
A grinding wheel consists of abrasive particles and bonding material. it holds the particles in place and establishes the shape and structure of the wheel.
Which of the following describes the ultrasonic machining process? A harden steel tool is vibrated at low frequencies (<1000) 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. 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 materail being machined and the tool as a process to remove material. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.
A harden steel tool is vibrated at high frequencies (>20,000 Hz) with a small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.
In foundry operations, robots can ___________. (Clean or lubricate dies, Coat cores, remove castings from molds, or All of these)
All of these
Which of the following statements is false regarding thread grinding? A. Threads in hardened steels can be produced B. Only coarse threads can be produced. C. Using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. Very accurate, fine pitched threads can be produced
B.
Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. mounted D. free
C.
Which of the following is not a type of broach construction? A. shell B. solid C. insert tooth D. segment
C.
Which of the following statements is false regarding thread grinding?
Only coarse threads can be produced
Non-traditional machining produces parts by which of the following (mark all that apply)? A. removing material from a base using chemicals B. Removing material from a base using a tool vibrated at ultrasonic frequencies. C. Removing material using ultra high pressure water. D. By an additive process where small, precise amounts of materials are built up into a shape E. Adding material to a base using high voltage electrical discharges.
Removing material from a base using chemicals Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra high pressure water By an additive process where small, precise amounts of materials are built up into a shape
Which of the the following is NOT a common tooth form for saw blades?
Square
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 or Helical
Surface texture; The measure of the surface texture is generally determined in terms of its :
Surface Texture or Surface Topography is the local deviations of a surface from a perfectly flat plane. roughness, waviness, lay, and flaws.
Evaluation of Surface Integrity
Surface texture Visual examination. Microstructural examination. Microhardness profile. Residual stress profile.
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. The mask is applied to the area of the part that it is desired to removal material from the part. The mask enhances the chemical machining process. None of the above.
The mask is applied to the area of the part that it 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.
Abrasive waterjet machining involves an abrasive grit carried with ultra high pressure water jet to cut metals and non-metals. True or False?
True
The chemical machining process is used in mass-production of parts True or False?
True
creep feed grinding
is performed at very high depths of cut and very low feed rates
The slot cut in the material by a saw blade is called ____.
kerf
Which of the following statements is false regarding thread grinding? A. only coarse threads can be produced B. threads in hardened steels can be produced C. using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. very accurate, fine pitched threads can be produced
only coarse threads can be produced
In centerless grinding, the regulating wheel controls _____ in the grinding process.
rotating speed and axial feed of the work piece
In centerless grinding, the regulating wheel controls _____ in the grinding process. A. rotating speed of the grinding wheel B. axial feed of the workpiece C. rotating speed of the workpiece D. rotating speed and axial feed of the work piece
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
Which of the following is not a common tooth for saw blades? A. square B. regular C. skip
square
Type of milling cutter: Deep slots in a work piece
staggered-tooth cutter
Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter. A. straight B. pointed C. spiral D. helical
straight helical
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 principle of 3-2-1 uses location points to define ___. A. three (3) intersecting planes B. 6 points C. 3 axis, 2 rotations, 1 point D. three (3) perpendicular planes
three perpendicular planes
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
vertical (z axis)
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?
vertical milling machine
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece
End mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part
End mill
A fluteless tap produces chips that are then sent forward out of a through hole.
False
Broaching is a process that can be used only in mass-production. True or False
False
Centerless grinding requires a high degree of skill to operate the machine.
False
Centerless grinding requires lots of operator skill to operate the machine. True or False
False
Centerless grinding requires that small grinding wheels be used in the grinding process. True or False
False
Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened. True or False
False
Electrochemical machining is deplating process using high DC voltage, high current for the process. True or False?
False
For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.
False
For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles. True or False
False
High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth
False
High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth. True or False?
False
The conversational controller does not require programming the machine.
False
The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes. True or False
False
The honing process used stones with a grit size of 1200 or more particles per inch. True or False
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. True of False
False
True or False: Broaching is a process that can be used only in mass-production.
False
True or False: Centerless grinding is a process that must be performed manually by the machinist.
False
True or False: Centerless grinding requires lots of operator skill to operate the machine.
False
True or False: Centerless grinding requires that small grinding wheels be used in the grinding process.
False
True or False: Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.
False
True or False: Electrochemical Machining is a deplating process using high DC voltage, high current for the process.
False
Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent. True or False?
False
With centerless grinding tubes will automatically have concentric inside and outside diameters. True or False
False
Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool. True or False
False
Why might the mechanical properties of a permanent mold casting be higher than a sand mold casting?
Fine grain size due to more rapid solidification
Match the following surface grinder types with the description / property / application. (answers may be used more than once). The most common type of surface grinding machine. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Horizontal spindle, reciprocating table
All of these are disadvantages of the die casting process EXCEPT: (Only useful for small production runs, Metal being cast needs to have high fluidity, Size of casting is limited, or High cost of tooling and dies)
Only useful for small production runs
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. A. perpendicular B. Parallel C. horizontal D. vertical
Parallel (x) horizontal (y)
Which of the following applies to plasma arc cutting? A. Plasma arc cutting involves superheated gas for cutting only steel plates B. Plasma cutting involves super high pressure gas propelled at mach 30 for cutting conductive metals. C. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
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. Rapid prototyping is used only for medical applications. Rapid prototyping is a very expensive process and has very limited applications. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.
Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.
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
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 or False
True
Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites). True or False?
True
For the honing process the amount of material removed is less than 0.005" from the surface. True or False
True
In centerless grinding, the work piece must be round and not include flats or keyways.
True
In centerless grinding, the work piece must be round and not include flats or keyways. True or False
True
The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials. True or False
True
The creep feed grinding process is used to grind deep slots with straight parallel sides into parts
True
True or False: 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
True or False: Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.
True
Which of the following surface grinding machines requires the grind wheel diameter to exceed the width of the part being abrasively machined?
Vertical spindle, reciprocating table
For the down milling process, complete the statements with the answers supplied In slab milling process, direction of cutting force is:
Vertically down
Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. grease B. oil C. water D. air
air
the abrasive materials of greatest commercial importance are:
aluminum oxide, silicon carbide, cubic boron nitride, and diamond.
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
ball end mill
The most common type of sawing machine for cutting metal is : A. cold saw B. power hacksaw C. bandsaw D. milling machine
bandsaw
In mass-production opeations, 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? A. knee-and-column milling machine B. universal milling machine C. bed milling machine D. gantry milling machine
bed milling machine
Which of the following is not an advantage of plasma arc cutting? A. small heat-affected zone B. Can be used for cutting metal based composite materials C. very fast cutting D. smooth cuts free of contaminants are produced
can be used for cutting metal based composite materials
The ability to load a part into a fixture only one way is called?
fool proofing
The ability to load a part into a fixture only one way is called? A. proofing B. fool proofing C. robotic design D. auto loading
fool proofing
Slab milling is typically performed using what type of knee-and-column milling machine?
horizontal milling machine
Slab milling is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. vertical milling machine C. both horizontal and vertical milling machines
horizontal milling machine
Which surface grinder type: The most common type of surface grinding machine.
horizontal spindle, reciprocating table
Which surface grinder type: Surface grinder not typically used due to limited type of work which it will accommodate.
horizontal spindle, rotary table
Wheel grade....................... This is largely dependent on the ......... present in the wheel structure Pb.
indicates the grinding wheel's bond strength in retaining the abrasive grits during cutting. amount of bonding material
Which of the following is not a type of broach construction? A. segment B. shell C. insert tooth D. solid
insert tooth
Broaching was orginally developed for the production of ____. A. splines B. internal keyways C. flat surfaces D. external keyways
internal keyways
Abrasive machining
is a material-removal process that involves the interaction of abrasive grits with the work piece at high cutting speeds and shallow penetration depth.
Honing
is an abrasive process performed by a set of bonded abrasive sticks. A common application is to finish the bores of internal combustion engines. Other applications include bearings, hydraulic cylinders, and gun barrels.
Lapping
is an abrasive process used to produce surface finishes of extreme accuracy and smoothness. It is used in the production of optical lenses, metallic bearing surfaces, gages, and other parts requiring very good finishes.
Centerless grinding
is an alternative process for grinding external and internal cylindrical surfaces. As its name suggests, the workpiece is not held between centers.
Waviness ;
is defined as the deviations of much larger spacing; they occur because of work deflection, vibration, heat treatment, and similar factors. Roughness is superimposed on waviness.
Lay ;
is the predominant direction or pattern of the surface. It is determined by the manufacturing method used to create the surface, usually from the action of cutting tool.
Surface integrity
is the study and control of this subsurface layer and any changes in it because of processing that may influence the performance of the finished part or product.
Buffing
is used to provide attractive surfaces with high lustre.
Polishing
is used to remove scratches and burrs and to smooth rough surfaces by means of abrasive grains attached to a polishing wheel rotating at high speed— around
An open structure is one in which Pp is relatively ...., and Pg is relatively ....... That is, there are more .....and fewer ......per unit volume in a wheel of open structure. It is recommended in situations in which ........................
large,small pores ,grains clearance for chips must be provided.
Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways.
longitudinal (X-axis)
grain size : The grain size of the abrasive particle is important in determining .......................... .............sizes produce better finishes, we use it when we have ............whereas .......... sizes permit larger material removal rates. we use it when we have .............. grain size also depend on ....... Grain sizes used in grinding wheels typically range between 8 and 250. Grit size 8 is very .......and size 250 is very ....... Even finer grit sizes are used for .....and ......
surface finish and material removal rate. Small grit , hard material larger grain, soft material hardness of the work material. coarse ,fine lapping , superfinishing.
Magnetic chucks are commonly used on what type of machinery? A. Lathes B. Surface grinders C. Micro-drill presses D. Milling machines
surface grinders
Grinding operation and grinding machine
surface grinding cylindrical grinding centerless grinding creep feed grinding disk grinder abrasive belt grinder
The structure of a grinding wheel refers to ____. A. the strength of the bonds between the abrasive grit in the wheel B. The ratio of the bonding material volume to the abrasive material volume C. The ration of the bonding material weight to the abrasive material weight D. the spacing of the abrasive grit in the wheel
the spacing of the abrasive grit in the wheel
For American pattern files, the coarseness of the file cut is given by: A. xx teeth/ inch B. the tooth pattern and the length of the file C. tooth pattern of the file D. the length of the file
the tooth pattern and the length of the file
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways.
vertical (Z-axis)
Superfinishing is an abrasive process similar to honing. use a bonded abrasive stick moved with a reciprocating motion and pressed against the surface to be finished. Superfinishing differs from honing in the following respects:
(1) the strokes are shorter, (2) higher frequencies are used (3) lower pressures are applied between the tool and the surface (4) workpiece speeds are lower (5) grit sizes are generally smaller.
cylindrical grinding divide into two basic types :
(a) external cylindrical grinding (b) internal cylindrical grinding.
Broaching (Machine)
- Broaching is performed using a multiple-teeth cutting tool by moving the tool linearly relative to the work in the direction of the tool axis. -Advantages include good surface finish, close tolerances, and a variety of work shapes.
Microhardness profile.
- Hardness differences near the surface can be detected using microhardness measurement techniques such as Knoop and Vickers. -The part is sectioned, and hardness is plotted against distance below the surface to obtain a hardness profile of the cross section.
Visual examination.
- Visual examination can reveal various surface flaws such as cracks, craters, laps, and seams. - This type of assessment is often augmented by fluorescent and photographic techniques.
profile meter
-In these electronic devices, a cone-shaped diamond stylus with point radius of about 0.005 mm(0.0002 in) and 90 tip angle is traversed across the test surface at a constant slow speed. -As the stylus head is traversed horizontally, it also moves vertically to follow the surface deviations. -The vertical movement is converted into an electronic signal that represents the topography of the surface. -This can be displayed as either a profile of the actual surface or an average roughness value
Surface texture.
-Surface roughness, designation of lay, and other measures provide superficial data on surface integrity. -This type of testing is relatively simple to perform and is always included in the evaluation of surface integrity.
The range of rise per tooth for internal broaching is (x) to (y) inches/tooth.
.001 .006
The amount of material removed in lapping is usually less than _____ A. None of these B. 1 millionth of an inch C. 0.0005" D. 0.001"
.001"
The range of rise per tooth for internal broaching is to inches/tooth.
.001-.0025
why Abrasive processes are important?
1. They can be used on all types of materials ranging from soft metals to hardened steels and hard nonmetallic materials such as ceramics and silicon. 2.Some of these processes can produce extremely fine surface finishes. 3.For certain abrasive processes, dimensions can be held to extremely close tolerances.
The bonding material must be:
1. able to withstand the centrifugal forces and high temperatures experienced by the grinding wheel 2. resist shattering in shock loading of the wheel, 3. hold the abrasive grains rigidly in place to accomplish the cutting action 4.while allowing those grains that are worn to be dislodged so that new grains can be exposed.
The four types of surface grinding:
1. horizontal grinding with reciprocating worktable/ 2.rotating work table. 3. vertical grinding with reciprocating worktable/4. rotating worktable.
Surfaces are described as consisting of two parameters:
1.surface texture. 2.surface integrity.
The milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches.
150
The milling process will produce a surface finish with a surface roughness measurement of 60 to ____ microinches.
150
The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.
30 40
What percentage of EDM is used to produce tool and die sets? A.10-20% B. 80-90% C. 70-80% D. 50-60%
80-90
What percentage of EDM is used to produce tool and die sets?
80-90%
Which of the following describes the ultrasonic machining process? A. 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 materail being machined and the tool as a process to remove material. B. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. C. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. D. A harden steel tool is vibrated at low frequencies (<1000) 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.
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 best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and rotating tooling B. A process involving a rotating tool and X-Y-Z linear movement of the work piece. C. A process involving a rotating work piece and X-Y-Z linear movement of the tooling D. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements.
A process involving a rotating tool and X Y Z linear movement of the work piece
Which of the the following is not a common tooth form for saw blades? A. square B. regular C. skip D. claw
A.
Which of the following is not a common material used for the teeth of a band saw blade? A. high speed steel B. CBN C. diamond D. tungsten carbide
B.
To finish threading a blind hole you would first use a taper tap, followed by a plug tap, and finally a [x] tap
Bottoming
Which of the following is NOT a thread forming process?
Broaching
Which of the following materials is not commonly used as a lap? A. Copper B. Cast iron C. Aluminum D. Cloth
C.
Which of the following is not an advantage of plasma arc cutting? Very fast cutting Smooth cuts free of contaminants are produced Can be used for cutting metal based composite materials small heat-affected zone
Can be used for cutting metal based composite materials
By using extremely hard materials for abrasives it is possible to machine such materials as
Ceramics
Which of the following is NOT a common material used for the teeth of a band saw blade
Cubic boron nitride
What device is used to manually produce external threads?
Die
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls
End mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece
Face mill
A fixture/jig should be design using the least number of standard elements as possible. True or False
False
Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder. True or False
False
Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened
False
In centerless grinding deep cuts are not possible due to the work support. True or False
False
The lapping process must be performed only by hand without machinery. True or False
False
True or False: A fixture/jig should be design using the least number of standard elements as possible.
False
True or False: The lapping process must be performed only by hand without machinery.
False
True or 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
True or False: Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.
False
True or False: With centerless grinding tubes will automatically have concentric inside and outside diameters.
False
True or False: Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.
False
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing
Form cutter
...............is the most important abrasive process. In terms of number of machine tools in use, .........is the most common of all metalworking operations.
Grinding
CBN (Cubic boran nitride) abrasives used to grind:
Hard materials: hardened tool steels
What type of machine would be used to do boring on large parts that cannot be turned in an engine lathe?
Horizontal boring machine
Which of the following is the most common type of surface grinder machine?
Horizontal spindle, reciprocating table
All of these are advantages of permanent mold casting EXCEPT: (Good surface finish of casting, Good dimensional accuracy of casting, Inexpensive molds and tooling, or Molds can be reused multiple times)
Inexpensive molds and tooling
Which of the following is NOT a type of broach construction?
Insert tooth
Broaching was orginally developed for the production of ____.
Internal keyways
Nominal surface ;
It representing the intended surface contour of the part. It is defined by lines, ideal circles, round holes, and other edges and surfaces that are geometrically perfect.
The slot cut in the material by a saw blade is called ____.
Kerf
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.
Maximum
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.
Minimum
Which of the following is NOT a delivery method that is used with abrasives?
Mounted
In a centrifugal casting operation, where would you expect to find any metal impurities or shrinkage defects?
Nearest the center of rotation
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 applies to plasma arc cutting? Plasma arc cutting involves superheated gas for cutting only steel plates. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals. Plasma arc cutting involves super-high pressure gas propelled at mach 30 for cutting conductive metals.
Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
A CNC milling machine ___. A. Requires highly trained operators to operate. B. Is used only in mass production operations. C. Can machine parts slower and more accurately than a manual milling machine D. Provides for machining of more complex parts than a manual 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
Which of these centrifugal casting methods would be best to produce wheels or pulleys?
Semi centrifugal
The milling machine was invented in approximately 1816 by ___.
Simeon North
The milling machine was invented in approximately 1816 by ____. A. Thomas Edison B. Simeon North C. James Watt D. Eli Whitney
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 ? A. L-Slot milling cutter B. T-slot milling cutter C. Staggered-tooth mill cutter D. Plain milling cutter
T slot milling cutter
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
What is most commonly used to produce internal threads?
Taps
Bonding Materials Desirable properties of the bond material include:
The bonding material holds the abrasive grains and establishes the shape and structural integrity of the grinding wheel. - strength, toughness, hardness, and temperature resistance.
Which of the following statements correctly describes the purpose of the mask in chemical machining? A. The mask is applied to the area of the part that is desired to not remove material from the part B. The mask is applied to the area of the part that it is desired to removal material from the part. C. The mask enhances the chemical machining process. D. None of the above.
The mask is applied to the area of the part that is desired to not remove material from the part
The grade of a grinding wheel refers to ____. A. the ratio of bonding material volume to abrasive material volume B. the strength of the bonds between the abrasive grits C. the spacing of the abrasive particles in the wheel D. the ratio of bonding material weight to abrasive material weight
The strength of the bonds between the abrasive grits
Microstructural examination.
This involves standard metallographic techniques for preparing cross sections and obtaining photomicrographs for examination of microstructure in the surface layers compared with the substrate.
The process for machining threads which requires a CNC machining center capable of circular interpolation is ____.
Thread milling
Which of the following statements is false regarding the thread rolling process? A. Thread rolling is a hot forming process B. Thread rolling can be used to form threads on tubular products C. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second.
Thread rolling is a hot forming process
Up process: The direction of the cutting forces are ____.
Toward the cutter
A fixture/jig should be designed to tolerate variations in the workpiece. True or False
True
Centerless grinding is a process that is performed quickly. True or False
True
Centerless grinding requires the use of special, dedicated equipment to perform the grinding process. True or False
True
More flat surfaces are produced by the milling process than any orher machining process.
True
More flat surfaces are produced by the milling process than any other machining process. True or False
True
The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process. True or False?
True
True or False: A fixture/jig should be designed to tolerate variations in the workpiece.
True
True or False: Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.
True
True or False: Centerless grinding is a process that is performed quickly.
True
True or False: Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.
True
True or False: 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
True or False: Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)
True
True or False: For the honing process the amount of material removed is less than 0.005" from the surface.
True
True or False: In centerless grinding, the work piece must be round and not include flats or keyways.
True
True or False: More flat surfaces are produced by the milling process than any other machining process.
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 or False
True
Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly. True or False
True
The honing process is not used for which of the following:
Truing of holes
The honing process is not used for which of the following: A. truing of holes B. removing taper, waviness, and tool marks from the boring process C. sizing and finishing of bored holes D. removing tooling marks
Truing of holes
Which of the following free-abrasive machining processes is safe in the event of accidental skin contact?
Ultrasonic
For the up milling process, complete the statements with the answers supplied: In the slab milling operations, the direction of the cutting force is ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
Up
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Vertical spindle, rotary table
Residual stress profile.
X-ray diffraction techniques can be employed to measure residual stresses in the surface layers of a part.
Which alloy group might best be cast with hot chamber die casting?
Zinc alloys
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
A dividing head is an accessory used with a milling machine primarily to provide what operation? A. rotation of a part 90 degrees so that additional machining can be performed on it B. rotation of a part 180 degrees C. accurate rotation of the work piece through any desired arc of rotation D. rotation of a group of parts so that the next piece in the group can be machined
accurate rotation of the work piece through any desired arc of rotation
For the up milling process, complete the statements with the answers supplied The mill cutter rotates ___ the direction of feed.
against
For the up milling process, complete the statements with the answers supplied: The mill cutter rotates ____ the direction of feed. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
against
Which of the following materials is not commonly used as a lap? A. Aluminum B. Copper C. Cloth D. Cast iron
aluminum
Which of the following is not an abrasive material used in commercial cleaning applications? A. walnut shells B. dry ice C. aluminum chips D. plastic media
aluminum chips
What is the most common material used for abrasives?
aluminum oxide
What is the most common material used for abrasives? A. plastic media B. silicon carbide C. diamond D. aluminum oxide E. dry ice F. CBN
aluminum oxide
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 45 degree, V shaped groove in the surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
angle cutter
Type of milling cutter: 45 degree, V shaped groove in the surface of a flat bar
angle cutter
Flaws ;
are irregularities that occur occasionally on the surface; these include cracks, scratches, inclusions, and similar defects in the surface.
Which cutter is best: producing a groove with a 1/8" diameter concave bottom
ball end mill
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
Which is the most frequently used mounting system for abrasives? A. free B. bonded C. mounted D. coated
bonded
Clamping forces must be greater than what four (4) forces? A. aerodynamic B. centrifugal C. frictional D. gravity E. inertial F. cutting
centrifugal gravity intertial intertial cutting
Clamping forces must be greater than what four (4) forces?
centrifugal, gravity, cutting, inertial
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material.
charged
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material. A. charged B. mounted C. lapped D. pasted
charged
The teeth of an end mill cutter are located on the ___.
circumference and the face of the cutter
The teeth of an end mill cutter are located on the ___. A. circumference and the face of the cutter B. circumference of the cutter C. face of the cutter
circumference and the face of the cutter
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 honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole? A. no defined pattern B. circular C. crosshatch
crosshatch
Which of the following is not an application for laser beam machining? Welding Drilling micro-sized holes Cutting thick materials Cutting thin materials
cutting thick materials
Which of the following is not an application for laser beam machining? A. welding B. cutting thin materials C. Drilling micro-sized holes D. cutting thick materials
cutting thick materials
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.
cylindrical external
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4. A. cylindrical external B. surface grinder C. None of these D. cylindrical internal
cylindrical external
What device is used to manually produce external threads? A .file B. taps C. Die D. grinding wheel
die
SiC (silicon carbide) abrasives used to grind:
ductile metals, and brittle materials
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit. A. dislodging B. sharp C. dull D. flattening
dull (x) flattening (y)
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in ___ edges and ___ 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 chuck
You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice? A. electrostatic chuck B. vise C. toggle clamps D. magnetic chuck
electrostatic chuck
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Producing a flat-bottom groove in the surface of a part
end mill
Which cutter is best: Deep slots with straight side walls
end mill
Which cutter is best: producing a pocket in a workpiece
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
face mill
Tapered end mills are used for ____ A. rough cutting in the machining of molds B. both rough and finished cutting in the machining of molds C. Finish cutting on molds to produce a desired angle D. machining a chamfer on finished parts
finish cutting on molds to produce a desired angle
Tapered end mills are used for ____.
finish cutting on molds to produce a desired angle
Which of the following is a function of the dielectric in the electical discharge machining process? A. Flushing agent B. heating agent C. lubricant D. protective coating for the finished part
flushing agent
Which of the following is a function of the dielectric in the electrical discharge machining process? Flushing agent Lubricant Protective coating for the finished part Heating agent
flushing agent
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 1/4" radius, convex shape along the edge of a part A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Deep slots in a work piece A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Type of milling cutter: 1/4" radius, convex shape along the edge of a part
form cutter
Type of milling cutter: Milling wood to produce wood trim
form cutter
Which cutter is best: bearing pocket in gearbox housing
form cutter
Friability refers to the ability of the abrasive material to ____.
fracture, producing new, sharp edges
Friability refers to the ability of the abrasive material to ____. A. form chips B. withstand high temperatures C. withstand exposure to water and cutting oils D. fracture, producing new, sharp edges
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 (m) glass(n) ceramics (o) carbides (p)
Diamond abrasives used to grind:
hard abrasive materials(ceramics, cemented carbides and glass)
By using extremely ___ materials for abrasives, it is possible to machine hardened steel, ___, ___, and ___. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics
hard, glass, ceramics, carbides
Abrasive material: General properties of an abrasive material used in grinding wheels include:.........................................,they are desirable properties of any cutting-tool material.
high hardness, wear resistance, toughness, and friability.
A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.
holds (x) size (y)
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder not typically used due to limited type of work which it will accommodate. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
horizontal spindle, rotate table
In ________ die casting, a gooseneck chamber is submerged to fill with metal and then a plunger is actuated to force the metal into the die.
hot-chamber
The slot cut int eh material by a saw blade is called ____. A. slot B. groove C. kerf D. gullet
kerf
The soft material used in the lapping process is called _______.
lap
The soft material used in the lapping process is called _______. A. felt B. rouge C. lap D. None of these
lap
A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.
location
Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
longitudinal (x axis)
soft wheel grade ,........ the grains readily, is used for............and when machining.........
lose ,low material removal rates hard work material.
In the abrasive machining process, ___ edges are cutting simultaneously resulting in a(n) ___ surface finish.
many, excellent
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.
maximum
For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ as the end of the chip formation as the tool exits the work piece
maximum
For the up milling process, complete the statements with the answers supplied: The chip thickness is a ____ at the end of the chip formation as the tool exits the work piece. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
maximum
Multiple-use molds are generally made of ___________.
metal
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.
minimum
For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.
minimum
The milling process uses [x] and involves [y] cutting. a) single-point tool b) multi-tooth cutter c) continuous d) interrupted
multi tooth cutter interrupted
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. A. single-stroke B.multi-stroke C.single D.multi (y) E.a single pass F.multiple passes
multi-stroke (x) multi (y)
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. A. one tooth B. multiple teeth C. more D. less E. rougher (higher surface roughness value) F. smoother (lower surface roughness value)
multiple teeth less smoother (lower surface roughness value)
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. A. positive B. negative C. 10-15 D. 3-5
negative 3-5
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? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. Cutting speed for steel is less than 1500 m/min D. One or more axes are always accelerating in a 3-D cut. E. A high material removal rate is obtained
one or more axes are always accelerating in a 3D cut
Wheel structure is measured on a scale that ranges between ''........'' and ''.........''.
open,dense
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 area of the cutter?
peripheral edge
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) finishing the top surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
plain cutter
Type of milling cutter: finishing the top surface of a flat bar
plain cutter
In ___ products, threads are frequently produced by casting.
plastic
In _____ products, threads are frequently produced by casting.
plastic
The abrasive machining process is a mixture of three processes; ___ moves material, ___ causes friction and ___ forms chips.
plowing, rubbing, cutting
The blade width of the saw blade determines the minimum ____ that can be cut with a bandsaw blade A. depth of cut B. radius C. rate of cutting D. thickness
radius
Friability
refers to the capacity of the abrasive material to fracture when the cutting edge of the grain becomes dull, thereby exposing a new sharp edge.
Wheel structure grinding wheels contain:
refers to the relative spacing of the abrasive grains in the wheel. abrasive grains and bond material, air gaps or pores
Roughness;
refers to the small, finely spaced deviations from the nominal surface that are determined by the material characteristics and the process that formed the surface.
"Power filing" is frequently performed with ___.
rotary burrs
"Power filing" is frequently performed with ____ A. a filing machine B. band filing C. rotary burrs D. disk filing
rotary burrs
What device is used to produce external threads with lathes, screw machines, and threading machines? A. self closing die head B. self opening die head C. die attachment D. threader
self opening die head
The pattern used to offset the saw blade teeth from the centerline of the blade is called ___
set
The pattern used to offset the saw blade teeth from the centerline of the blade is called ___.
set
The pattern used to offset the saw blade teeth from the centerline of the blade is called ____. A. pitch B. rake C. set
set
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?
sewing machine
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device? A. revolvers B. sewing machines C. bicycle bearings D. steam engines
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
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) deep, straight walled, narrow slots A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
slitting saw cutter
Type of milling cutter: deep, straight walled, narrow slots
slitting saw cutter
wheel grade measured on a scale ranges from.......to.....
soft,hard
To thread a blind hole the threes types of taps used, in order are ___, ___, and ___.
taper, plug, bottom
To thread a blind hold the three types of taps used, in order are ___, ___, and ___.
tapered plug bottoming
What is used to produce internal threads?
taps
To reduce the chance of slag and other impurities entering a mold, metal in the ladle should be extracted from _________.
the bottom of the ladle
The grade of a grinding wheel refers to ____.
the strength of the bonds between the abrasive grits
Which of the following statements is false for rolled threads? A. Rolled threads have a hard, wear resistance, smooth surface. B. the threads produced by thread rolling have a lower strength than cut threads. C. Rolled threads have a major diameter larger than the diameter of the base stock.
the threads produced by thread rolling have a lower strength than cut threads
For the up milling process, complete the statements with the answers supplied The direction of the cutting forces are ____.
toward the part
For the up milling process, complete the statements with the answers supplied: The Direction of the cutting forces are ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
toward the part
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways
transverse (Y-axis)
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
transverse (y axis)
The honing process is not used for which of the following:
truing of holes
A requirement for broaching is that ___ teeth be in contact with the workpiece.
two
A requirement for broaching is that _____ teeth be in contact with the workpiece. A. two B. one C. three D. five
two
For the up milling process, complete the statements with the answers supplied In slab milling operations, the direction of the cutting force is _____.
up
cylindrical grinding
used for rotational parts.
Surface grinding
used to grind plain flat surfaces. performed using the periphery of the grinding wheel or the flat face of the wheel.
The most common type of broaching machine construction is ____.
vertical
The most common type of broaching machine construction is ____. A. vertical B. Horizontal
vertical
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinding machine used in production operations. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
vertical spindle, rotary table
Which surface grinder type: Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.
vertical spindle, rotary table
Which surface grinder type: Surface grinding machine used in production operations.
vertical spindle, rotary table
For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.
vertically down
Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.
vise chuck
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom
Ball end mill
Centerless grinding is a process that must be performed manually by the machinist. True or False
False
In face milling, most of the cutting occurs at what area of the cutter? A. Equal amount of cutting both at the center and peripheral edge B. Peripheral edge
Peripheral edge
Which casting process would have the lowest cost for a high production quantity?
Permanent mold casting
The most common type of sawing machine for cutting metal is____.
bandsaw
A dense structure is one in which Pp is relatively ........., and Pg is ........ Dense structures are used to obtain.....................
small,larger better surface finish and dimensional control.
Al2o3 (aluminum oxide) abrasives used to grind:
steel and ferrous materials and high strength alloys.
Magnetic chucks are commonly used on what type of machinery?
surface grinders
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. both vertical and horizontal milling machines C. vertical milling machine
vertical milling machine
Which surface grinder type: Surface grinder where the wheel diameter must exceed the width of the part being ground
vertical spindle, reciprocating table
The range of rise per tooth for external broaching is (x) to (y) inches/tooth.
.003 .006
The range of rise per tooth for surface broaching is to inches (per tooth).
.003 to .006
What is the typical MRR for electrochemical machining? A. in^3/ min/ 1000 amps B. .1 in^3/min/1000 amps C. 100 in^3/min/1000 amps
.1 in^3/min/1000 amps
The amount of material removed in lapping is usually less than _____
0.001"
The range of rise per tooth for internal broaching is ___ to ___ inches/tooth.
0.001, 0.0025
The range of rise per tooth for external broaching is ___ to ___ inches/tooth
0.003, 0.006
What is the typical MRR for electrochemical machining? 0.01 in^3/min/1000 amps 0.1 in^3/min/1000 amps 1 in^3/min/1000 amps 100 in^3/min/1000 amps
0.1 in^3/min/1000 amps
determine the five basic parameters of a grinding wheel:
1 abrasive material 2 grain size 3 bonding material 4 wheel grade 5 wheel structure
The maximum operator force in loading/unloading a part should be less than ___ to ___ lbf.
30, 40
The surface finish obtained from the broaching process has a surface finish measurement of (x) to (y) microinches
32 125
Which of the following statements for Electrical Discharge Machining is incorrect? A very specialized process for machining developed for machining parts for NASA rocket engine parts. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. Most frequently used of NTM processes. A matt finished is produced by the EDM process
A very specialized process for machining developed for machining parts for NASA rocket engine parts
Which of the following statements for electical discharge machining is incorrect? A. A matt finished is produced by the EDM process B. A very specialzied process for machining developed for machining parts for NASA rocket engine parts. C. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. D. Most frequently used of NTM processes.
A very specialized process for machining developed for machining parts for NASA rocket engine parts.
Which of the following statements is false for rolled threads? A. The threads produced by thread rolling have a lower strength than cut threads. B. Rolled threads have a major diameter larger than the diameter of the base stock. C. Rolled threads have a hard, wear resistant, smooth surface.
A.
Which of the following does NOT apply to non-traditional machining? Removing material from a base using chemicals. Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra-high pressure water. Adding material to a base using high voltage electrical discharges. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. By an additive process where small, precise amounts of materials are built-up into a shape.
Adding material to a base using high voltage electrical discharges
Up process: The mill cutter rotates ___ the direction of feed.
Against
Which of the following is not an abrasive material used in commerical cleaning applications? A. dry ice B. aluminum chips C. walnut shells D. plastic media
B.
Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.
C.
Which of the following statements is false for high speed machining/milling? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. One or more axes are always accelerating in a 3-D cut. D. Cutting speed for steel is less than 1500 m/min E. A high material removal rate is obtained
C.
Which of the following statements is false regarding the thread rolling process? A. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second. B. Thread rolling can be used to form threads on tubular products. C. Thread rolling is a hot forming process.
C.
Which of the following is not a common material used for the teeth of a band saw blade? A. tungsten carbide B. diamond C. high speed steel D. CBN
CBN
Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and X-Y-Z linear movement of the tooling B. A process involving a rotating work piece and rotating tooling C. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements. D. A process involving a rotating tool and X-Y-Z linear movement of the work piece.
D
Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. water B. oil C. grease D. air
D.
True or False: Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.
False
True or False: For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.
False
True or False: High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.
False
True or False: In centerless grinding deep cuts are not possible due to the work support.
False
True or False: The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.
False
True or False: The honing process used stones with a grit size of 1200 or more particles per inch.
False
The drawbacks of multiple-use molds include___________.
Limited part size
In the abrasive machining process, ___ edges are cutting simultaneously resulting in a(n) ______ surface finish
Many and excellent
Which of the following is a correct statement for rapid prototyping? A. Rapid prototyping is an additive manufacturing process that can be produce parts fro various materials using various processes. B. Rapid prototyping is very expensive process and has very limited applications C. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.
Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.
What thread forming process is the largest by volume (# of parts produces)?
Rolling
The creep feed grinding process is used to grind deep slots with straight parallel sides into parts. True or False
True
The filing process is used to remove small amounts of material from a part. True or False
True
The operator should not have to reach past the tool to load/unload parts for machining. True or False
True
The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel. True or False
True
The use of a spiral fluted tap is to force chips up (rearward) and out of a hole during the threading process.
True
True or False: The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.
True
True or False: The chemical machining process is used in mass-production of parts.
True
True or False: The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.
True
True or False: The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.
True
True or False: The filing process is used to remove small amounts of material from a part.
True
True or False: The operator should not have to reach past the tool to load/unload parts for machining.
True
True or False: The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.
True
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder where the wheel diameter must exceed the width of the part being ground.A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Vertical spindle reciprocating table
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Which cutter is best: finishing the top surface of a work piece
face mill
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Milling wood to produce wood trim A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
A fixture is a special workholding device that ___ the workpiece during machining or assembly operations and establishes ___ dimensions.
holds, size
Superfinishing is a variation of what process to finish flat surfaces.
honing
Superfinishing is a variation of what process to finish flat surfaces. A. lapping B. None of these C. surface grinding D. honing
honing
the traditional abrasive processes include ................,......,.....,...,,..... The abrasive machining processes are generally used as ...........operations,
honing, lapping, superfinishing, polishing, and buffing. finishing
Broaching was originally developed for the production of ____.
internal keyways
In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish. A. Rough B. excellent (y) C. many (x) D. few E. two F.three
many (x) excellent (y)
For the up milling process, complete the statements with the answers supplied: The chip thickness is a _____ at the beginning of the chip formation. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
minimum
Loading and unloading of a fixture will often abuse the fixture ____ .
more than the machining operation
Loading and unloading of a fixture will often abuse the fixture ____ . A. less than the machining operation B. more than the machining operation C. equal to the machining operation
more than the machining operation
The main advantage of turret lathes compared to an engine lathe is _____.
more tools can be set up for machining, thereby decreasing setup time and increasing machine productivity
Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. free D. mounted
mounted
Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter.
negative 3-5
The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips. A. Cutting B. digging C. plowing (x) D. rubbing (y) E. scrapping F. planning
plowing (x) rubbing (y)
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
hard wheel grade ,........ the grains , is used for............and when machining.........
retains, high material removal rate soft work materials
Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.
the damping forces should be spread over a small area
The structure of a grinding wheel refers to ___.
the spacing of the abrasive grit in the wheel
Common base elements for fixtures are a ___ for milling and a ___ for lathe operations.
vise, chuck
For the down milling process, complete the statements with the answers supplied 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
What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment? A. end mill cutter B. T-slot milling cutter C. woodruff keyseat milling cutter D. Slitting saw cutter
woodruff keyseat milling cutter
