Turning

Which of the following type of personal protective equipment (PPE) is best for turning operations: a) Safety glasses with side shields b) Steel toe work shoes with metatarsal protection c) Ear plugs d) Heat resistant gloves e) Back support vest

A

Reaming operations on a lathe require less RPM than drilling for the same diameter. The RPM for reaming is approximately _________ the RPM for drilling. a) One-third b) One-half c) Twice d) The same as e) Three times

B

The distance the carriage moves per revolution of the spindle is determined by: a) Feed reverse lever b) Quick change gear box c) Thread dial d) Clutch rod

B

The feed reverse lever will reverse the direction of the __________ and controls the direction of movement for both the _________and the __________: a) Motor, crossfeed, tailstock b) Leadscrew, crossfeed, longitudinal feed c) Back gear, headstock, tailstock d) Leadscrew, tailstock, crossfeed

B

The tailstock of the lathe is identified by the letter: a) M b) C c) R d) F

B

To machine ream a hole on the lathe, the machinist should: a) Drill a hole to the diameter specified on the print prior to reaming b) Use twice the feed rate for a drilling operation with the same diameter c) Use twice the cutting speed of a drilling operation for that same diameter d) Install the reamer in the headstock within a live center e) Let the cutting edges of the reamer rub to glaze to a finished size

B

Using the Machinery's Handbook as a reference, calculate the diameter of a shaft for an LN2 interference fit with 1.500 inch diameter hole: a) 1.5051 b) 1.5013 c) 1.4998 d) 1.4963

B

What is the angle formed by the sides of the thread for an American National thread form? a) 30° b) 60° c) 90° d) 120°

B

When calculating the RPM for a turning operation, the machinist uses _________ instead of the diameter of the tool. a) Tool nose radius b) The diameter of the work piece c) Cutter speed compensation d) Surface feet per minute

B

Which of the basic precision layout tools is used with a height gage? a) Machinist scale with a 1/100 inch resolution b) Surface plate c) Dial caliper d) One inch micrometer

B

Which of the following is not a true statement for taking the first cut on a cast iron shaft? a) Take a depth of cut that cuts below the hard casting scale on the outside surface b) Apply heavy cutting oil c) Machine the part dry d) Reduce the cutting speed by 5% - 10%

B

Which of the following is not characteristic of a parting operation? a) The parting tool must be set on center and the carriage of the lathe should be locked to the ways b) The RPM is the same as for drilling the same diameter c) The parting tool must be set square to the work piece d) The tool should always be making a chip applying a lubricant e) Diagonally ground parting tools reduce the burr

B

Which of the following is not part of a procedure for knurling? a) Mount the work piece between centers to prevent creeping b) Do not lubricate the knurling tool and work piece c) Use low RPM similar to RPM used for threading d) Use a feed of .005" to .015 inches e) Center the knurling rollers vertically

B

Which one of the following steps should not be performed when lifting heavy objects? a) Lift with the knee bent b) Lift with the arms only, keeping the back hunched c) Keep the back straight d) Keep the arms straight

B

Which one of the following types of information is not found on MSDS? a) Chemical composition b) Container size c) Flash point d) Recommended PPE

B

need diagram

B

A part can be rejected when: a) A dimension is made out of tolerance b) The wrong material is used c) The part does not follow the process flow d) The wrong revision of the print is used to make the part e) All of the above f) Only a and b

E

The size of the lathe is determined by: a) The size of the lathe centers b) Length of the bed c) The largest diameter of material capable of turning d) The highest RPM of the motor e) Only b and c f) Only a and d

E

A high-speed steel lathe tool bit has to be ground. Which characteristics of the lathe tool bit must be ground first? a) Side relief angle and the side cutting angle b) Back rake and the end relief angle c) Side rake and the side cutting angle d) Side relief angle and the side rake e) Back rake and side rake

A

Identify the best method for aligning centers when turning between centers: a) Take a trial cut and measure each end with a micrometer b) Visually align the points of the lathe centers c) Use a true bar and two dial indicators (one on each end) d) Align the largest witness marks on the tailstock

A

Identify the proper formula for determining the RPM for a turning operation: a) (CS • 3.82) / D b) D / (CS/3.82) c) (D • 3.82) / CS d) (D •CS) / 3.82

A

Identify the statement that is not characteristic of a lathe steady rest: a) The jaws on a steady rest are made of hardened tool steel b) The steady rest is clamped to the bed of the lathe and the jaws are initially clamped finger tight c) The jaws on a steady rest are soft and support long shafts d) The steady rest should not be used on rough castings

A

If the tailstock is offset in a direction away from the operator, the shaft will: a) Have a taper with the end by the tailstock being larger b) Be stepped with the larger step nearest the headstock c) Cut oversize evenly across the shaft the amount of the offset d) Have a taper with the end by the headstock being larger

A

Name the tool and process used to precisely enlarge an existing hole: a) Boring bar, boring b) Twist drill, drilling c) Counterbore, counterboring d) Parting tool, parting e) Spotfacing tool, spotfacing

A

The carriage of the lathe is identified by the letter: a) Z b) H c) A d) E

A

The compound rest is set perpendicular to the axis of the work piece (centerline of the lathe). To cut (chase) an internal right-handed thread, the compound rest must be swiveled: a) 29.5° to the left b) 29.5° to the right c) 59.5° to the right d) 59.5° to the left

A

The leadscrew of the lathe is identified by the letter: a) C b) U c) W d) L

A

The main function of the lathe half-nut lever is to facilitate: a) Threading b) Counterboring c) Taper turning d) Straight turning

A

The primary advantage of turning between centers is that: a) The work piece can be turned end for end without losing concentricity b) Each end can be total faced off in one setup c) The part is totally clamped (360° of contact) d) Chatter is reduced on long work pieces

A

Using the Machinery's Handbook as a reference, calculate the diameter of a hole for an RC1 clearance fit with a 2.000 inch diameter shaft: a) 2.0005 b) 1.9997 c) 2.0058 d) 1.9963

A

What feature of a screw thread is measured with a screw thread micrometer? a) Pitch diameter b) Minor diameter c) Helix angle d) Major diameter

A

Which of the following accessories is attached to the carriage and used to support long thin shafts? a) Follower rest b) Collet c) Faceplate, lathe centers and a lathe dog d) Steady rest

A

Which of the following statements best defines feed? a) The machine movement that causes a tool to cut into or along the surface of a work piece b) The distance the work piece moves past the tool in one minute c) The revolution of the tool per minute d) The diameter of the tool correlated to the distance the tool moves in one second

A

Which of the following statements best describes a root cause for excessive tool wear when machining a hard material? a) The RPM is set too high b) The feed is set slightly below the recommended feed rate c) The cutting tool is defective and must be replaced d) The depth of cut is too shallow and must be increased

A

A part is being turned at 250 RPM with a feed rate of .008 inches per revolution. How long will it take to make one pass if the part is 10.625 inches long? a) 4.25 minutes b) 5.30 minutes c) 1.75 minutes d) 2.10 minutes

B

An X-bar R chart is used with control charts to monitor: a) Number and type of rejects b) Variation between sample sets of parts c) Number of parts that are good and number that are bad d) The difference between the largest and smallest readings of sample set

B

Each division found on the thimble of a micrometer is equal to ________ and each division found on the sleeve is equal to ___________. a) .100, .001 b) .001, .025 c) .025, .001 d) .010, .025

B

A ____________ is used to align a single point threading tool with the work piece. a) Screw pitch gage b) Feeler gage c) Center gage e) Taper gage

C

A drilling and boring operation has to be performed on one end of a shaft measuring 3" in diameter and 25" long. Which of the following methods provides the most stable set up? a) A faceplate, lathe dog and live center (in the tailstock) b) A three jaw universal chuck, follower rest and live center (in the tailstock) c) A three jaw universal chuck and a steady rest d) Collet, follower rest, lathe dog and faceplate, dead center

C

A small tip was left on the end of the part when performing a facing operation. The root cause of this problem is: a) Setting the tool at a right angle to the facing surface with the tool on center b) Setting the tool on center c) Setting the tool slightly below center d) The end relief angle of the cutting edge is too large

C

If a small particle becomes lodged in the eye, the first step for self-imposed first aid is to: a) Rub the eye to dislodge the particle b) Use compressed air to blow out the particle c) Pull the top lid over the bottom lid to help dislodge the particle d) Pull at the outside corner of the eyelid and then at the inside corner of the eyelid to dislodge the particle

C

On most lathes, the crossfeed speed is about ___________ that of the longitudinal feed. a) Two to three times b) One eighth to one quarter c) One third to one half d) The same speed to two times

C

One factor to consider when choosing the appropriate measuring device to measure a specific feature of a part is the: a) Labor involved when measuring the part b) The expense of each measuring device capable of measuring the feature c) The tolerance of the dimension to inspect d) The skill level of the operator

C

The bed of the lathe is identified by the letter: a) X b) Q c) F d) Z

C

The compound rest is set perpendicular to the axis of the work piece (centerline of the lathe). To cut (chase) an external right-handed thread, the compound rest must be swiveled: a) 60° to the left b) 45° to the left c) 29.5° to the right d) 90.5° to the right

C

The included angle of a lathe center measures: a) 30° b) 45° c) 60° d) 75°

C

The work holding device best used to clamp round, square or irregular shaped pieces is a/an: a) Collet b) Faceplate, lathe dog, lathe center c) Independent chuck (4-jaw chuck) d) Universal chuck e) Follower rest

C

To prevent the creation of a small protrusion when performing a facing operation, the machinist must set the tool point: a) Slightly above center b) Slightly below center c) On center d) Below center with a negative side relief angle

C

Using the Machinery's Handbook as a reference, determine the tap drill diameter that will produce a 75% thread for a 3⁄4-10 American National form thread: a) 17/32 drill b) 23/32 drill c) 21/32 drill e) 19/32 drill

C

Which of the following formulas is the correct formula for determining the time to make one cut across a given distance? {T = time f = feed (IPR) L = length of cut (inches) N = spindle speed (RPM)} a) T = (fN) / L b) T = f / NL c) T = L / (fN) d) T = (Lf) / N

C

Which of the following instruments is not capable of making fine lines on a metal surface? a) Dial caliper b) Scriber c) Machinist square or a combination set scale d) Specially ground lathe tool bit with a sharp edge

C

Which of the following provides the highest level of repeatability when turning a shoulder on a work piece held in a lathe? a) Screw feed stop on the cross side b) Compound rest set perpendicular to the centerline axis of the lathe c) Compound rest set parallel to the centerline axis of the lathe d) Tailstock e) Indicol stop set on the tailstock

C

Which of the following shapes cannot be held adequately by a 3-jaw universal chuck: a) Hexagon b) Rounds c) Octagon d) All of the above e) Only a and c

C

Which of the following statements best defines cutting speed? a) Cutting speed is based on RPM and is the amount a times a tool revolves in 1 second b) Cutting speed is based on the diameter of the tool and is given in surface revolutions per minute c) Cutting speed is based on the distance the work moves past the tool based on the number of feet that passes the tool in one minute and is given in surface feet per minute d) Cutting speed is based on revolutions per diameter of the tool and is given in feet per inch

C

A trail cut was taken on the lathe. The readings on the work piece are 2.240" at the headstock end and 2.220" at the tailstock end. To align the centers, the machinist should adjust the tailstock: a) .005 inches toward the operator b) .010 inches toward the operator c) .020 inches away from the operator d) .010 inches away from the operator

D

Control charts measure the range. The range can be defined as: a) The mean of a sample set of parts b) The number of rejects for a production c) The capability index of a specific dimension d) The difference between the largest reading and smallest reading of a sample set

D

How is a feed rate designated on a lathe? a) Feet per second b) Inches per minute c) Feet per revolution d) Inches per revolution

D

Knurling is: a) A raised impression on the surface of a turned work piece b) Displacement of material and not impressions caused by a cutting action c) Usually produced with hardened rolls that create a pattern d) All of the above e) Only a and c

D

Lathe center runout in the headstock may be caused by: a) Burrs and nicks on the center sleeve or spindle b) Chips inside the spindle area that accommodates the lathe center c) The angle and centerline of the angle was ground off center from the center axis d) All of the above e) Only a and b

D

Surface finish can be checked with a profilometer or a: a) Surface plate b) Toolmakers eye loupe c) Dial indicator with .0001 resolution d) Surface finish comparison chart

D

The apron of the lathe is identified by the letter: a) M b) F c) T d) W

D

The compound rest can be rotated: a) 45° b) 180° c) 235° d) 360°

D

The feed rate is at .008 IPR. How many RPM will it take to move the tool a distance of 3.600 inches in a minute? a) 288 RPM b) 225 RPM c) 576 RPM d) 450 RPM

D

The process plan calls for a 2.5" diameter clearance fit hole. The best process plan is to: a) Center drill, drill, bore and ream b) Drill, double drill, hand ream and countersink c) Ream, bore, drill and center drill d) Center drill, double drill, bore

D

The spindle of the lathe is identified by the letter: a) K b) P c) C d) H

D

To change the RPM on a geared head lathe, the machinist must: a) Move the belt from one set of pulleys to the next set b) Engage the half nut lever to get twice the RPM of the motor c) Use the feed reverse lever and the tailstock lock lever d) Shift speed change levers and feed selection levers

D

Using the Machinery's Handbook as a reference, calculate the amount of infeed for an American Standard Unified Inch Screw thread form with 18 threads per inch. Use the following equation: P = pitch Infeed = P* .708 a) .03608 b) .04687 c) .05293 d) .03934

D

What is the RPM needed to drill a .750" hole in mild steel with a cutting speed of 100 SFM on 3.50" diameter stock (use 3.82 for the constant)? a) 262.5 RPM b) 286.5 RPM c) 123 RPM d) 509 RPM

D

What is the tap drill for a 1⁄2-14 American National Pipe thread? a) 7/16 drill b) 37/64 drill c) 27/32 drill d) 23/32 drill

D

Which of the following statements does not describe a universal chuck: a) A universal chuck can have two, three or six jaws b) All the jaws move in or out equally by means of a scroll plate located behind the jaws c) Accuracy is lost when the scroll and jaws wear d) Each jaw can move independently of the others with the jaws always being soft

D

Which of the following statements is a step for clamping a square block using a 4-jaw chuck? a) Facing the end of the block to prepare the block for center drilling b) Using a draw bar to compress the jaws around the work piece c) Mounting the block on the faceplate and using a lathe dog as a driver d) Use the concentric rings on the chuck to visually align the jaws and work piece on center, then use a dial indicator for final alignment

D

Which one of the following colors is not found on HMIS stickers? a) Red b) Blue c) White d) Green

D

Which of the following is not characteristic of the gibs found in the cross slide and compound slide? a) Only adjust the gibs when the slide is completely over the mating dovetail b) Tapered gibs only have one thrust screw c) Gib adjustments are used to control the amount of side play on the slide d) The gibs are adjusted to maintain a .003" clearance gap that is checked with a feeler gage

E

To align lathe centers using a dial indicator and a test bar, the plunger of the dial indicator should be set: a) Perpendicular to the lathe center axis b) On center c) In a horizontal position d) In a vertical position e) a, b, and d f) a, b and c

F

Which of the following are potential safety hazards when operating a lathe? a) Removing long stringy chips with bare hands b) Removing shields when turning to view the operation c) Failing to use a lube on a dead center d) Cutting a length less than two diameters in a chucking operation e) All of the above f) Only a and b

F