Midterm
A riser in casting is described by...
- Metal that is not part of the casting - Source of molten metal to feed the casting and compensate for shrinkage during solidification - Waste metal that is usually recycled
What features and terms are associated with BATCH PRODUCTION?
-Medium quantity production -Setup time between batches is a disadvantage
A production planning and control department accomplish what?
-Orders materials and purchased parts -Schedules the order of products on a machine
1. In a turning operation, the change in diameter of the workpart is equal to which one of the following
2x depth of cut
9. Which one of the following metals would usually have the lowest specific energy in a machining operation
Aluminum
2. A lathe can be used to perform which of the following machining operations
Boring, Drilling, and Turning
Products purchased by companies to produce products or provide services are called...
Capital goods
Cupolas are furnaces used to melt what type of metals?
Cast iron
What casting metal is most important commercially?
Cast iron
In casting processes, a runner is...
Channel in the mold leading from the downsprue to the main mold cavity
In a GO/NO GO gage, what best describes the function of the GO gage?
Checks the maximum material condition
The empirical relationship that determines total solidification time in casting is known as...
Chvorinov's rule
The upper half of a sand-casting mold is called...
Cope
The internal surfaces of a casting are determined during the casting process by means of...
Core
10. Which one of the following cutting conditions has the strongest effect on cutting temperature
Cutting speed
8. In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut corresponds to which one of the following cutting conditions in turning
Depth of cut
Sand casting is what type of casting processes?
Expandable mold
5. With which one of the following geometric forms is the turning operation most closely associated
External cylinder
In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity. True or False?
False
What qualifies as a precision-casting process?
Investment casting and Plaster-mold casting
3. A facing operation is normally performed on which one of the following machine tools
Lathe
The pattern that determines the geometry of the casting in expendable mold processes is usually made...
Oversized
An outside micrometer is appropriate for measuring...
Part length and Shaft diameter
What is a type of machine used to perform extrusion?
Press
Particulate processing of metals involves...
Pressing and sintering
Precision is...
The degree of repeatability in the measurement process
Accuracy is...
The degree to which the measured value agrees with the true value of the quantity of interest
The term PLANT CAPACITY refers to what?
The maximum rate of production that a factory can achieve under assumed labor manning levels, hours of operation per week, and other operating conditions
Total solidification time is...
Time between pouring and complete solidification
A tolerance is...
Total permissible variation from a specified dimension
4. Boring and reaming share the common feature that they are both used to enlarge an existing hole
True
5. The twist drill is the most common type of drill bit
True
4. A lathe is used to perform which one of the following manufacturing operations
Turning
6. A single-point cutting tool is used for which one of the following operations
Turning
The expanded polystyrene casting process uses...
a mold of sand packed around a polystyrene foam pattern that vaporizes when the molten metal is poured into the mold
9. A broaching operation is best described by which one of the following
a tool with multiple teeth moves linearly past a stationary workpart
3. Of the following cutting conditions, which one has the greatest effect on tool wear
cutting speed
4. As an alloying ingredient in high-speed steel, tungsten serves which of the following functions
forms hard carbides to resist abrasion, increases hot hardness
2. The basic Taylor tool life equation defines the relationship between which two of the following variables
tool life, cutting speed
8. Chip breakers are frequently used with single-point tools. They work by forcing the chips to curl more tightly than they would naturally be inclined to curl, thus causing them to fracture
true
According to the empirical relationship in the previous question, total solidification time is proportional to what quantities?
(V/A)^2
5. Which of the following is not a common ingredient in cemented carbide cutting tools
(a) Al2O3, (c) CrC,
7. Which of the following processes are used to provide very thin coatings on the surface of coated carbide inserts
(a) chemical vapor deposition,(c) physical vapor deposition
7. A tap is a cutting tool used to create which one of the following geometries
) internal threads
6. Steel-cutting grades of cemented carbide are typically characterized by which of the following ingredients
): (a) Co,(e) TiC, and (f) WC?
8. Reaming is used for which of the following functions
, (c) enlarge a drilled hole, (d) improve surface finish on a hole, (e) improve tolerance on hole diameter
What are advantages of die casting over sand casting?
- Better surface finish - closer tolerances - Higher production rates - mold can be reused
Surface texture includes what characteristics of a surface?
- Deviations from the nominal surface - Feed marks of the tool that produced the surface - Surface cracks
What casting processes are expendable mold operations?
- Investment casting - Vacuum molding - Shell molding -Sand casting
6. When the drill bit in a drilling operation exits the opposite side of the work, the resulting hole is called which one of the following:
A through hole
What cost categories are considered to be variable costs rather than fixed cost?
Direct labor and work material
2. Which of the following are the three most common machining operations
Drilling, Milling, and Turning
3. Machining is noted for which of the following characteristics relative to other manufacturing processes
Good dimensional accuracy and wasteful of material
What manufacturing processes is likely to result in the best surface finish?
Grinding
1. Which of the following manufacturing processes are classified as material removal processes
Grinding and Machining
What operations are classified as material removal processes?
Grinding, Milling, and Turning
Investment casting is also known as...
Lost wax process
One of the first applications of digital computers in manufacturing was direct numerical control, which is best described as...
Mainframe computers used to remotely control machine tools in a factory
In inspection, what procedure provides more information?
Measurement
A misrun is what defect in casting?
Metal solidifies before filling the cavity
10. Gear hobbing is a special form of which one of the following machining operations
Milling
During solidification of an alloy when a mixture of solid and liquid metals is present, the solid liquid mixture is referred to as...
Mushy zone
What casting processes is the most widely used?
Sand casting
What manufacturing processes is likely to result in the worst surface finish?
Sand casting
7. The mechanism of chip formation in machining is best described by which one of the following
Shear deformation
What measurement instruments are considered to be graduated measuring devices?
Slide caliper, Steel rule, and Vernier caliper
9. Which of the following drill types would be the most likely choice to drill a hole with a 100 mm (4.0 in) diameter
Spade drill
Ferrous metals include...
Steel and Cast Iron
1. Of the three possible modes by which a cutting tool can fail during a machining operation, which one is most preferable
gradual wear
10. Which of the following are the two main functions of a cutting fluid in machining
reduce friction at the tool chip interface, (d) remove heat from the process,
