MEGT 1321 Final Exams
Which statement best describes proper electric power tool safety?
Make sure to ground an electric power tool before use.
What is the purpose of the speed change handwheel? The speed change handwheel:
Makes variable speed changes within a range.
How much workpiece material should an operator leave for reaming a hole to its finished size?
0.005-0.010 in. (0.127-0.254 mm)
What does the prefix "centi-" indicate about the size of a centimeter? A centimeter is:
0.01 m.
What is the reading on the micrometer shown?
0.262 in.
To cut an internal thread that has a nominal size of 0.875 in. (22.225) with 10 threads-per-inch, what is the minor diameter of the hole that must be drilled in the workpiece?
0.775 in. (19.685 mm)
To determine thread depth for 60° V-shaped threads, multiply the specified thread pitch by what constant value?
0.866
Hard turning is:
A single-point machining process, conducted on a lathe, involving workpieces with a hardness above 45 Rc.
Which statement describes threading on the manual lathe?
A single-point tool is used to cut a helical ridge around a cylindrical part.
A collet is:
A split tapered sleeve-like workholder.
Which sentence about steel classifications is true?
A stainless steel with an "L" suffix has a low carbon content.
Which sentence about steel is true?
A steel's grade is determined by its alloying elements and carbon percentage.
Which sentence is true about the grain structure of metal?
Annealing is a heat treatment that involves gradual heating and cooling.
When should an operator engage the half-nut lever to turn external threads on a workpiece that requires 9 threads per inch? Engage the half-nut lever when the threading dial reaches:
Any numbered line on the dial.
What should be included in a change block? A change block should include:
Any revisions, as well as the dates they were made.
What action is necessary throughout an external taper turning operation using the tailstock offset?
Apply adequate lubricant to the centers.
Which choice best encourages chip removal during ID operations?
Applying air or fluid through the boring bar.
What machine component holds and rotates the cutter on a horizontal column-and-knee mill?
Arbor
Which component of a horizontal column and knee milling machine supports the spindle?
Arbor
Which of the following is directly responsible for producing an arc flash?
Arc fault
What are benchwork operations? Benchwork operations:
Are any operation performed on a workpiece before or after manual machining.
When does OSHA require employers to implement hearing conservation programs? When employees:
Are exposed to noise that exceeds the levels set by OSHA.
Which statement is true about common OD toolholders on the lathe? OD toolholders:
Are fitted in the turret and heat-treated for extra strength.
Which of the following statements is true about cubic boron nitride (CBN) and diamond tools? CBN and diamond tools:
Are the hardest tool materials and have excellent abrasive wear resistance.
Which statement is true about the neutral axis in bent sheet metal? The neutral axis is the:
Area between the stretched and compressed metal.
How should drill size compare to the final hole size when preparing for boring? The drill size should be:
As close as possible to but still smaller than the final size.
Which describes conductive hearing loss? Conductive hearing loss is:
Associated with problems with the outer ear.
How should a machinist position a cutoff tool for parting off operations on the lathe? A machinist should position a cutoff tool:
At a 90° angle to the workpiece axis.
How do magnetic chucks hold workpieces? Through:
Attraction between charged materials.
Which refers to the series of hearing tests that measure an employee's hearing?
Audiometric testing
Which member of a permit space entry team orders evacuation when a worker shows signs of exposure?
Authorized attendant
Which best describes proper hand tool safety?
Avoid using steel tools near flammable substances.
What type of misalignment occurs when only one end of a workpiece is concentric to the spindle?
Axial runout
When must platform and runway openings and holes be protected? They must be protected when they are:
Beside hazardous equipment or substances.
How many band saw teeth should contact the workpiece at once?
Between 3 and 24
Which of the following is manufactured from spring steel alloys and high-speed steel (HSS)?
Bi-metal blade
How does the fixed guard differ from the interlock switch on a CNC machine?
Fixed guards provide a physical barrier while interlock switches do not.
Which of the following types of ladders might be equipped with cages and lifebelts?
Fixed ladders
What is the only acceptable type of tool wear?
Flank wear
Knurling operations typically use a dead center in the tailstock to prevent what from happening?
Flexing
What determines the number of pounds per square foot that may rest on floors and rooftops? The number of pounds per square foot that can rest on floors and rooftops is determined by the:
Floor loading requirements of a building.
What are some of the key factors in determining the severity of cutting fluid exposure?
Fluid composition and chemical refinement
How should the flutes of an end mill relate to the dimensions of the workpiece surface to be milled?
Flutes must be longer than the surface.
Drop hammers are machines that:
Forge parts through a series of impacts.
What tool wear is particularly likely to occur when using inserts that are hard and brittle or incorrectly clamped to the toolholder?
Fracture
Proper ventilation is mandatory when using which type of tool?
Fuel-powered tools
Which overcurrent device contains a part that melts and opens a circuit?
Fuse
What organization standardizes the numerical flammability rating that must appear on all flammable and combustible liquid labels?
GHS
Which type of inspection device provides a known measurement used for mastering devices like micrometers?
Gage Blocks
What component of a metal cutting print includes information relevant to most part features?
General note
Which of the following statements about workholding for the lathe is true? Workholding for the lathe:
Generally positions the workpiece to rotate around its centerline.
What device is used with the ways to increase the mill table's rigidity?
Gibb
What PPE completely covers eyes, sockets, and the surrounding facial area and protects against impact?
Goggles
What term describes the composition of a carbide insert and sometimes includes information about applications for which the tool is best suited?
Grade
What analog readout devices appear on an engine lathe's carriage and cross-slide handwheels?
Graduated dials
Modular toolholders offer:
Greater versatility.
Which type of guard for a wall opening or hole has a screen-like barrier with openings that are no wider than eight inches (203 mm)?
Grillwork
General fit testing consists of which actions? Fit testing includes wearing a facemask and:
Grimacing to check for seal tightness.
What is a vise? A vise is a workholding device that:
Grips a workpiece between two parallel jaws.
According to the OSHA safety standards, what must be done to moving parts on hoists? Moving parts on hoists must be:
Guarded.
When using a taper attachment for taper turning, what component does an operator adjust to set the taper angle?
Guide bar
Which of the following statements about prints for metal cutting operations is true? Prints for metal cutting operations:
Guide operators in the machining of parts.
What is the function of the pilot on a counterboring tool? The pilot:
Guides the tool straight and concentric to the hole.
Why are HSK toolholders better than V-flange toolholders at high speeds?
HSK toolholders are more rigid.
What machine tool uses a solid, straight multi-point tool that cuts in a reciprocating motion?
Hacksaw
To turn an external taper using the compound rest, what must the machine operator first calculate?
Half the included angle.
What benchwork operation can a machinist perform in order to fit a bushing?
Hand reaming
What should portable dockboards have for easy movement and lifting?
Handholds
Because of the possibility of ricochet, using a powder-actuated tool requires operators to wear which PPE item?
Hard hat
Which workpiece materials would likely require an advanced tool material?
Hardened metal or superalloys
How do carbide cutting tools compare to high-speed steel tools? Compared to high-speed steel tools, carbide cutting tools are:
Harder but more expensive.
What two properties allow carbide tools them to make both continuous and interrupted cuts? Carbide tools are able to make continuous and interrupted cuts because they balance:
Hardness and toughness.
Which characteristic describes a flammable liquid? A flammable liquid:
Has a flash point of less than 100° F (38° C).
What makes a carbide insert indexable? An indexable insert:
Has additional cutting edges that can be used if one cutting edge fails.
When compared to a multiple-spindle screw machine, a single-spindle screw machine:
Has the shortest setup time.
Which of the following statements about safe lifting practices is true? When lifting heavy objects, be sure to:
Have a clear path to the destination before lifting.
What is an OSHA requirement for tagout devices? A tag must:
Have a standard color, shape, and size.
What is an advantage of an indexable insert drill? Indexable insert drills:
Have a very high metal removal rate.
When should a machinist use a T-handle tap wrench during hand tapping operations? T-handle tap wrenches should be used for taps that:
Have smaller diameters and break easily.
What do construction rules require of wood ladders? Construction rules require that wood ladders:
Have solid and visibly flaw-free structures.
What statement is true of Class IIIB combustible liquids? Class IIIB combustible liquids:
Have the highest flash point and are the least dangerous.
Which is a way that employers measure and monitor noise exposure levels? Employers monitor noise levels by:
Having employees wear meters on their shoulders.
Which step of the fluid management occupational safety and health program involves using and assessing engineering controls to reduce potential hazards?
Hazard prevention control
What does an arc flash's incident energy consist of?
Heat
What harmful byproducts of metal cutting, which can reduce part quality and degrade tools, do cutting fluids help reduce?
Heat and friction
Which of the following is most likely to impact the properties of steel stock?
Heat treatment
Which angle describes how the flutes twist around a milling cutter?
Helix angle
What is the importance of layout? Layout:
Helps to ensure a part meets its required tolerances.
A metal with a BCC structure, such as iron, usually exhibits which mechanical property?
High hardness
Which group of plain carbon steels contains more than 0.6% carbon?
High-carbon steels
Which fluid delivery method improves a cutting fluid's cooling and lubrication properties by propelling the fluid at a high rate of speed?
High-pressure high-volume method
What type of tool material should an operator use when machining a ductile metal?
High-speed steel (HSS)
What type of metal cutting operations should use chemical fluids?
High-speed turning and milling of hard materials
Which of the following describes the proper way to carry a tool?
Hold the tool with a tight grip.
Which of the following is required to verify that a hole meets its specifications?
Hole inspection
Milling machines can perform which of the following cutting operations?
Holemaking
What does the rake angle measure? The rake angle measures:
How far the front edge of the cutting tool is from being perpendicular to the workpiece.
In milling, what does feed measure? Milling feed measures:
How fast the cutting tool moves along the workpiece.
In turning, what does feed measure? Turning feed measures:
How fast the cutting tool moves along the workpiece.
In drilling, what does feed measure? Drilling feed measures:
How fast the drill is moving into the workpiece.
What production activity requires workers to compare part dimensions to desired specifications?
Inspection
What must a machine operator do to turn an internal taper using a taper attachment?
Install a boring bar in the tool post.
Which housekeeping method allows the floor to stay dry when using liquids?
Installing proper drainage.
Respirators guard against which of the following hazards?
Insufficient Oxygen
What issue can increase cutting fluid exposure through inhalation?
Insufficient ventilation
Which type of fit is designed so that the shaft diameter must be slightly larger than the hole to meet specifications?
Interference
What type of operation does not keep a tool's cutting edges in constant contact with the workpiece, causing a tool to experience temperature fluctuations, jars, and shocks?
Interrupted cutting
The casting method that uses a mold made from a wax pattern coated with a ceramic shell is known as:
Investment casting.
What is the difference between ferrous and nonferrous metals?
Iron is the main ingredient in ferrous metals, but NOT in nonferrous metals.
Which describes sensorineural hearing loss? Sensorineural hearing loss:
Is caused by damage to cilia.
What does high strength and hardness indicate about a workpiece material? A workpiece with high strength and hardness usually:
Is harder to machine.
When should air hoses be fitted with a safety excess flow valve? An air hose requires a safety excess flow valve when:
Its diameter is more than ½ inch.
Which column-and-knee mill component supports the worktable and can be adjusted vertically?
Knee
Which component on the vertical mill supports the saddle and table from underneath and moves up and down?
Knee
What does making a light pass to begin facing operations achieve? A light facing pass creates a(n):
Known surface
Which statement best describes requirements for information about flammable and combustible liquids? Hazardous liquid manufacturers must:
Label each container, and include an SDS for each type of liquid.
Which of the following is NOT an advantage of powder metallurgy? Powder metallurgy can create:
Large parts with close dimensional tolerances.
What machine tool uses a single-point tool to remove material from a workpiece that rotates in a spindle?
Lathe
Which of the following statements about injury risks for manual lathe operators is true?
Lathe operators work in close proximity to the moveable components.
Which ductile nonferrous metal is used in sound dampening applications?
Lead
What angle describes how far the peripheral cutting edge tilts away from a line parallel to the axis of a cutter?
Lead angle
Which material is often used for hand and foot arc flash PPE?
Leather
Which type of gloves protect from sparks and heat?
Leather gloves
When aligning the tool to begin face milling a step on the top surface of a rectangular workpiece, what precaution should the operator take? The operator should:
Leave a small approach distance.
To calculate taper per inch (TPI), divide a taper's change in diameter by what taper measurement?
Length
Which of the following slot dimensions usually appears along with the depth dimension on a print?
Length
What is the difference between a rated load test and an operational test? A rated load test assesses:
Lift capacity.
How are portable lifting stands primarily used? Portable lifting stands are used to:
Lift loads in confined areas.
Which factor does not affect calibration?
Lighting
Which type of tolerance specifies a range of acceptable measurements rather than a target dimension?
Limit dimensions
Which of the following is a characteristic of a confined space?
Limited means of entry or exit.
What features of a closed piping system reduce the fire risk involved with flammable and combustible liquids? A closed piping system:
Limits air flow and vapor generation during liquid transport.
What is the primary difference between ballscrews and linear motors?
Linear motors can move faster.
What parts of a drill create chips during cutting?
Lips
What may metal tools or machinery do if exposed to arc flash?
Liquefy
Which of the following should machine operators avoid while working?
Listening to music.
What device has a stationary shaft with a pointed, rotating end used to support center-drilled workpieces?
Live center
What type of cutting tool is used to create a hole off the centerline of a part on the lathe?
Live tooling
Which list best describes the order of the screw machine cycle?
Load bar stock, feed bar stock into collet, rotate workpiece, cut and retract, cutoff.
What type of ventilation system ventilates a specific production area by capturing air right at the source of contamination before it can enter an operator's breathing zone?
Local exhaust system
What step should a machine operator take after moving the tailstock close to the workpiece face to begin center drilling?
Lock the tailstock to prevent backward movement.
What item is designed to keep an energy-isolating mechanism in a safe position?
Lockout device
Which statement about methods of detecting environmental hazards is true?
Long-term exposure can be expected to require medical testing.
Which of the following is true about metal grain growth?
Longer cooling times usually mean larger grains.
In which situation should an employee undergo a respiratory fitting re-evaluation? Respirator fit should be re-evaluated after a worker:
Loses weight.
What aspect of a center drill helps to ensure that a center hole location is accurate and precise?
Low length-to-diameter ratio
How should a band saw operator break in a new blade? The operator should use:
Lower speed and feed rates.
What factor affecting cutting speed selection describes the ease of cutting a workpiece material?
Machinability
What material quality prolongs the life of tools, reducing cost and increasing efficiency?
Machinability
What device may be used as alternative protection to lockout/tagout procedures when performing minor tool changes?
Machine guard
What two items are involved in every metal cutting process? Every metal cutting process involves a cutting tool and a(n):
Machine tool.
What is the general term for any process that utilizes a tool to remove material and create chips?
Machining
What measure of thread width or size is often used to identify tap tools?
Major diameter
How should an operator approach speed and feed settings? An operator should:
Make adjustments during a cutting operation to optimize settings.
Which of the following statements about cutting tool selection is true? During cutting tool selection, operators should:
Make sure cutting tools are harder than workpiece materials.
Which is a strategy to increase the rigidity of a machine?
Make sure the machine is well secured to the floor and the tool insert is sitting solid in the tool holder pocket.
Which is a strategy to optimize ID hard turning?
Make sure the tool is on center, or slightly off center if accounting for deflection.
Which lists the main steps in powder metallurgy in the correct order?
Manufacturing powder, blending, compacting, and sintering.
Which of the following are two of the factors operators should consider when selecting a carbide tool?
Material removal rate and workpiece material
What is the goal of ergonomics? Ergonomics:
Maximizes employee safety while increasing productivity.
Which is true of visually inspecting threads? A visual inspection:
May detect deformed threads and problems with starts.
What statement is true about ergonomic hazards? Ergonomic hazards:
May lead to chronic disorders even if they are not obvious.
What does the ISO 9000 standard state about measurement and monitoring devices?
Measurement and monitoring devices must be calibrated and traced to the highest standard.
What does drill geometry describe? Drill geometry describes the:
Measurements of the physical characteristics and angles of a drill.
What step should a machinist perform before taking finishing passes to complete a turning operation? After finishing roughing cuts, the machinist:
Measures the workpiece diameter with a micrometer.
What type of chipbreaker is clamped into the toolholder separate from the insert and is effective at removing large amounts of metal?
Mechanical chipbreaker
Which of the following is a general confined space hazard?
Mechanical hazard
Which manufacturing materials are valued for electrical and thermal properties?
Metal
Which statement about hot and cold working is true?
Metal heated below its recrystallization temperature requires more force to shape than metal heated above its recrystallization temperature.
What type of tool wear occurs when a softened insert presses against a workpiece and becomes distorted?
Plastic deformation
Which type of hand tap does a machinist use second when hand tapping blind holes?
Plug tap
What type of energy uses pressurized air or gas and is often used to power assembly tools?
Pneumatic
Which type of devices use bleeding as a blocking method?
Pneumatic
Which of the following types of exposure is often responsible for negatively affecting the alignment of the body?
Poor positioning
What type of ergonomic hazard involves improper alignment of the body?
Poor posture
What results from an operator stopping the feed in the middle of a cut?
Poor workpiece surface finish
Which is a requirement regarding the care and usage of portable metal ladders?
Portable metal ladders that have fallen must be inspected for damage immediately.
What general-purpose milling geometry sets inserts so that they tilt away from a line parallel to the center axis of the mill axially and twist away from the center of the mill radially?
Positive/negative geometry
What worksite organization step should manufacturers take to ensure operator safety? Manufacturers should:
Post warning signs in both English and the predominant language of non-English speakers.
What method of creating advanced material cutting tools consists of compressing and sintering powdered tool and binder materials?
Powder metallurgy
What process uses compression and heating to create carbide tools?
Powdered metallurgy
What does "operation type" for hoists refer to? Operation type refers to the:
Power used to produce hoisting motion.
For a machine tool designed specifically for HSM, you would expect to find:
Powerful CNC hardware.
Which is the function of leadscrew? The leadscrew:
Powers the carriage.
What step of the OSHA onsite inspection involves the compliance officer showing their credentials?
Presentation
What is the purpose of hearing conservation programs within the workplace? The purpose of hearing conservation programs in the workplace is to:
Prevent occupational hearing loss.
What is the purpose of a safety pin on a portable fire extinguisher? A safety pin:
Prevents accidental discharge.
What process can restore a worn drill, improving its efficiency and prolonging its service life?
Regrinding
Which statement about OSHA's role in the regulation of environmental safety hazards is true? OSHA:
Regulates the use, handling, and removal of many hazardous substances.
What angles describe the space between the tool flanks and the newly cut workpiece surface?
Relief angles
Which of the following statements about relief angles is true?
Relief angles should be just large enough to balance edge strength and surface finish quality.
In addition to reducing heat and friction, what other benefits do cutting fluids provide? Cutting fluids:
Remove chips and prevent corrosion.
What course of action should be taken with chains that are worn or deemed unsafe?
Removed from service immediately and replaced.
What is a revolved section view? A revolved section view:
Removes a thin slice of a part and rotates it ninety degrees.
What type of ergonomic hazard causes disorders such as trigger finger and tendonitis, which involve inflammation or compression of nerves, tendons, and joint cushions?
Repetitive motion
What does OSHA require employees to do to maintain safety? Employees must:
Report hazards and injuries to the employer.
Which of the following information is included in a fire prevention plan?
Requirements for building extinguishing and alarm systems.
Which of the following statements about manual milling is true? Manual milling:
Requires an operator to control the machine.
Which of the following statements is true about cutting fluid disposal? Cutting fluid disposal:
Requires the use of approved methods that preserve personal and environmental safety.
Which of the following is an example of an illness?
Respiratory disease
What is the biggest limitation of polycrystalline diamond (PCD) cutting tools? PCD tools:
Revert to graphite when used to machine ferrous metals.
Which of the following measures the rate at which a spindle rotates?
Revolutions per minute
What is the purpose of using constant surface speed (CSS) on the CNC machine? CSS adjusts:
Revolutions per minute according to workpiece diameter to keep the sfm constant.
What term describes a drill's resistance to flexing under pressure?
Rigidity
How does an increase in length-to-diameter ratio (L/D ratio) affect rigidity and deflection? As L/D ratio increases:
Rigidity decreases and deflection increases.
What is the lowest point of a thread?
Root
Which hoisting mechanism is most used with derricks?
Rope reeving
What undesirable outcome can result from a built-up edge?
Rough surface finish
How do both ISO and ANSI classification systems rank inserts within categories? Both systems rank inserts within categories according to their suitability for:
Roughing or finishing applications.
What insert shape provides the strongest possible cutting edge?
Round
What is the defining characteristic of a tool with a nose radius? A tool with a nose radius has a:
Rounded tip.
Which statement is true about the care and usage of portable wood ladders?
Rung ladders must be used at a pitch that is one-quarter the length of the ladder.
Which is a requirement regarding the construction and dimension of portable metal ladders?
Rungs must be made slip resistant through knurling, dimpling, or other means.
Which manual mill component allows the worktable to move side to side and back and forth?
Saddle
Which of the following is classified as hazard communication?
Safety data sheets
Which documents provide information about the specific chemicals used in a workplace?
Safety data sheets (SDS)
What type of personal protective equipment should engine lathe operators always wear?
Safety glasses
What feature is required on all safety cans to prevent explosions if a fire occurs?
Safety vent
Which of the following statements best describes green sand casting?
Sand and binders are compacted around a wood or metal pattern.
Which of the following should include safeguards installed on all platforms higher than 10 feet?
Scaffolding
Which of the following print representations uses solid lines to show the basic look of threads without depicting its actual shape?
Schematic
What must an inspector do to inspect threads with a thread plug gage? The inspector must:
Screw the go side into the hole first, followed by the no go side.
Which atmospheric confined space hazard can cause systemic effects?
Secondary irritants
What print view illustrates an interior portion of a part?
Section view
What is the purpose of workholding? Workholding:
Secures, supports, and locates the workpiece.
How can operators adjust cutting variables to prevent notch wear? Operators can:
Select a tool with a protective coating.
How can operators adjust cutting variables to prevent chipping? Operators can:
Select an insert with a stronger geometry.
What category of cutting fluid, composed of oils, water, chemical additives, and emulsifiers, includes extreme pressure fluids, plain fluids, and super-fatted fluids?
Semi-chemical fluids
Which cutting fluid has a long sump life and is composed mostly of water combined with moderate amounts of oil, emulsifiers, and other additives?
Semi-synthetic fluid
Which term describes the smallest change in measurement that an instrument can detect?
Sensitivity
What is the primary purpose of sawing operations?
Separating stock into multiple pieces.
Which is true about the standards for lifting devices in the workplace? The standards for lifting devices in the workplace are:
Set by OSHA.
What is the function of a quick-change gearbox on an engine lathe?
Setting spindle speed
What manual milling process requires operators to study blueprints, determine settings, align components, and select cutting tools?
Setup
What process may include aligning the various milling machine components and selecting cutting tools?
Setup
What type of part feature does a ring gage inspect?
Shafts
What factor does the first character in an ANSI insert number describe?
Shape
Which of the following statements is true about sheet metal drawing and roll forming?
Sheet metal drawing shapes blanks using a punch and die.
Which statement about sheet and bulk metal is true?
Sheet metal is usually cold worked.
Which statement about metal shaping processes is true?
Sheet metal processes and extrusion shape metal without creating chips.
What information must be included on a label for equipment capable of causing arc flash?
Shock hazard
Which is a requirement for eye and face protection? Eye and face protection:
Should fit the user properly and comfortably.
Which accurately describes the function of gaging inspection tools? Gaging inspection tools:
Show whether or not the parts fit.
Which type of ceramic tool is, when uncoated, rated only for use with cast irons?
Silicon nitride ceramics
How is the order of operations generally selected for manual milling?
Simplest to most complex features
Which clamping method is being used?
Single screw.
What type of tool frequently cuts with one edge of an insert?
Single-point tool
What type of tooling involves a cutting edge that keeps in contact with the workpiece throughout a cut?
Single-point tooling
Which type of hearing protection is most sanitary, comfortable, and commonly used in manufacturing?
Single-use earplugs
How should the keyboard and mouse of a computer workstation be positioned? The computer keyboard and mouse should be positioned so that employees can:
Sit with a neutral back and wrists.
How is the ISO carbide classification system organized? The ISO classification system is organized using:
Six color-coded categories divided by workpiece material.
Which tools can be used to clean tramp oil from a cutting fluid?
Skimmers and filters
Which type of milling operation performed on a horizontal mill produces a flat top surface?
Slab milling
What is a collet? A collet is a:
Sleeve with a highly accurate machined opening.
What should operators do after placing the adapter in the spindle nose?
Slide the collet closer through the headstock.
What does the helix angle measure? The helix angle measures the:
Slope of the drill flutes.
What is true of harder, less-machinable workpiece materials? Harder, less-machinable workpiece materials demand:
Slower initial speeds and feeds.
The primary purpose of a screw machine is to manufacture:
Small cylindrical parts with automated production rates.
Which statement about HSM tooling is true?
Solid tooling is ideal for HSM because of its excellent stability.
Which cutting fluid generally contains a large percentage of oil combined with emulsifiers and water and tends to become contaminated more easily than other fluids?
Soluble oil
What category of cutting fluid is best-suited for both light- and medium-duty cutting operations?
Soluble oils
What cutting variable has the greatest affect on tool life and should be set last?
Speed
What cutting variable measures how fast the workpiece spins past the cutting edge of the tool?
Speed
What variable impacts tool life the most?
Speed
Which cutting variable affects tool life the most?
Speed
Manual milling machines are classified by the orientation of what machine component?
Spindle
Which lathe component has a graduated rule for measuring the movement of a cutting tool into a workpiece?
Tailstock sleeve
Which of the following is true about taper turning operations on an engine lathe? For taper turning operations using a taper attachment, operators should:
Take several passes to reach the required final diameter on the workpiece face.
What material is added to carbide tools to help them retain their hardness during high-speed, high-temperature applications?
Tantalum carbide (TaC)
What should a machinist check before and during a hand tapping operation?
Tap alignment
Which should an operator do before using a hand-held abrasive wheel tool?
Tap the side of the wheel with a non-metallic instrument.
What part feature can engineers represent on a print with a symbol of a line cutting through a triangle and include a dimension in the form of a ratio or angle?
Taper
Which of the following devices can inspect both external and internal tapers?
Taper micrometer
Why is it essential to balance and tightly clamp workpiece material that is bundled? Balancing and tightly clamping a bundle of workpiece material prevents the:
Teeth stripping from the blade.
What feature of a broach allows it to perform a full cut in one stroke?
Teeth that gradually change in size.
Which physical confined space hazard can cause hypothermia?
Temperature
Which variance requires the employer to meet alternative OSHA guidelines until compliance is attained?
Temporary
A digital micrometer or manual vernier micrometer is how many times more sensitive than a standard manual micrometer?
Ten times
Which step for establishing electrically safe work conditions comes directly after performing lockout/tagout?
Testing for voltage.
Which of the following is a proper work practice for permit space entry?
Testing the atmosphere for gases lighter or heavier than air.
Through what means does OSHA provide 10-hour or 30-hour safety courses in construction, general industry, and other topics?
The OSHA Outreach Training Program
What does a quantitative fit test assess?
The amount of hazardous substances that leak into a respirator
What does mass measure? Mass measures:
The amount of material in an object.
If you are using carbide inserts for turning on the lathe:
The carbide insert is fitted in a matching toolholder and clamped in place.
How does the chip creation of HSM differ from traditional machining? In HSM:
The chip carries away more heat.
What is the main purpose of steel classifications? Steel classifications help to identify:
The steel's contents.
Which statement about the machining elements of hard turning is true?
The surface speeds for hard turning are often triple or quadruple the speed used for traditional turning.
What aspect of lathe tooling do the back and side rake angles measure?
The tilt or position of the tool face.
What is the latency of an ergonomic hazard? Latency is:
The time between hazard exposure and appearance of injury.
What cutting fluid contaminant can cause smoking, residue formation, and reduce tool service life?
Tramp oil
What insert shape is considered the best for general-purpose use and has a large end cutting-edge angle?
Triangle
What material is commonly combined with carbon to create carbide particles?
Tungsten
What are the two main alloying elements that separate high-speed steel (HSS) into two groups?
Tungsten and molydenum
What type of carbide material is harder than HSS but quickly develops crater wear?
Tungsten carbide
Which cutting operation is ideal for advanced tool materials because it involves continuous cutting, reducing potential causes of tool fracture?
Turning
Which of the following engine lathe operations uses a radial depth of cut?
Turning
The American single-spindle screw machine is distinguished by the presence of a:
Turret
How much material should a machinist remove from a workpiece to create the proper undercut diameter?
Twice the required thread depth
What type of drill is characterized by having two cutting edges at the point of the drill and flutes that twist around the body of the drill?
Twist drill
How is the ANSI carbide classification system organized? The ANSI carbide classification system is organized using:
Two categories based on the workpiece material a tool grade is best suited to machine.
How do ISO insert identification numbers indicate insert thickness? ISO insert numbers indicate thickness with:
Two digits rounded down to the nearest whole millimeter.
How does milling differ from most single-point cutting operations? When milling:
Two or more edges of the cutting tool are continually engaged during the operation.
What carbide coating has a characteristic yellow color and reduces friction between the workpiece and cutting tool?
Titanium nitride (TiN)
Which ceramic cutting tool material is also used as a coating, has a characteristic yellowish-gold color, and reduces friction?
Titanium nitride (TiN)
In what section of the blueprint is the general scale listed for the entire drawing?
Title block
Why is calibration necessary? Calibration is necessary:
To ensure accurate measurements of tightly toleranced parts.
What type of safeguard should be found on all scaffolding surface levels higher than 10ft. (3.05 m.)?
Toeboard
What insert characteristic refers to the allowable deviation from the intended design and is described by the third ANSI character?
Tolerance
What is the allowed range of a dimension?
Tolerance
In the ISO metric thread specification M9 x 2 - 3G, what does 3G indicate?
Tolerance class
What specification of an ISO metric thread indicates its degree of fit?
Tolerance class
What is the difference between dimensions and tolerances?
Tolerances provide a realistic guideline for distinguishing acceptable parts.
What cutting condition may result in rough chips or bad surface finish?
Tool chatter
What occurs if the chip formed by the saw tooth is too large for the gullet?
Tool damage and reduced cutting efficiency.
Which of the following is an important factor for drilling operations?
Tool diameter for any holemaking operations that follow.
What term is used to describe the angles and positioning of a cutting tool?
Tool geometry
What do Type I hard hats protect against? Type I hard hats protect against:
Top-only impact.
What key material property allows a tool to absorb shock and resist fracture during operation?
Toughness
Which of the following is defined as an unbroken chain of comparisons with higher-level standards?
Traceabillity
What documentation lists the specific steps required to lockout and tagout an individual machine?
Typical minimal lockout procedure
A micrometer used for daily production should be calibrated to which standard?
Working standard
Which workpiece is a candidate for hard turning?
Workpiece hardness of 50 Rc; L/D ratio of seven-to-one supported.
What is the most important factor to consider when selecting cutting speed for engine lathe operations?
Workpiece machinability
In addition to applying OSHA's walking and working surface rules to their workspaces, to what other areas should employees apply these same rules?
Workpieces and materials being produced
Which of the following accurately defines environmental hazards? Environmental hazards are:
Workplace factors that can cause injury, illness, or death.
How does OSHA define an "affected employee?" An affected employee:
Works on or near a machine that must be locked out during maintenance.
Along which Cartesian axis does a mill's worktable move from side to side?
X axis
Forward-and-backward movement of the cross slide aligns with which axis on the engine lathe?
X axis
In what axis must an operator touch off and zero the cutting tool for outside diameter operations on the lathe?
X axis
Which Cartesian coordinate system axis runs side to side along the longest dimension of a vertical column and knee mill's worktable?
X axis
How should an operator align a vise when using it as a workholding device? An operator should align a vice along the:
X axis with the worktable.
Which of the following units measures length in the English System?
Yard
On a spade drill, what angle measures the distance between the cutting edge and the workpiece?
Clearance angle
Which individual checks office spaces to ensure that no one is left behind during a fire?
Evacuation warden
What does the sixth position of an ANSI number indicate?
Insert thickness
Which hole inspection device uses a thimble rotated by the inspector?
Inside micrometer
Why may a machinist ream only the top half of a through hole? Reaming to a set depth may be used to:
Fit a dowel pin.
Choose the answer that matches the sheet metal cutting process to the correct image.
(A) blanking, (D) parting, (F) notching
Choose the correct labels for the toolholder:
(A) shank (B) seat (C) pocket.
Choose the answer that correctly identifies parts of a mold.
(D) runner, (B) riser, (C) cope
Identify the components of a screw machine from the diagram:
(a) cross slide, (b) headstock, (c) spindle, (d) collet, (e) turret.
What is the rpm for a milling operation if the tool diameter is 3.5 inches (88.9 mm) and the sfm is 1,500 (457.2 m/min)?
1,637.14
If a part is 3 centimeters long, how long is it in inches?
1.18 in.
Which AISI-SAE number correctly identifies a plain carbon steel with 0.15% carbon?
1015
Which plain carbon steels have no significant alloying elements?
10xx
How many millimeters are contained in thirteen centimeters?
130 mm
Which table in NFPA 70E indicates whether or not a specific task requires arc flash PPE?
130.7(C)(15)(A)(a)
If someone has 8 pieces of wood that are each 10 feet long, how many 7-inch parts will they be able to make?
136 parts
How many cubic inches are in a cubic foot?
1728 in³
A flat rectangular part has a length of 12 centimeters and a width of 10 cm. What is the area of the part in square inches?
18.6 square inches
During setup for threading a 60° right-hand external thread on the engine lathe, how should the machinist set the compound rest?
29° to the right of 90 degrees.
What feed ratio does an engine lathe have if its cross slide moves the cutting tool the same distance set by the cross slide feed dial?
2:1
What is the rpm for a turning operation if the workpiece diameter is 2.5 inches (63.5 mm) and the sfm is 2000 (609.6 m/min)?
3,056
What is the inches per minute (millimeters per minute) for a milling operation using a cutting tool with 8 teeth if the feed per tooth is 0.008 in. (0.203 mm) and the revolutions per minute is 900?
57.60 ipm (1,463.04 mm/min)
Threading operations typically use a V-shaped form tool with what cutting edge angle?
60 degrees
What included angle do V-shaped symmetrical threads have?
60°
At what point do spindle speeds start to approach the high-speed machining range?
8,000 rpm
What is an ideal pH level for cutting fluids? The ideal cutting fluid pH level is between:
8.7 and 9.2, or slightly alkaline.
What is the most commonly used countersink tool angle?
82°
Which of the following statements is true about bulk metal?
A billet is smaller than a bloom.
Which properly describes sound? Sound is:Which properly describes sound? Sound is:
A change in air pressure perceived by the ears.
How can a machine operator improve workholding setup when cutting with an advanced tool material? Operators can improve workholding for advanced cutting tools by using:
A chuck with additional jaws.
How does the musculoskeletal disorder carpal tunnel syndrome occur? Carpal tunnel syndrome develops from:
A compressed nerve in the wrist.
A cam is:
A cylindrical plate-like component that rotates to control feed and depth of cut.
How does an orthographic view appear on a print? An orthographic view appears as:
A flat, two-dimensional image.
Which of the following is an example of a well-organized work station?
A floor free of cutting fluid.
Which measuring instrument is used to master other instruments?
A gage block
What is a fire brigade? A fire brigade is:
A group of employees trained to fight workplace fires.
Which statement is true of head protection? Proper head protection should have:
A headband and straps inside the shell.
Which of the following is included in tool steel classifications?
A letter indicating the steel's special properties.
Which of the following statements about machinability is true?
A material with a high machinability rating is easier to machine than a material with a low machinability rating.
What is the purpose of mastering? Mastering compares:
A measurement device to a known measurement standard.
What is a machinist's rule? A machinist's rule is:
A metal strip with graduations along its edges indicating increments of measurement.
According to OSHA, what is a standard? A standard is:
A policy that employers must legally follow.
Which statement about hard turning tools is true?
A positive rake orientation can decrease and better control the cutting forces on lathes with limited rigidity.
Which is a required component of an energy control program? An energy control program must include:
A procedure for shutting down and blocking equipment.
What is the difference between an auxiliary and a section view?
A section view slices the part in half and an auxiliary provides a full straight-on picture.
When compared to grinding, hard turning may be the best strategy when:
A workpiece is being cut to a unique geometry involving angles and contours.
What statement is true of reducing ergonomic hazards in the workplace?
A workstation that is ergonomic for one employee may be a hazard to another.
Choose the letter and angle in the image that represents the lead angle:
A.
What does the tooth back clearance angle measure? Back clearance angle measures the:
Angle between the tooth back and workpiece.
Which service should employers provide to all employees in the event of a fire or emergency? Employers should provide:
Access to medical personnel.
What must an inspector do to inspect threads with a thread snap gage? The inspector must:
Adjust the anvils to the proper distance and wiggle them onto the part.
Which hand reamers can change in size to fit a smaller or larger hole?
Adjustable hand reamers
What is indicated by a feature with a tighter tolerance than the rest of a print's dimensions? The tightest tolerance on a blueprint indicates a feature that:
Affects a part's fit or function.
Which type of portable fire extinguisher is silver in color?
Air-pressurized water extinguisher
Which type of respirator uses cartridges or canisters to clean contaminants from ambient air?
Air-purifying
What does an operator use a precision machinist square for in mill setup?
Aligning the workpiece
Which of the following is true regarding training after a hearing conservation program is instituted in a workplace?
All employees must receive training for the program.
Which statement about safety hazards on the manual mill is true?
Allow the spindle to come to a complete stop before changing parts.
Which of the following addresses proper PPE compliance? PPE should be worn:
Always, regardless of the existence of visible hazards.
Which of the following is an important consideration when selecting a respirator?
Ambient air quality.
Which of the following statements about OSHA coverage is true?
An approved state program may cover employees instead of OSHA.
Which of the following is likely to cause a point-of-operation injury?
An employee's finger contacts a moving spindle.
What dimension do engineers include in a print callout for a chamfer?
Angle
Which statement about rake angles is true? Rake angles:
Balance reduced cutting forces with edge strength.
What cutting process uses a flexible, looped blade with multiple teeth to rough-cut workpiece material to its basic size?
Band sawing
Load shifting is a primary concern for which of the following lifting devices?
Baskets
What is a right employees have under OSHA? Employees have the right to:
Be notified if the employer applies for a variance.
Which statement best illustrates OSHA's medical evaluation requirements? Medical evaluations are required:
Before any employee may wear a respirator.
What strategy can avoid the majority of work-related back injuries? The majority of work-related back injuries can be avoided by:
Bending at the knees and turning with the feet when lifting objects.
What negative effect can result from compression of the band saw blade? Compression of the band saw blade may result in the:
Blade being unable to form straight cuts.
What does speed refer to in band sawing? Band sawing speed refers to the rate at which the:
Blade itself moves.
What type of micrometer is used to measure narrow grooves and slots?
Blade micrometer
Which statement correctly describes an appropriate method for assuring proper fit and function of a negative pressure respirator?
Block the filter or air source while inhaling to confirm that the mask will tighten around the face.
What part of a drill extends from the toolholder and contains components such as the flutes and drill point?
Body
When counterboring, what measurement determines the final knee depth?
Bolt head thickness
Which type of hole inspection device detects out-of-round conditions?
Bore gage
Which of the following operations performed on the lathe is an inner diameter (ID) operation?
Boring
What type of tool is held in a head that adjusts to various hole diameters?
Boring tool
Which list contains only inner-diameter operations?
Boring, reaming, drilling, tapping.
Which type of cutting tool has an expensive cutting material fused to a less expensive material?
Brazed-tipped
What type of line would be used to shorten drawings for extremely long parts?
Break line
Which statement about overhead cranes is true? An overhead crane has a:
Bridge with a wheeled trolley that travels across it.
What property increases as a tool material's hardness increases?
Brittleness
Which type of tool wear occurs when workpiece material adheres to the flank and rake face of a tool?
Built-up edge (BUE)
Which type of thread form is used when the screw or bolt must undergo a great deal of pressure?
Buttress threads
Which part would most likely be made on a screw machine?
C
What ANSI C-system carbide grades are ideal for roughing operations?
C1 and C5
Which type of lathe is operated using a series of numerical commands?
CNC lathe
If a bushing with a 1.0-inch internal diameter is measured with four calipers, which caliper has good accuracy and good precision based on the data below?
Caliper 3
What instrument can measure both ID and hole depth?
Calipers
Which measuring device consists of a metal strip with measurement graduations along its edges and a pair of jaws at one end?
Calipers
What is the key advantage of chucks? Chucks:
Can be adjusted to fit a variety of workpiece shapes and sizes.
Which of the following is an advantage of soft chuck jaws? Soft chuck jaws:
Can be cut to fit a workpiece exactly.
What statement is true about ergonomic practices? Using proper ergonomic practices and equipment:
Can reduce serious workplace injuries by half.
What major health concern results in cell mutations due to long-term exposure to cutting fluids?
Cancer
When do produced tolerances become unacceptable? Tolerances are unacceptable when parts:
Cannot perform their intended function.
What does a lathe operator use to reach the finish depth during boring?
Carriage handwheel
Which of the following is a requirement of fixed industrial stairs? Fixed industrial stairs must:
Carry five times their normal anticipated load.
Which component of an air-purifying respirator usually has an end-of-service-life indicator?
Cartridge
Which order arranges the following manufacturing processes from the least precise to the most precise tolerance limits?
Casting, turning, grinding
Which category of flammable liquids can be considered the least flammable, with a flash point between 140 and 200° F (60—93 C)?
Category 4 liquids.
Which of the following statements about the pressure generated by arc blast is true? Arc blast pressure can:
Cause shrapnel to fly from an electric arc.
What cutting tool should an operator use first to create a hole in a rectangular workpiece?
Center drill
What is the first step a machinist must complete before tapping a hole?
Center drill the hole.
What type of lines are used to indicate the midpoint of a cylindrical part or feature?
Center lines
Which of the following units measures length in the metric system?
Centimeter
What cutting tool material is useful for cutting very hard workpieces at high speeds and temperatures but is not suited for interrupted cutting?
Ceramic
Which statement best describes high-speed spindle bearings?
Ceramic balls are lighter and provide increased wear resistance.
What cutting tools are made from hard, nonmetallic particles and have excellent hot hardness?
Ceramic tools
What tool material is created by suspending ceramic particles in a metallic binder?
Cermet
What type of cutting tool material possesses properties that normally do not exist together within individual materials?
Cermet
What lathe operation removes burrs or sharp corners, creating an angled edge on a part?
Chamfering
Which of the following describes engineering controls?
Changes that eliminate or minimize hazards before workers are harmed.
Which character in the ANSI number describes insert type, including the presence and design of holes, chipbreakers, and countersinking?
Character four
What action should an operator take after making any adjustment to correct mill head alignment?
Check alignment with the dial indicator.
What is the purpose of using a refractometer? The purpose of using a refractometer is to:
Check fluid concentrate levels.
What is the primary use of pin and plug gages? Pin and plug gages are used to:
Check the diameter of a feature.
What does the practice of mastering consist of? Mastering is:
Checking a device against a known standard.
What PPE is used when there is a particularly high risk of splashing cutting fluid or the fluid in use is especially hazardous?
Chemical protective clothing (CPC)
Which process applies a thick layer of coating that improves a carbide tool's wear resistance but decreases its edge toughness?
Chemical vapor deposition
What tool coating process involves flooding a vacuum chamber with gaseous coating compounds so that they can condense on a tool substrate?
Chemical vapor deposition (CVD)
What does the number and spacing of flutes on a hand tap determine? A hand tap's flutes determine the:
Chip clearance and evacuation.
What is improved by chamfering a workpiece hole prior to a tapping operation?
Chip evacuation
What type of tool wear can be prevented by adjusting the lead angle, changing the insert shape, or using the correct chipbreaker?
Chip hammering
What factors in cutting fluid selection are considered cutting functions?
Chip removal and surface finish quality
What issues can occur if drill speed is set too slow?
Chipping and breakage
What is the product of all metal cutting processes?
Chips
What metal-cutting hazard can be airborne and cause cuts and burns to the skin and eyes?
Chips
Which is cut from a workpiece?
Chips
How does an increased lead angle affect chip formation? Increased lead angles create:
Chips that are wider and thinner, allowing for faster cutting speeds.
What sharp area of the drill connects the cutting lips and is the first part of the drill to make contact with the workpiece?
Chisel edge
Which workholding device consists of two or more jaws that clamp down on a workpiece?
Chuck
What devices are used to hold a workpiece in a lathe spindle?
Chucks and collets
What is an accurate, effective method of preventing flammable or combustible liquid ignition due to static electricity? Ignition from static electricity can be prevented by:
Clamping a bond wire between a storage container and the nozzle of a portable container.
What information is included in the OD toolholder classification system?
Clamping, shape, size, and shank style.
What type of standpipe system is a combined hose system used by trained employees to fight fires larger than the incipient stage?
Class III system
In the unified thread specification .500 -16 UNF - 1A x 5.0000, what does 1 indicate?
Class of fit
What corrective action should be taken when skin exposure to a cutting fluid occurs? Operators should:
Clean the exposed area with soap and water.
What type of fire extinguisher is harmful to human health and requires evacuation or the use of PPE for anyone in the area where it is used?
Clean-agent extinguishing system
What angle measures the space between the insert flank and the workpiece surface?What angle measures the space between the insert flank and the workpiece surface?
Clearance angle
What type of milling creates chips that become narrower as they form and produces a more refined surface finish?
Climb milling
Which of the following statements about forging methods is true?
Closed die forging uses two dies with a cavity shaped like the desired part.
Choose the tool material and its correct matching property that provides the best choice for HSM:
Coated carbide for its thermal resistance.
Which of the following describes a safe tool handling practice for cutting operations?
Coating a sharpened cutting blade in wax.
What engine lathe workholding device uses split, tapered sleeves to grip a workpiece?
Collet
What toolholder is a split-sleeve device that expands or contracts to grip the cutting tool?
Collet
Which of the following statements is true?
Column-and-knee mills are often used for short production runs and customized work.
What taper turning method is well-suited for turning a steep but short external taper?
Compound rest
For internal taper turning using the compound rest, what should an operator adjust prior to each cutting pass?
Compound rest feed dial
Lathes can create workpiece tapers that have what shape?
Cone
Which type of indicating thread gage measures pitch diameter?
Cone and vee rolls
Which statement best describes the effects of calibration cycles? Effective calibration:
Considers the frequency of instrument use.
What should employees do before working with hand or power tools?
Consult the tool's owner's manual.
What type of band saw has a tilting table to cut irregular shapes?
Contouring band saw
What type of part feature do engineers represent on prints using curved or semi-circular lines with accompanying angle, radius, and length dimensions?
Contours
Which OSHA standard covers lockout/tagout regulations?
Control of Hazardous Energy
What hole feature is indicated on prints with an upside-down staple symbol?
Counterbore
Which of the following milling machine operations allow a fastener to sit flush with a workpiece surface?
Counterboring
What is true about employee training requirements for permit space entry? Training should:
Cover proper use of PPE.
Which PPE should be worn if a fire hazard is present?
Coveralls and boots
What is generally the first step in the layout process?
Covering a workpiece surface with layout dye.
What type of tool wear occurs when a chemical breakdown in the tool causes the formation of depressed areas in its rake face?
Crater wear
Which of the following types of tool wear can be reduced by using a positive rake angle?
Crater wear
Why are cutting fluids generally NOT used in HSM? Cutting fluids:
Create the possibility of thermal shock.
How does lubrication affect a cutting operation? Lubrication:
Creates a film between the tool and workpiece to separate points of contact and reduce friction.
What is slot milling? Slot milling is:
Creating a narrow, recessed path within a workpiece.
What engine lathe component moves a cutting tool forward and backward, perpendicular to the ways?
Cross slide
What engine lathe component moves the cutting tool forward and backward, across the workpiece, in the X axis?
Cross slide
What information can be found in the ID toolholder specification?
Insert shape, insert size, bar diameter, and hand.
Which term describes the most efficient way for atoms to arrange themselves in a particular space?
Crystal structure
What cutting material has a hardness that is second only to diamond?
Cubic boron nitride
Multiple-spindle screw machines:
Cut multiple workpieces with multiple tools.
Swiss-type screw machines:
Cut workpieces with tools in the radial orientation.
Which of the following is an outer diameter cutting operation?
Cutoff
What operations use the end flank of rectangular tools to cut the workpiece rather than the cutting edge and side flank used to cut in most turning applications?
Cutoff and grooving
Clothing made from duck fabric protects workers from what?
Cuts
A multiple-spindle screw machine:
Cuts several workpieces simultaneously.
What process removes bits of unwanted metal in the form of chips to form and shape parts?
Cutting
When used, the character in the eighth position of the ANSI insert number indicates information about which part of the insert?
Cutting edge
What factor can increase the possibility of eye contact with cutting fluids?
Cutting fluids applied with a high-pressure jet.
What often increases as feed rates increase?
Cutting forces and vibration
What effect do positive rake angles generally have on a cutting operation?
Cutting forces are decreased, but the cutting edge is weakened.
What are the two most common categories of cutting fluids?
Cutting oils and water-miscible fluids
Which type of line is indicated in the drawing?
Cutting plane line
Which term describes the speed of a workpiece past a cutting tool?
Cutting speed
What actions should an operator take if cutting tools are wearing away excessively during a production run? An operator should first try reducing:
Cutting speed and then try reducing feed rates.
What two factors determine cutting speed? Operators determine cutting speed using spindle rpm and:
Cutting tool diameter
Who produces the optimal speed and feed selection charts?
Cutting tool manufacturers
When should employees wear an air-supplied respirator? Employees should wear an air-supplied respirator when the atmosphere inside the space:
Does not contain enough oxygen.
Which variables would likely characterize a HSM operation?
DOC = 0.01 in., feed = 400 ipm, spindle speed = 10,000 rpm.
How often should slings and their attachments and fastenings be inspected?
Daily
How should a band saw operator set the feed rate for round or irregularly-shaped workpieces? The feed rate should:
Decrease at the widest point.
Which of the following is a risk when using hearing protection? Using hearing protection may:
Decrease the chances of a worker hearing sounds that ensure proper machine operation.
How does a positive axial rake angle affect a milling operation? A positive axial rake angle:
Decreases cutting edge strength.
What adjustment can improve surface finish for a grooving operation on the lathe?
Decreasing feed rates
What term describes a drill flexing under pressure and sliding off-center from the hole?
Deflection
Where on a workpiece are shear forces introduced? The cutting process introduces shearing forces at the:
Deformation boundary.
How do the dimensions specified on a print differ for through and blind holes? Unlike through holes, blind holes include a:
Depth dimension
What lathe cutting variable describes how far the cutting tool penetrates the workpiece surface?
Depth of cut
What variable describes the distance between the original workpiece surface and the newly machined workpiece surface?
Depth of cut
Which cutting variable is the least adjustable since it is usually determined by workpiece dimensions?
Depth of cut
What condition that may arise from cutting fluid exposure causes an itchy, burning rash that may lead to scarring?
Dermatitis
What is the ANSI B212.4-1995 standard? The ANSI B212.4-1995 standard:
Describes the identification system for indexable inserts used in the U.S.
Which of the following cleaning fluids should be used to clean a respirator?
Detergent and disinfectant
What is the main purpose of calibration? Calibration:
Determines an instrument's accuracy in relation to a standard.
Which of the following is true about gaging? Gaging:
Determines if a measurement is either acceptable or unacceptable.
What device can an operator use to check mill head alignment?
Dial indicator
What insert shape is most commonly available with 80°, 55°, and 35° included angles?
Diamond
Which material creates the hardest available tools with excellent wear resistance?
Diamond
Which mill component measures worktable movements as small as 0.0001 in. (0.0025 mm)?
Digital readout
Which of the following is a thin, solid line with arrows on each end that indicates a part feature's measurement on a metal cutting print?
Dimension line
What generally forms when machining a hard or brittle workpiece?
Discontinuous chips
What type of chips are likely to be produced by a hard, brittle metal such as cast iron?
Discontinuous chips
What is one of the rights that OSHA grants to employers? Employers can:
Dispute compliance inspection results.
An employee is following the typical minimal lockout procedure and just locked out the energy isolating device. What is the next step in a typical minimal lockout procedure?
Dissipate or restrain any stored or potential energy.
How can fires be prevented? Fires can be prevented by:
Distancing flammable liquid storage sites from heat and sparks.
What is the last step in a hazard assessment?
Document the hazard assessment.
Which of the following describes one resource an operator might consult to find information on selecting the right cutting variables?
Documentation from the tool material manufacturer.
What milling geometry sets inserts so that they tilt away from a line parallel to the axis of the cutter axially and twist toward the center of the mill radially?
Double positive geometry
What object is threaded through the top of the mill head to secure toolholders?
Drawbar
Pulling bar stock through a die opening to reduce its diameter and refine its surface is called:
Drawing.
What cutting tool for the mill includes helical flutes and a pointed cutting tip?
Drill
Which application would most likely use a lower feed rate? A lower feed rate would be used when:
Drilling a large or deep hole.
What fluid application method involves a machinist using a brush to manually apply fluid?
Drip method
What cutting method is always used to cut cast iron but often requires reduced cutting speed?
Dry machining
Which statement best describes a metal's mechanical properties?
Ductility describes how much a metal can be stretched without breaking.
Why is it important to correctly identify the specific type wear on a tool? It is important to correctly identify the specific type of wear on a tool because:
Each type of tool wear requires a different corrective action.
Which type of ear protection covers the full ear?
Earmuffs
Which tool do machinists use to accurately locate a hole before a drilling operation?
Edge finder
Which choice is the most common advantage of hard turning? Hard turning:
Eliminates the need to use one or more heat treatment or grinding steps in the process.
What document details strategies for dealing with any workplace crisis?
Emergency action plan
Which of the following is a factor that can increase or decrease the risks of environmental hazards?
Employee's physical condition
Which scenario accurately reflects employee involvement during an onsite inspection?
Employees may request a separate closing conference without the employer present.
Who is responsible for obtaining hearing protection for employees?
Employer
Who is responsible for ensuring that equipment is properly labeled?
Employers
Which of the following does OSHA require for written respiratory protection programs?
Employers must write worksite-specific procedures for using respirators.
Which of the following is a safeguard that separates areas with the potential for arc flash?
Enclosure
What angle measures the tilt of the end flank in relationship to the workpiece centerline?
End cutting edge angle
What part of a single-point tool is set facing away from the cut, sometimes trailing over the newly machined workpiece?
End flank
When milling a groove in the underside of a rectangular workpiece, what cutting tool should an operator use for finishing the groove walls?
End mill
Which type of milling cutter has one or more helical flutes on its surface?
End mill
Which system of measurement uses the units inches, feet, and gallons?
English System
What benchwork operation would a machinist use to create a serial number on a part surface?
Engraving
Compared to pure metals, alloys usually possess which of the following?
Enhanced properties
What is the purpose of boring on the lathe?
Enlarging an existing hole.
According to OSHA, what is a fundamental step in storing flammable and combustible liquids safely?
Ensure that all containers and storage facilities are ventilated.
Which of the following items document confined space pre-entry preparations and safety?
Entry permit
Which member of a permit space entry team ensures that entry operations remain consistent with the permit?
Entry supervisor
Which of the following is a common cause of arc flash?
Equipment failure
Employers are responsible for which of the following activities? When working with various lifting devices, employers must:
Establish a preventative maintenance program.
What is the purpose of OSHA? OSHA is the agency that:
Establishes workplace safety standards in the U.S.
What is the safest emergency response plan for the majority of workplace fires?
Evacuate everyone from the building immediately.
Why are split-ball gages unable to detect out of round conditions? Split-ball gages:
Expand to contact the highest points in the hole.
What does an arc flash boundary define? An arc flash boundary defines the place where an employee would:
Experience second degree burns.
Which term describes the maximum volumes and durations workers may be safely exposed to hazards?
Exposure limits
Which of the following statements about tool life is true?
Extending tool life should be balanced with optimizing production rates.
Which of the following lines visually connect a dimension line to the feature it indicates?
Extension line
What type of metals pose difficulties to a machining operation because they tend to tear during the cutting process as chips form?
Extremely soft and ductile metals.
Which statement about metal extrusion is true?
Extrusion typically creates long pieces with uniform profiles.
Which lifting accessory features lifting eyes with threads that securely fasten to the load being lifted?
Eyebolts
What type of milling cutter is generally used to remove material from wide, flat surfaces?
Face mill
What type of milling creates a broad, flat surface, and is generally used to perform roughing cuts?
Face milling
Which type of PPE protects against dust or splashes but not impacts?
Face shields
What is the purpose of a floor plan? A floor plan:
Facilitates effective evacuation in an emergency.
Which OD operation cuts material from the end of a workpiece?
Facing
Which list contains only outer-diameter operations?
Facing, form turning, taper turning.
How would OSHA classify a missing handrail? A missing handrail is a:
Fall hazard
What safety hazards are associated with cutting fluid?
Fall hazards
Which statement is true regarding OSHA-approved flammable storage rooms? Flammable storage rooms must:
Feature self-closing fire doors at openings.
What cutting variable describes the rate that the cutting tool moves during one rotation of the spindle?
Feed
What component of a drill press moves the spindle and tool up and down?
Feed handle
What feed rate measurement determines chip thickness and manages heat?
Feed per tooth
Squaring which two sides of a rectangular workpiece requires the operator to re-orient the workpiece vertically in the vise?
Fifth and sixth
Which benchwork operation uses abrasion to smooth and shape a workpiece?
Filing
How does an inspector inspect threads using a screw pitch gage? The inspector must:
Find the corresponding pitch and place it on the threads.
What type of cut brings a part to within its required tolerance?
Finishing
What type of fire extinguisher also acts as a fire detector and alarm to alert occupants?
Fire extinguishing system
Which of the following is a characteristic of a well-organized worksite?
Fire shields put up to protect bystanders from flying debris.
What is the difference between the appearance of ID and OD toolholders?
ID toolholders are longer and round, OD toolholders are not.
Which best describes AISI-SAE designations? The AISI-SAE system:
Identifies a steel's alloying elements and carbon content.
How does an object line function in a blueprint? An object line:
Identifies the shape and size of a part as it appears in each view.
What does qualitative fit testing assess?
If the wearer can detect certain odors while wearing a respirator
How must atmospheres lacking oxygen or with unknown contents be classified and treated? These atmospheres must be classified as:
Immediately dangerous to life and health.
Which of the following is a duty of the authorized entrant for a permit space? The authorized entrant should:
Immediately exit the space when a prohibited condition exists.
What statement is true of implementing an ergonomics program in the workplace? Ergonomics programs:
Improve productivity by reducing sick time and turnover.
What is the primary purpose of using an insert with a parallel land? Parallel lands:
Improve surface finish quality.
Proper balancing of HSM toolholders and tools is necessary because it:
Improves surface finish.
Which is a common challenge of hard turning?
In many cases, hard turning cannot meet the fine finishes characteristic of grinding.
What are unilateral tolerances? Unilateral tolerances specify the acceptable measurements:
In one direction from a given dimension.
What type of cutting fluid cannot be mixed with water, contains sulfur that remains attached to the fluid, and is primarily used to lubricate?
Inactive cutting oil
What variable are arc ratings based on?
Incident energy
Which quality makes a device capable of lockout? To be to be locked out, a device must:
Include a hasp or other part to which a lock could be attached.
What statement accurately describes a flammable and combustible liquid safety plan? A flammable and combustible liquid safety plan:
Includes conducting employee training and hazard communication.
What is an advantage of a modular drill? Modular drills:
Increase production speed because they have easily replaceable drill points.
How do cold working and case hardening improve machinability? Cold working and case hardening:
Increase surface hardness and create a built-in shear region.
How can operators adjust a cutting operation to prevent rapid flank wear? Operators can:
Increase the clearance angle.
The deflection of the tool during ID operations is mostly due to:
Increased boring bar length.
What type of cutting variables should a machinist select for a closely toleranced part requiring an above-average surface finish?
Increased speed and less aggressive feed
How does a large web affect a drilling operation? A large web:
Increases a drill's thrust tolerance.
How does workpiece diameter affect sfm when rpm is constant? The sfm:
Increases as workpiece diameter increases.
How does increasing the drill point angle affect a drilling operation? Increasing the drill point angle:
Increases cutting edge strength while cutting edge length decreases.
What type of chuck has jaws that can be tightened or loosened one at a time?
Independent chuck
Which of the following cutting tools do machinists most commonly use for turning operations on an engine lathe?
Indexable inserts
How do telescoping gages perform and report measurement? Telescoping gages report measurement:
Indirectly through comparison.
Who develops PPE design standards?
Industrial professional groups
Which of the following is one of the ways that chemical exposure can occur?
Inhalation
What alphanumeric label indicates insert features such as shape and thickness?
Insert number
What is used to describe the size, thickness, and shape of an indexable cutting tool?
Insert number
Which type of sling is recommended for lifting hot or sharp objects and assists users in balancing loads?
Metal mesh slings
Which type of foot and leg protection protects the upper portion of the foot from impacts and crushing?
Metatarsal guards
What device prevents an engine lathe's carriage from running into the chuck during turning operations?
Micrometer stop
What device prevents the carriage from running into the chuck during operation?
Micrometer stop
What cutting fluid contaminants can cause skin and lung irritation and lead to long-term illness?
Microorganisms
Which amplifies waves in the ear canal?
Middle ear
What type of machine uses a rotating, multi-point cutter that can create contours and complex features?
Mill
What term describes the positioning of a milling tool and its cutting edges?
Milling geometry
Which statement about overhang and rigidity is true?
Minimizing overhang increases machine rigidity and cutting accuracy.
What is the measured distance between the roots on opposite sides of an OD thread?
Minor diameter
Which cutting fluid application method sprays both air and cutting fluid onto the tool and workpiece?
Mist cooling
What are described as being small, different-sized liquid particles that can be inhaled or contacted through the skin and eyes?
Mists
When must employers review and update an arc flash risk assessment? Employers must update an arc flash risk assessment when:
Modifications are made to the electrical system.
An operator working on an operation involving particularly high pressures would likely use which of the following cermet material types?
Molybdenum carbide
Which sentence is true about the physical properties of metals?
Most metals transfer thermal energy easily, which makes them good heat conductors.
Which is NOT required for successful implementation of HSM?
Moving away from proofing a program into production.
How should an operator determine the Z axis depth for the tool when countersinking?
Multiply the screw head diameter by the factor for the countersink angle.
What negative consequence can be caused by poor body positioning and poor posture? Poor body positioning and poor posture can lead to:
Muscle strain that can lead to musculoskeletal disorders.
What does the letter "R" signify if it appears in the ninth position of an ANSI insert number? The letter "R" indicates the insert:
Must be used to make right-handed cuts.
Which statement best describes OSHA training requirements for employers? Employers:
Must retrain employees any time they fail to properly use PPE.
Which of the following is a duty of a permit space rescue team? The rescue team:
Must train in cardiopulmonary resuscitation.
What ISO system carbide grades ideal suited for machining nonferrous metals and nonferrous metal alloys?
N grades
Which organization publishes a standard that tells employees what to do to stay safe from arc flash?
NFPA
What results from positioning the cutting tool tip below the centerline for facing operations? This tool position will produce a:
Nib at the center.
Which of the following materials is hard enough to require the use of an advanced tool material?
Nickel-based superalloy
What does a number in the seventh position of an ANSI identification number signify?
Nose radius
What insert feature indicates the roundness of an insert at its cutting point?
Nose radius
In addition to the drawing and the dimensions, what other basic element is found in all blueprints?
Notes
What is the final step in a typical minimal lockout procedure to restore equipment to service?
Notify affected employees that maintenance is complete and the machine is ready for use.
What does tpi (tpm) measure?
Number of teeth per inch (millimeter)
Choose the best description of high-speed machining. High-speed machining involves:
Numerous, light cuts at high speeds.
Which organization's primary purpose is to help employers reduce injuries, illnesses, and deaths in the workplace?
OSHA
Which of the following is a primary purpose of safeguarding walking and working surfaces? One of the primary purposes of safeguarding walking and working surfaces is to help prevent:
Objects falling from raised platforms onto workers below.
Which is true about wall holes?
Objects may fall through wall holes.
What should the employer do if a confined space has a potentially hazardous atmosphere?
Obtain a permit before allowing entry.
Which statement is true? Sheet metal shearing:
Occurs only when the shear force overcomes the material.
Which of the following is true regarding chronic exposure? Chronic exposure:
Occurs repeatedly over a lengthy duration.
Which insert shape is characterized by its excellent edge strength, second only to round inserts, and the fact that it must be used at a positive lead angle?
Octagon
Which of the following poses the greatest fire hazard?
Oily rags placed in an open container
What type of hole condition does the illustration demonstrate?
Ovality
Which lifting device has movable bridges?
Overhead crane
Which of the following is an example of a common workplace fire hazard?
Overloaded electrical circuits
Which criteria does OSHA require when multiple PPE items are worn together?
PPE items worn together must be compatible with each other.
When squaring the long sides of a rectangular workpiece, what should be used to ensure the top surface rests above the vise?
Parallels
What refers to the starting point of X, Y, and Z mill coordinates for each given workpiece?
Part zero
Which of the following is a requirement for employees who must wear PPE?
Participate in PPE training.
What is one of the employee safety requirements that OSHA requires employers to meet? To keep employees safe, employers must:
Pay for and provide necessary PPE.
When are large built-up edges (BUE) most likely to form on a cutting tool? Large BUEs are most likely to form when:
Performing severe machining operations.
Which statement is true about frequent and periodic inspections?
Periodic inspections target items such as bolts, rivets, and bearings.
What are the two primary cutting edges on a milling cutter?
Peripheral and face cutting edges
What safety gear, including safety goggles and respirators, helps keep operators safe when working with cutting fluids?
Personal protective equipment (PPE)
In which hazard category do excessive noise, vibration, and intense temperatures belong?
Physical hazards
What high-speed steel (HSS) treatment process allows evaporated material to condense and solidify on a tool's surface?
Physical vapor deposition
What does a thread micrometer measure?
Pitch diameter
Which of the following is a thread ring gage used to check?
Pitch diameter
Which list includes all thread requirements needed for System 22?
Pitch diameter and functional diameter
According to OSHA, what would be the safest way to store flammable liquids?
Place quantities larger than 25 gallons in an approved storage room.
What tool material loses its hardness at modest cutting temperatures and requires very low cutting speeds?
Plain carbon steel
Which type of steel contains less than 3% of elements other than iron and carbon?
Plain carbon steel
Which milling cutter is held on the arbor of a horizontal milling machine?
Plain mill
What is the last priority for OSHA compliance inspections? The last priority for OSHA inspections is:
Planned or programmed routine inspections.
Under OSHA's compliance program, what do compliance officers have the right to do? Compliance officers have the right to:
Privately question any employer, owner, or employee.
Which is true about measurements in manufacturing?
Products will not fit properly if they do not meet their necessary specifications.
Which of the following statements about CNC speeds and feeds is true? A CNC machine's speed and feed rates are:
Programmed prior to the start of any cutting operation.
What is the mostly commonly used type of hand and arm PPE?
Protective gloves
What is the purpose of PPE? PPE:
Protects employees from hazards that cannot be eliminated or controlled.
Which statement best explains a reference dimension? Reference dimensions:
Provide auxiliary, non-crucial information about the part.
Which of the following is a requirement of a permit space entry program? The employer must:
Provide employees with necessary PPE.
Which statement accurately describes the difference between machining with solid tools over indexable inserts? Compared to indexable inserts, solid tools:
Provide more accurate cuts and are better for machining parts requiring close tolerances.
Why is double negative geometry the best choice for metals hard metals? Double negative geometry:
Provides the greatest cutting edge strength.
How do cutting fluids reduce heat? Cutting fluids reduce heat by:
Providing lubrication and carrying heat away from the cutting area.
During internal threading, what should a lathe operator do once the cutting tool reaches the required threaded length in the hole?
Quickly move the cutting tool away from the thread toward the workpiece axis and back out of the hole.
Why is high-speed machining being used by the aerospace industry? HSM:
Quickly produces thin-walled parts with large cavities.
What two mill head controls are used to automatically adjust spindle feed?
Quill feed selector and power feed engagement crank
Which angle measures how far the face cutting edge twists toward or away from the center axis of a milling cutter?
Radial rake angle
Which of the following measurements is necessary to locate part zero using an edge finder? Operators must measure the pin's:
Radius
What is a thread? A thread is a:
Raised, helical rib.
What tooth set has a three-tooth sequence of left, right, and straight teeth?
Raker
Which type of errors occur erratically?
Random errors
Why is high-speed machining being used by the die and mold making industry? HSM:
Rapidly machines harder metals and leaves an excellent surface finish.
What is the combination of dosage and duration called?
Rate of exposure
Which tests are performed on new and modified cranes prior to operation?
Rated load tests
What holemaking operation first requires a drilling operation using a drill that is precisely 0.007-0.018 in. (0.178-0.457 mm) smaller than the final hole diameter?
Reaming
What holemaking operation uses a multi-point tool to enlarge a hole to an accurate tolerance with an improved surface finish?
Reaming
What type of holemaking operation is used to finish the interior of a hole and bring its diameter to the final size?
Reaming
Which ID operation is used to create a smooth finish on a workpiece interior?
Reaming
Which statement is true about OSHA's requirements for employees who need respirators? Employees who require respirators must:
Receive comprehensive, understandable training before wearing one.
What lockout/tagout training is required for authorized employees? Authorized employees must be trained to:
Recognize hazardous energy sources, understand their risks, and perform energy-control procedures.
What is the most likely factor that would motivate a company to retrofit a machine tool for HSM?
Reduced costs for equipment.
What is the key advantage that high-speed machining can provide? High-speed machining:
Reduces the number of steps used to make a part.
Which of the following describes an effective administrative control?
Reducing the time employees spend near noisy equipment.
In HSM, higher spindle speeds often require what type of adjustment?
Reducing torque.
Why do operators use digital readout in manual milling? Operators use readout to:
Reference part features.
What determines if a milling machine is classified as vertical or horizontal? A milling machine is considered vertical or horizontal based on the orientation of its:
Spindle
What part of the mill holds and rotates the cutting tool?
Spindle
Where do operators attach chucks to a lathe?
Spindle
How should operators align the cutting tool when performing setup on a lathe? Operators should position the cutting tool tip at the same height as the:
Spindle centerline
Which variable does the micrometer adjustment nut control?
Spindle depth
Which variable do the forward-reverse switch and hi-neutral-lo lever control?
Spindle rotational direction
Which example would qualify as a recordable incident? It is considered a recordable incident if an employee:
Sprains his or her wrist and must perform modified tasks until it heals.
What insert shape has four or eight available cutting edges and balances edge strength with a reduced risk of chatter?
Square
What is the third step involved in properly using a portable fire extinguisher?
Squeeze the handle.
Which type of steel is extremely corrosion resistant due to high levels of chromium?
Stainless steel
Which floor openings should be guarded with railing with a rise between 30 and 34 inches (76.2 and 86.36 cm.)?
Stairways
What is the master from which other measurements are judged?
Standard
What tooth form describes evenly spaced teeth, deep gullets, and zero-degree rake angles?
Standard
What type of vise can only move its movable jaw?
Standard vise
What must an inspector do to inspect threads with a metal rule? The inspector must:
Start the measurement in the root of the thread.
What risk is posed by moving a flammable liquid through a pipe or opening at or above its flash point?
Static electricity may ignite the liquid's vapors.
Which toolholder holds up to four cutting tools for use in a single operation?
Station toolholder
What are the two main categories of ferrous metals?
Steel and cast iron.
Which of the following tapers is considered "self-releasing"?
Steep
Which cutting tool material is typically made from cobalt, chromium, and tungsten and is harder than high-speed steel (HSS) but not as hard as carbide?
Stellite
What type of collet must operators machine to exactly fit a workpiece?
Step collet
What safety procedure should employees use if their clothing or hair catches fire?
Stop, drop, and roll
Which of the following flammable liquid storage options should include a three-point lock system?
Storage cabinet
What properties decrease as general machinability increases?
Strength and hardness
What is true about band saw blades? Band saw blades must be:
Strong enough to resist compression but flexible enough to curve around wheels.
Which cutting oil is well-suited for machining tough, ductile metals?
Sulfurized mineral oil
Which alloys are highly complex, proprietary metals often used in jet engines?
Superalloys
When setting up a vise, what device might operators use to expose more of the workpiece?
Support
What is the purpose of the tailstock on a lathe?
Supporting the opposite end of long workpieces.
What part feature do engineers indicate on a print using a checkmark symbol?
Surface finish
On what is a height gage usually mounted?
Surface plate
Which list contains only lathes?
Swiss-type screw machine, CNC turning center, vertical turning machine, multiple-spindle screw machine.
How are part dimensions found on a blueprint?
The dimensions are listed with the features they indicate.
What is the lead of a thread?
The distance that a screw travels in one revolution.
What does ipr (mm/rev) measure?
The distance the tool feeds along the workpiece during one spindle revolution.
Who is responsible for providing training on the proper handling and storage of flammable/combustible liquids?
The employer.
Which area indicates the type of steel in AISI-SAE alloy steel classifications?
The first two numbers.
How does an inspector measure a part with an instrument of known accuracy?
The instrument should match the dimensions on a gage block before part measurement is taken.
Which of the following is a cause of confined space hazards?
The material stored or used in a confined space.
What is a key disadvantage of using the mating part as a gage?
The mating part can wear over time.
What is the swing of a lathe?
The maximum diameter of workpiece that can be rotated on the lathe.
What is the purpose of a guard on a tool? A guard protects:
The operator from contact with the point of operation.
What is the crest of a thread?
The peak or top of the thread
Which statement about the attaching of tagout devices is true?
The person who attaches the tag should be the person who removes the tag.
What does speed measure? Speed measures:
The rate of movement of an object.
Which statement about coolant and the type of cut is true?
The relative heating and cooling associated with interrupted cutting can cause thermal shock and insert breakage.
Which of the following is an example of pinch back?
The sides of the newly cut groove closing over the blade.
What measurement does a plug gage determine is within tolerance?
The size of a hole
What does a single number in the fifth position of the ANSI insert number indicate?
The size of the inscribed circle.
What tools would a machinist use to lay out a 110° angle on a workpiece surface?
The steel rule and protractor head of a combination set
What does area measure? Area measures:
The two-dimensional space contained within an enclosed flat surface.
What is error? Error is:
The variation an inspector should try to eliminate.
Which statement about the white layer is true?
The white layer is caused by dull inserts and can be predicted by monitoring insert wear.
During a turning operation:
The workpiece is rotated while a single-point cutting tool is dragged along its surface.
What information are employers required to report to OSHA within eight hours? Employers must notify OSHA within eight hours if:
There is an employee fatality.
What type of tool wear creates fissures perpendicular to the cutting edge of a tool?
Thermal cracking
Why are carbide cutting tools a popular choice for many metal cutting operations? Carbide tools are a popular choice because:
They provide a good balance between service life, affordability, and finished part quality.
What does the gage of a blade measure? Blade gage measures the:
Thickness of the blade back from side to side.
How should chips appear if band saw speed and feed settings are set correctly?
Thin, warm, silvery, and curled
How does high shear plane angle affect chip formation? High shear plane angle creates:
Thinner, curled chips and raises cutting efficiency.
Other than finishing, which step in milling a rectangular workpiece achieves the final height and width? To achieve the final workpiece height and width, square the:
Third and fourth surfaces.
Which type of spindle nose can cause the chuck to unscrew and fly off the machine when a machinist reverses the spindle direction?
Threaded spindle nose
Which engine lathe component precisely sets the leadscrew and carriage positions in relation to the workpiece?
Threading dial
What amount of contact is required to report an out-of-round condition?
Three-point contact
Which statement about cost and tolerance is true?
Tight tolerances increase the cost of parts.
What part of the saw blade tooth performs the cutting action?
Tip
Which system uses a prefix and five digits to identify both ferrous and nonferrous metals?
UNS
What is the range in which the true value is expected to lie?
Uncertainty
What thread standard usually includes information about a thread's series, class, and type?
Unified Thread Standard (UTS)
What type of tolerance specifies a measurement range that is either larger or smaller than the given dimension?
Unilateral tolerance
To operate a machine tool safely, which should be performed?
Untangle power cords or cables and check for wear.
What method can be used to convert length measurements between English and Metric?
Use a digital instrument that automatically displays units of measurement.
Which of the following precautions can help prevent injury from repetition, force, or vibration?
Use an appropriate tool while assuming a straight stance.
What makes a screw machine different from other types of lathes? A screw machine:
Uses automated processes to make numerous parts from long bar stock.
What type of inspection device determines actual part dimensions?
Variable Inspection Tools
What term describes an employer's exception or allowed deviation from an OSHA standard?
Variance
Which of the following is considered an engineering control?
Ventilation systems
If a machine must be locked out and tagged out over the course of multiple shifts, what is the correct lockout/tagout procedure? When lockout/tagout carries over into more than one shift, incoming authorized employees must:
Verify that the machine has been de-energized.
What type of lathe was developed to turn particularly large or heavy workpieces?
Vertical lathe
What ergonomic hazard may be posed by a hand-held grinder and can cause numbness and irritation to nerves, blood vessels, and other body parts?
Vibration
What is the most common type of workholding device for the mill?
Vise
What is the most common workholding device used on the mill?
Vise
What devices can be used to dispose of flammable and combustible liquids?
Waste drums and safety disposal cans
Which statement about fire control is true?
Water used to fight fires can react violently with some chemicals.
What type of surface texture is made up of repeating widely spaced irregularities?
Waviness
What lathe component allows the carriage to slide into position?
Ways
What cutting issues can occur if relief or clearance angles are made too large?
Weakened cutting edges and chatter
Which of the following statements about chip control is true?
Wear gloves to protect hands from hot or sharp chips.
What tool defect develops as flank wear occurs?
Wear land
If employees cannot be physically moved away from a hazard, what is the next step that should be taken to minimize hazard exposure?
Wearing personal protective equipment.
What measures the effect of gravity on an object?
Weight
Which statement is true of ergonomics?
What is ergonomically sound for one employee may be a safety risk for another.
Which statement about the use of coolant is true?
When chips are not large enough to carry the heat away from the cut, coolant may be necessary.
What insert feature is a specialized cutting edge with a long parallel land designed to improve surface finish?
Wiper
What was one of the effects of the creation of OSHA? After the establishment of OSHA:
Work-related fatalities dropped from 14,000 to 4,500 per year.
What does a blueprint help an operator select in order to complete engine lathe setup?
Workholding device
