MPE Midterm
Which of the following cost categories are considered to be variable costs rather than fixed costs (2): (a) direct labor (b) equipment (c) insurance (d) maintenance (e) work material (f) research and development
(a) direct labor (e) work material
Steel-cutting grades of cemented carbide are typically characterized by which of the following ingredients (3): (a) Co (b) CrC (c) Mo (d) Ni (e) TiC (f) WC
(a) Co (e) TiC (f) WC
Which one of the following metals would usually have the lowest specific energy in a machining operation (1): (a) aluminum (b) brass (c) cast iron (d) steel
(a) aluminum
Which of the following criteria are generally recognized to indicate good machinability (4): (a) ease of chip disposal (b) good surface finish (c) high cutting temperatures (d) high power requirements (e) long tool life (f) low cutting forces (g) zero shear plane angle
(a) ease of chip disposal (b) good surface finish (e) long tool life (f) low cutting forces
An outside micrometer is appropriate for measuring which of the following (2): (a) hole depth (b) hole diameter (c) part length (d) shaft diameter (e) surface roughness
(c) part length (d) shaft diameter
Investment casting is also known by which one of the following names (1): (a) fast payback molding (b) full mold process (c) lost foam process (d) lost-pattern process (e) lost wax process
(e) lost wax process
In water jet cutting and abrasive water jet cutting, the separation between the nozzle opening and the work surface is called which one of the following (1): (a) gap (b) gap size (c) orifice (d) overcut (e) standoff distance
(e) standoff distance
The term plant capacity refers to the maximum rate of production that a factory can achieve under assumed labor manning levels, hours of operation per week, and other operating conditions (T/F)
True
Tumbling is a mass finishing method that uses a rotating barrel that contains a mixture of parts and media (T/F)
True
Ultrasonic cleaning combines chemical cleaning and mechanical agitation of the cleaning fluid to remove surface contaminants (T/F)
True
Which of the following is not a common ingredient in cemented carbide cutting tools (2): (a) Al2O3 (b) Co (c) CrC (d) TiC (e) WC
(a) Al2O3 (c) CrC
Which one of the following fuels used in flame cutting produces the highest flame temperatures (1): (a) acetylene (b) methylacetylene-propadiene (c) propane (d) propylene
(a) acetylene
In general, which of the following materials has the highest machinability (1): (a) aluminum (b) cast iron (c) copper (d) low carbon steel (e) stainless steel (f) titanium alloys (g) unhardened tool steel
(a) aluminum
With which of the following metals is anodizing most commonly associated (1): (a) aluminum (b) magnesium (c) steel (d) titanium (e) zinc
(a) aluminum
Which one of the following abrasive materials is most appropriate for grinding steel and cast iron (1): (a) aluminum oxide (b) cubic boron nitride (c) diamond (d) silicon carbide
(a) aluminum oxide
Which of the following processes involves electrochemical reactions (2): (a) anodizing (b) chromate coatings (c) electroless plating (d) electroplating (e) phosphate coatings
(a) anodizing (d) electroplating
Which of the following time components in the average production machining cycle is affected by cutting speed (2): (a) average tool change time per piece (b) part loading and unloading time (c) setup time for the machine tool (d) time the tool is engaged in cutting
(a) average tool change time per piece (d) time the tool is engaged in cutting
Which of the following are advantages of die casting over sand casting (4): (a) better surface finish (b) closer tolerances (c) higher melting temperature metals can be cast (d) higher production rates (e) larger parts can be cast (f) mold can be reused
(a) better surface finish (b) closer tolerances (d) higher production rates (f) mold can be reused
Which of the following chemicals are associated with alkaline cleaning (2): (a) borax (b) hydrochloric acid (c) propane (d) sodium hydroxide (e) sulfuric acid (f) trichlorethylene
(a) borax (d) sodium hydroxide
A lathe can be used to perform which of the following machining operations (3): (a) boring (b) broaching (c) drilling (d) milling (e) planing (f) turning
(a) boring (c) drilling (f) turning
Which one of the following operations is generally capable of the best surface finished, which means the lowest value of Ra (1): (a) broaching (b) drilling (c) end milling (d) planing (e) turning
(a) broaching
Which one of the following operations is generally capable of the closest tolerances (1): (a) broaching (b) drilling (c) end milling (d) planing (e) sawing
(a) broaching
In casting processes, a runner is which one of the following (1): (a) channel in the mold leading from the donsprue to the main mold cavity (b) worker who moves the molten metal to the mold (c) vertical channel into which molten metal is poured into the mold
(a) channel in the mold leading from the donsprue to the main mold cavity
Which of the following processes are used to provide very thin coatings on the surface of coated carbide inserts (2): (a) chemical vapor deposition (b) electroplating (c) physical vapor deposition (d) pressing and sintering (e) spray painting
(a) chemical vapor deposition (c) physical vapor deposition
The upper half of a sand-casting mold is called which one of the following (1): (a) cope (b) drag (c) flask (d) pattern
(a) cope
The internal surfaces of a casting are determined during the casting process by means of which one of the following (1): (a) core (b) gating system (c) parting line (d) patter (e) sprue
(a) core
Of the following cutting conditions, which one has the greatest effect on tool wear (1): (a) cutting speed (b) depth of cut (c) feed
(a) cutting speed
Which one of the following cutting conditions has the strongest effect on cutting temperature (1): (a) cutting speed (b) depth of cut (c) feed
(a) cutting speed
The basic Taylor tool life equation defines the relationship between which two of the following variables (2): (a) cutting speed (b) depth of cut (c) feed (d) feed rate (e) tool life (f) work material hardness
(a) cutting speed (e) tool life
Which of the following will improve surface finish in grinding (3): (a) denser wheel structure (b) higher wheel speed (c) higher work speeds (d) larger infeed (e) lower infeed (f) lower wheel speed (g) lower work speed (h) more open wheel structure
(a) denser wheel structure (b) higher wheel speed (g) lower work speed
Surface texture includes which of the following characteristics of a surface (3): (a) deviations from the nominal surface (b) feed marks of the tool that produced the surface (c) hardness variations (d) oil films (e) surface cracks
(a) deviations from the nominal surface (b) feed marks of the tool that produced the surface (e) surface cracks
The liquid used to create the discharge path between the tool and the work in electric discharge machining is called which one of the following (1): (a) dielectric fluid (b) electrolyte
(a) dielectric fluid
The metal removal rate in electric discharge machining depends on which of the following variables and properties (2): (a) discharge current (b) hardness of the work metal (c) melting temperature of the work metal (d) tensile strength of the work metal
(a) discharge current (c) melting temperature of the work metal
Disadvantages of electrochemical machining include which of the following (2): (a) disposing of the electrolyte sludge created in the process (b) high cost of electrical power (c) high tool wear (d) low metal removal rates for hard metals (e) surface damage to work
(a) disposing of the electrolyte sludge created in the process (b) high cost of electrical power
A machinability rating greater than 1.0 indicates that the work material is (1): (a) easier to machine than the base metal (b) more difficult to machine than the base metal, where the base metal has a rating = 1.0
(a) easier to machine than the base metal
Sand casting is which of the following types of casting process (1): (a) expendable mold (b) permanent mold
(a) expendable mold
With which one of the following geometric forms is the turning operation most closely associated (1): (a) external cylinder (b) flat plane (c) round hole (d) screw threads (e) sphere
(a) external cylinder
Which one of the following abrasive processes is commonly used to finish the bores of internal combustion engines (1): (a) honing (b) lapping (c) superfinishing
(a) honing
Which of the following are the usual objectives of heat treatment (3): (a) increase hardness (b) increase melting temperature (c) increase recrystallization temperature (d) reduce brittleness (e) reduce density (f) relieve stresses
(a) increase hardness (d) reduce brittleness (f) relieve stresses
The pattern that determines the geometry of the casting in expendable mold processes is usually made (1): (a) oversized (b) the same size (c) undersized relative to the dimensions of the casting
(a) oversized
Total solidification time is defined as which one of the following (1): (a) time between pouring and complete solidification (b) time between pouring and cooling to room temperature (c) time between solidification and cooling to room temperature (d) time to give up the heat of fusion
(a) time between pouring and complete solidification
In a turning operation, the change in diameter of the work part is equal to which one of the following (1): (a) 1 x depth of cut (b) 2 x depth of cut (c) 1 x feed (d) 2 x feed
(b) 2 x depth of cut
The empirical relationship that determines total solidification time in casting is known as which one of the following (1): (a) Bernoulli's theorem (b) Chvorinov's rule (c) continuity law (d) flow curve (e) Hooke's law (f) Ohm's law
(b) Chvorinov's rule
A broaching operation is best described by which one of the following (1): (a) a rotating tool moves past a stationary work part (b) a tool with multiple teeth moves linearly past a stationary work part (c) a work part is fed past a rotating cutting tool (d) a work part moves linearly past a stationary single-point tool
(b) a tool with multiple teeth moves linearly past a stationary work part
Of the following quenching media, which one produces the most rapid cooling rate (1): (a) air (b) brine (c) oil (d) pure water
(b) brine
Products purchased by companies to produce products or provide services are called which one of the following (1): (a) assembled products (b) capital goods (c) consumer goods (d) final products (e) manufactured products
(b) capital goods
Cupolas are furnaces used to melt which of the following metals (1): (a) aluminum (b) cast iron (c) steel (d) zinc
(b) cast iron
Ferrous metals include which of the following (2): (a) aluminum (b) cast iron (c) copper (d) gold (e) steel
(b) cast iron (e) steel
In a GO/NO GO gage, which one of the following best describes the function of the GO gage (1): (a) checks the limit of maximum tolerance (b) checks the maximum material condition (c) checks the maximum size (d) checks the minimum material condition (e) checks the minimum size
(b) checks the maximum material condition
Which one of the following plating metals produces the hardest surface on a metallic substrate (1): (a) cadmium (b) chromium (c) copper (d) nickel (e) tin
(b) chromium
Of the following abrasive materials, which one has the highest hardness (1): (a) aluminum oxide (b) cubic boron nitride (c) silicon carbide
(b) cubic boron nitride
Which cutting speed is always lower for a given machining operation (1): (a) cutting speed for maximum production rate (b) cutting speed for minimum cost
(b) cutting speed for minimum cost
Which of the following are the three most common machining operations (3): (a) broaching (b) drilling (c) lapping (d) milling (e) planing (f) shaping (g) turning
(b) drilling (d) milling (g) turning
The principal methods of applying powder coatings are which of the following (2): (a) brushing (b) electrostatic spraying (c) fluidized bed (d) immersion (e) roller coating
(b) electrostatic spraying (c) fluidized bed
When selecting the appropriate cutting conditions for a given machining operation, which of the following parameters should be selected before the other (1): (a) cutting speed (b) feed
(b) feed
In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut (t0) corresponds to which one of the following cutting conditions in turning (1): (a) depth of cut (b) feed f (c) speed v
(b) feed f
As an alloying ingredient in high-speed steel, tungsten serves which of the following functions (2): (a) depth hardenability during heat treatment (b) forms hard carbides to resist abrasion (c) improves strength and hardness (d) increases corrosion resistance (e) increases hot hardness (f) increases toughness
(b) forms hard carbides to resist abrasion (e) increases hot hardness
Machining is noted for which of the following characteristics relative to other manufacturing processes (2): (a) creates three-dimensional geometries (b) good dimensional accuracy (c) net shape process (d) poor surface finish (e) wasteful of energy (f) wasteful of material
(b) good dimensional accuracy (f) wasteful of material
Of the three possible modes by which a cutting tool can fail during a machining operation, which one is most preferable (1): (a) fracture failure (b) gradual wear (c) temperature failure
(b) gradual wear
Which one of the following manufacturing processes is likely to result in the best surface finish (1): (a) arc welding (b) grinding (c) machining (d) sand casting (e) sawing
(b) grinding
The time-temperature-transformation curve (TTT curve) for steel can best be described by which one of the following (1): (a) indicates how annealing is used to achieve a given desired microstructure (b) indicates how cooling rate affects the transformation of austenite into various possible phases (c) indicates how martensite is gradually transformed into tempered martensite as a function of time (d) indicates how various phases are obtained during heating as a function of time and temperature
(b) indicates how cooling rate affects the transformation of austenite into various possible phases
Which of the following qualifies as a precision-casting process (2): (a) ingot casting (b) investment casting (c) plaster-mold casting (d) sand casting (e) shell molding
(b) investment casting (c) plaster-mold casting
Which one of the following abrasive processes is commonly used in the production of glass optical lenses (1): (a) honing (b) lapping (c) superfinishing
(b) lapping
A facing operation is normally performed on which one of the following machine tools (1): (a) drill press (b) lathe (c) milling machine (d) planer (e) shaper
(b) lathe
In inspection, which procedure provides more information (1): (a) gaging (b) measurement
(b) measurement
Gear hobbing is a special form of which one of the following machining operations (1): (a) grinding (b) milling (c) planing (d) shaping (e) turning
(b) milling
Which of the following drill types would be the most likely choice to drill a hole with a 100mm diameter (1): (a) gun drill (b) spade drill (c) straight-flute drill (d) twist drill
(b) spade drill
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 (1): (a) blind hole (b) through hole
(b) through hole
Which of the following terms applies to the procedure of sharpening the grinding wheel and restoring the shape of its outside perimeter (1): (a) dressing (b) truing
(b) truing
Martensite can be best defined as which one of the following (1): (a) a mixture of ferrite and carbide phases obtained by rapid cooling of austenite (b) a mixture of ferrite and carbide phases obtained by slow cooling of austenite (c) a phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived (d) a solution of cementite in ferrite obtained by rapid cooling of austenite
(c) a phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived
Which one of the following surface-hardening treatments is the most common (1): (a) boronizing (b) carbonitriding (c) carburizing (d) chromizing (e) nitriding
(c) carburizing
Which one of the following casting metals is most important commercially (1): (a) aluminum and its alloys (b) bronze (c) cast iron (d) cast steel (e) zinc alloys
(c) cast iron
Which of the following processes use mechanical energy as the principal energy source (3): (a) electrochemical grinding (b) laser beam machining (c) conventional milling (d) ultrasonic machining (e) water jet cutting (f) wire EDM
(c) conventional milling (d) ultrasonic machining (e) water jet cutting
Reaming is used for which of the following functions (3): (a) accurately locate a hole position (b) create a stepped hole (c) enlarge a drilled hole (d) improve surface finish on a hole (e) improve tolerance on hole diameter (f) provide an internal thread
(c) enlarge a drilled hole (d) improve surface finish on a hole (e) improve tolerance on hole diameter
Which one of the following is not one of the five basic parameters of a grinding wheel (1): (a) abrasive material (b) bonding material (c) grain hardness (d) grain size (e) wheel grade (f) wheel structure
(c) grain hardness
Smaller grain size in a grinding wheel tends to (1): (a) degrade surface finish (b) have no effect on surface finish (c) improve surface finish
(c) improve surface finish
Which of the following casting processes are expendable mold operations (4): (a) centrifugal casting (b) die casting (c) investment casting (d) low pressure casting (e) sand casting (f) shell molding (g) slush casting (h) vacuum molding
(c) investment casting (e) sand casting (f) shell molding (h) vacuum molding
One of the first applications of digital computers in manufacturing was direct numerical control, which is best described by which one of the following (1): (a) computers used to count work units on a production line (b) flexible manufacturing (c) mainframe computers used to remotely control machine tools in a factory (d) personal computers used to schedule production (e) shop floor control
(c) mainframe computers used to remotely control machine tools in a factory
Which one of the following features and terms are associated with batch production (2): (a) cellular manufacturing (b) mass production (c) medium quantity production (d) production equipment is dedicated to one product (e) setup time between batches is a disadvantage
(c) medium quantity production (e) setup time between batches is a disadvantage
A misrun is which one of the following defects in casting (1): (a) globules of metal becoming entrapped in the casting (b) metal is not properly poured into the downsprue (c) metal solidifies before filling the cavity (d) microporosity (e) "pipe" formation
(c) metal solidifies before filling the cavity
A riser in casting is described by which of the following (3): (a) an insert in the casting that inhibits buoyancy of the core (b) gating system in which the sprue feeds directly into the cavity (c) metal that is not part of the casting (d) source of molten metal to feed the casting and compensate for shrinkage during solidification (e) waste metal that is usually recycled
(c) metal that is not part of the casting (d) source of molten metal to feed the casting and compensate for shrinkage during solidification (e) waste metal that is usually recycled
A production planning and control department accomplishes which of the following functions in its role of providing manufacturing support (2): (a) designs and orders machine tools (b) develops corporate strategic plans (c) orders materials and purchased parts (d) performs quality inspections (e) schedules the order of products on a machine
(c) orders materials and purchased parts (e) schedules the order of products on a machine
When annealing is performed to allow for further cold working of the part, it is called which one of the following (1): (a) full anneal (b) normalizing (c) process anneal (d) recovery anneal
(c) process anneal
Which of the following are the two main functions of a cutting fluid in machining (2): (a) improve surface finish on the work piece (b) reduce forces and power (c) reduce friction at the tool chip interface (d) remove heat from the process (e) wash away chips
(c) reduce friction at the tool chip interface (d) remove heat from the process
The mechanism of chip formation in machining is best described by which one of the following (1): (a) compression (b) fracture failure (c) shear deformation (d) tensile failure
(c) shear deformation
Which of the following are reasons why work parts must be cleaned in industry (4): (a) to avoid air pollution (b) to avoid water pollution (c) to enhance appearance (d) to enhance mechanical properties of the surface (e) to improve hygiene conditions for workers (f) to improve surface finish (g) to prepare the surface for subsequent processing (h) to remove contaminants that might chemically attack the surface
(c) to enhance appearance (e) to improve hygiene conditions for workers (g) to prepare the surface for subsequent processing (h) to remove contaminants that might chemically attack the surface
A tolerance is which one of the following (1): (a) clearance between a shaft and a mating hole (b) measurement error (c) total permissible variation from a specified dimension (d) variation in manufacturing
(c) total permissible variation from a specified dimension
A single-point cutting tool is used for which one of the following operations (1): (a) drilling (b) milling (c) turning
(c) turning
Which of the following operations are classified as material removal processes (3): (a) anodizing (b) brazing (c) forging (d) grinding (e) milling (f) sintering (g) turning
(d) grinding (e) milling (g) turning
Tempering is a heat treatment applied to hardened steels that is best defined as which of the following (1): (a) heating and soaking at a temperature above the austenitizing level followed by rapid cooling (b) heating and soaking at a temperature above the austenitizing level followed by slow cooling (c) heating and soaking at a temperature below the austenitizing level followed by rapid cooling (d) heating and soaking at a temperature below the austenitizing level followed by slow cooling
(d) heating and soaking at a temperature below the austenitizing level followed by slow cooling
A tap is a cutting tool used to create which one of the following geometries (1): (a) external threads (b) flat planar surfaces (c) holes used in beer kegs (d) internal threads (e) square holes
(d) internal threads
Which one of the following processes would be appropriate for cutting a hole of 0.075mm diameter through a plate of aluminum that is 1.6 mm thick (1): (a) abrasive jet machining (b) chemical milling (c) EDM (d) laser beam machining (e) oxyfuel cutting (f) water jet cutting (g) wire EDM
(d) laser beam machining
During solidification of an alloy when a mixture of solid and liquid metals is present, the solid liquid mixture is referred to as which one of the following (1): (a) eutectic composition (b) ingot segregation (c) liquidus (d) mushy zone (e) solidus
(d) mushy zone
Which one of the following is a type of machine used to perform extrusion (1): (a) forge hammer (b) milling machine (c) rolling mill (d) press (e) torch
(d) press
Which one of the following casting processes is the most widely used (1): (a) centrifugal casting (b) die casting (c) investment casting (d) sand casting (e) shell casting
(d) sand casting
Which one of the following manufacturing processes is likely to result in the worst surface finish (1): (a) cold rolling (b) grinding (c) machining (d) sand casting (e) sawing
(d) sand casting
Which of the following measurement instruments are considered to be graduated measuring devices (3): (a) divider (b) limit gage (c) sine bar (d) slide caliper (e) snap gage (f) steel rule (g) vernier caliper
(d) slide caliper (f) steel rule (g) vernier caliper
Which one of the following abrasive processes is capable of achieving the best surface finish (1): (a) centerless grinding (b) honing (c) lapping (d) superfinishing
(d) superfinishing
Which of the following manufacturing processes are classified as material removal processes (2): (a) casting (b) drawing (c) extrusion (d) forging (e) grinding (f) machining (g) molding (h) pressworking (i) spinning
(e) grinding (f) machining)
Which of the following processes could be used to cut a large piece of 12.7mm plate steel into two sections (2): (a) abrasive jet machining (b) chemical milling (c) EDM (d) laser beam machining (e) oxyfuel cutting (f) water jet cutting (g) wire EDM
(e) oxyfuel cutting (g) wire EDM
Of the following processes, which one is noted for the highest material removal rates (a) electric discharge machining (b) electrochemical machining (c) laser beam machining (d) oxyfuel cutting (e) plasma arc cutting (f) ultrasonic machining (g) water jet cutting
(e) plasma arc cutting
Of the various methods for testing machinability, which one of the following is the most important (1): (a) cutting forces (b) cutting temperature (c) horsepower consumed in the operation (d) surface roughness (e) tool life (f) tool wear
(e) tool life
A lathe is used to perform which one of the following manufacturing operations (1): (a) broaching (b) drilling (c) lapping (d) milling (e) turning
(e) turning
Which one of the following plating metals is associated with the term galvanizing (1): (a) iron (b) lead (c) steel (d) tin (e) zinc
(e) zinc
According to the empirical relationship in the previous question, total solidification time is proportional to which one of the following quantities (1): (a) (A/V)n (b) Hf (c) Tm (d) V (e) V/A (f) (V/A)^2
(f) (V/A)^2
Particulate processing of metals involves which two of the following steps (2): (a) adhesive bonding (b) deformation (c) forging (d) material removal (e) melting (f) pressing (g) sintering
(f) pressing (g) sintering
The treatment in which the brittleness of martensite is reduced is called which one of the following (1): (a) aging (b) annealing (c) austenitizing (d) normalizing (e) quenching (f) tempering
(f) tempering
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 (T/F)
False
In ultrasonic machining, material removal rate decreases with increasing frequency and amplitude of vibration (T/F)
False
The actual surface roughness Ra almost always has a lower value than the ideal surface roughness Ri (T/F)
False
Accuracy is the degree to which the measured value agrees with the true value of the quantity of interest (T/F)
True
Annealing consists of heating a metal to a suitable temperature, holding at that temperature for a certain time, and then slowly cooling (T/F)
True
Boring and reaming share the common feature that they are both used to enlarge an existing hole (T/F)
True
Chemical vapor deposition can be defined as the interaction between a mixture of gases and the surface of a heated substrate, causing chemical decomposition of some of the gas constituents and formation of a solid film on the substrate (T/F)
True
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 (T/F)
True
Hardenability refers to the relative capacity of a steel to be hardened by transformation to martensite (T/F)
True
Precision is the degree of repeatability in the measurement process (T/F)
True
The abrasive machining processes are generally used as finishing operations (T/F)
True
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 (T/F)
True
The twist drill is the most common type of drill bit (T/F)
True