IME 330 Quizzes 2
Microsystem technology is concerned with products and components whose feature sizes are measured in microns. A micron is equal to which one of the following:
10^-4
Which one of the following is closest to the temperatures used in plasma arc cutting:
11,000ºC
In preparing a CNC path you need to trace the part detailing the X,Y coordinate dimensions. Based on the image below, determine the X,Y coordinates of point 3 and point 12 based on an absolute position from 0,0. Note that each answer corresponds to only one point location. Assume the part is symmetrical.
3 - 2.75, 1.5; 12 - 1.5, 2.75
Martensite can be defined as which one of the following:
A phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived
Match each sand-casting defect with the appropriate description. (Matching) Balloon Pin Holes Penetration Mold shift
Balloon: other Pin Holes: consist of many small gas cavities formed at or slightly below the surface of the casting Penetration: refers to a surface defect that occurs when the fluidity of the liquid metal is high and it penetrates into the sand mold... Mold shift: sidewise displacement of the mold cope
Of the following quenching media, which one produces the most rapid cooling rate:
Brine
The chemical formula for acetylene is which one of the following:
C2H2
Which one of the following plating metals produces the hardest surface on a metallic substrate:
Chromium
Which one of the following processes would be appropriate to drill a hole with a square cross section, 6mm (0.25 in) on a side and 25mm (1 in) deep in a steel workpiece:
EDM
Which one of the following arc welding processes uses an electrode consisting of continuous consumable tubing containing flux and other ingredients in its core:
FCAW
MIG welding is a term sometimes applied to which one of the following processes:
GMAW
Which one of the following arc welding processes has the lowest heat transfer factor:
GTAW
Which one of the following processes uses a thick rubber pad to form sheet metal over a positive form block:
Guerin Process
Tempering is a heat treatment applied to hardened steels that is best defined as which one of the following:
Heating and soaking at a temperature below the austenitizing level followed by slow cooling
A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the arc center axes?
I,j,k
The rate fo heat energy supplied in a resistance spot welding operation is determined by which one of the following equations, where RH=rate of heat energy, E=voltage, I=current, R=resistance, and t=time:
I^2R
The time-temperature-transformation curve (TTT curve) for steel can best be described by which one of the following:
Indicates how cooling rate affects the transformation of austenite into various possible phases
Match the following casting defects with their definitions. (Matching)
Misruns: Casting that solidify before completely filling the mold cavity Cold Shuts: Occurs when two portions of the metal flow together but there is a lack of fusion between them due to premature freezing Cold Shots: Results from splattering during pouring, causing the formation of solid globules of metal that become entrapped in the casting Shrinkage Cavity: A depression in the surface or an internal void in the casting caused by a restriction in the amount of molten metal available to the last region of the cavity Microporosity: A network of small voids throughout the casting caused by localized solidification and shrinkage of the final molten metal in the dendritic structure
What are the three main factors to successfully pouring molten metal?
Pouring temperature, pouring rate and turbulence
"Stick" welding is a term sometimes applied when referring to whcih one of the following processes:
SMAW
In sand blasting, which one of the following blast media is used:
SiO2
Silica sand has which one of the following compositions:
SiO2
Match each mold property to its definition. (Matching)
Strength: to maintain shape and resist erosion Collapsibility: ability to give way and allow casting to shrink without cracking the casting Thermal Stability: to resist craving on contact with hot metal Permeability: to allow hot air and gases to pass through voids in sand
A cupola is a vertical, cylindrical furnace equipped with a tapping spout near its base.
True
A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the incremental or secondary axes?
U,V,W
Which of the following steel parts will cool from the austenite region most quickly:
a cylinder 4 meters long
In casting, the term chaplet has multiple meanings. One use of the term refers to _____.
a support made of a metal having a higher temperature than the casting metal
A CNC machine can be designed with have multiple axes. Conventionally we consider the X, Y, and Z axes as the primary axes. What are the rotary axes?
a,b,c
A stepper motor is which one of the following types of devices?
actuator
In abraisive water jet cutting, the abrasive particles are added to the water stream:
after it exits the nozzle
In precipitation hardening, the hardening and strengthening of the metal occurs in which one of the following steps:
aging
The cleaning fluids in ultrasonic cleaning are generally aqueous solutions containing which of the following types of chemicals:
alkaline detergents
Calorizing is the same as which one of the following surface processes:
aluminizing
Electroslag welding uses an arc as in arc welding to initiate welding but is not classified as an arc welding process for which one of the following reasons:
an arc is not used during welding
In anodizing, the work part to be coated is which one of the following during the electrolytic process:
anode
A SCARA robot is normally associated with which one of the following applications:
assembly
A contact input interface is a device that reads which one of the following types of data:
binary
Flash welding is normally used to weld which one of the following joint types:
butt
The typical application of friction stir welding is which one of the following joint types:
butt
Which one of the following surface-hardening treatments is the most common:
carburizing
The standard coordinate system for numerical control machine tools is based on which one of the following:
cartesian coordinates
The standard coordinate system for numerical control machine tools is based on which one of the following?
cartesian coordinates
Which one of the following casting metals is most important commercially:
cast iron
Shell molding is best described by which one of the following:
casting process in which the mold is a thin shell of sand bonded by a thermosetting resin
Most sheet metalworking operations are performed as:
cold working
A stamping die that performs two or more operations on a sheet-metal coil at two or more stations with each press stroke is called which one of the following:
combination die? NOT! maybe progressive die?F
Which one of the following is not one of the major components of a PLC:
control console
The ability of a positioning system to return to a previously defined location is measured by which one of the following terms?
control resolution - wrong, accuracy -wrong repeatability?
In which of the following spinning processes does the thickness of the starting sheet-metal blank remain unchanged after the process:
conventional spinning
Which one of the following is the name of the resistance welding process widely used to produce welded wire products such as wire fence and shopping carts:
cross-wire welding
An indirect fuel-fired furnace is an alternative name for which one of the following furnace types:
crucible
The liquid used to create the discharge path between the tool and the work in electric discharge machining is called which of the following:
dielectric fluid - wrong (but should be according to slides) electrolyte - actual
Laser metal deposition is classified into which one of the following AM process categories:
directed energy deposition
A control system in which multiple computers are used to share the process control workload is called which one of the following:
distributed process control
Ballistic-particle manufacturing is another name for which one of the following RP technologies?
droplet deposition manufacturing
Springback in a sheet-metal bending operation is the result of which one of the following:
elastic recovery of the metal
Electroplating is also known as which one of the following:
electrochemical plating
Which one of the following is used to create indentations in sheet metal, such as raised letter or strengthening ribs:
embossing
Fused deposition modeling uses which one of the following layer-forming techniques in the layer-by-layer construction of a three-dimensional part:
extruder heads
Rapid tool making (RTM) applications divide into two approaches: Direct RTM and indirect RTM. Direct RTM refers to which of the following:
fabrication of the tool itself
The crystal structure of austenite is which one of the following:
face centered cubic
In the context of rapid prototyping and additive manufacturing, tessellation refers to the process of slicing the CAD model of the part into layers: (a) true or (b) false?
false
Machining is never used for rapid prototyping because it takes too long: (a) true or (b) false?
false
The three basic types of automated systems used in manufacturing are fixed automation, programmable automation, and flexible automation. Programmable automation is an extension of flexible automation in which there is virtually no lost production time for setup changes or reprogramming.
false
Soaking is a term that refers to which one of the following:
heating the metal to a suitable temperature and holding at that temperature for a certain time
The aspect ratio in microsystem technology is best defined by which one of the following:
height-to-width ratio of the fabricated features
Tungsten is the preferred nonconsumable electrode metal in GTAW for which one of the following reasons:
high melting temperature
In a blanking operation, as the hardness of the sheet metal increases, the clearance between punch and die should be:
increased
As the ratio of tube diameter over wall thickness increases, the tendency for a tube to collapse and fold during bending:
increases
A positioning system in which the next work head position is defined with respect to the previous position is called which one of the following:
incremental positioning
Which one of the following expendable mold processes is known as a precision-casting process:
investment casting
In ion implantation, the concentration of the impregnated element in the substrate is greatest
just below the surface
Which one of the following RP technologies uses solid sheet stock as the starting material?
laminated-object manufacturing
Resistance spot welding is most widely used for which one of the following joint types:
lap
The typical application of ultrasonic welding is which one of the following joint types:
lap
Which one of the following processes would be appropriate for cutting a hole of 0.075mm (0.003 in) diameter through a plate of aluminum that is 1.6mm (1/16 in) thick:
laser beam machining
Stereolithography uses which one of the following layer-forming techniques in the layer-by-layer construction of a three-dimensional part:
lasers
The linear velocity of a worktable driven by a leadscrew equals which one of the following:
leadscrew pitch multiplied by leadscrew rotational speed
Which of the following is the best definition of bend allowance:
length before bending of the straight sheet-metal section to be bent
In die casting, the term flash means _____.
liquid metal under high pressure squeezes into the small space between the die halves at the parting line
In the LIGA process, the letters LIGA stand for which one of the following:
lithography, electroplating, and plastic molding
Investment casting is also known by which one of the following names:
lost-wax process
Surface finish in EDM is best under which one of the following combinations of process parameters:
low discharge current and high frequency
The method of NC part programming in which the machine operator enters the part program into the machine control unit is called which one of the following:
manual data input
A misrun is which one of the following defects in casting:
metal solidifies before filling the cavity
Which one of the following is not considered a category of devices associated with microsystem technology:
microscopic biological entities
For which one of the following reasons is a green mold named:
moisture is contained in the mold
Stereolithography uses which one of the scanning modes in the layer-by-layer construction of a three-dimensional part:
moving-spot mode
Which of the following are characteristics of work situations that tend to promote the substitution of a robot in place of a human worker (three best answers)?
multiple work shifts, hazardous work environment, repetitive work cycle
A sheet-metal cutting operation that cuts out a portion of metal from the side of a sheet or strip is called which one of the following
notching
In CNC programming the term "modal" is often used to describe the state of variables. What does this mean?
once a variable is set, it remains constant until it is changed
Which one of the following press type is associated with the highest production rates in the sheet-metal-stamping operations:
open-backed inclinable
Which one of the following is not an advantage of laser-beam welding over electron-beam welding:
optical lenses and mirrors can be used - wrong...deeper welds are possible?-correct
Which of the following are problems with the current rapid prototyping and additive manufacturing technologies (three best answers)?
part accuracy limited material variety part shrinkage
Which of the following are examples of appropriate applications of additive manufacturing in the actual production of parts and products (three best answers)?
parts with intricate and/or complex geometries customized one-of-a-kind parts plastic parts in small batch sizes
Steel car bodies are commonly conversion coated with which one of the following thin films in preparation for painting:
phosphate
Typical sheet-metal thicknesses are between 0.4 mm (1/64 in) and 6 mm (1/4 in). When thickness exceeds the upper limit of this range, the stock is usually referred to as which one of the following:
plate
The polymer used to make compact discs (CDs) and digital versatile discs (DVDs) is which one of the following:
polycarbonate
The common resist material used in LIGA is which one of the following:
polymethylmethylacrylate
The arm‑and‑body of a robot manipulator generally performs which one of the following functions in an application:
positions the wrist within the work volume
When a control box is used in leadthrough programming to move the manipulator to a desired position in the work volume, the programming method is called which one of the following:
powered leadthrough
The quenching step in precipitation hardening results in which one of the following effects:
precipitation of fine particles that strengthen the alloy - wrong formation of martensite- wrong
A device that converts a series of pulses from an external source into a digital value is which one of the following:
pulse counter
In the sheared edge of a sheet-metal part, the depression made by the punch prior to actual cutting is called which one of the following:
rollover
How can you produce multiple etches with a single mask?
rotating the mask
Which one of the casting processes is the most widely used?
sand casting
Which of the following RP technologies uses powders as the starting material (two correct answers)?
selective laser sintering and three-dimensional printing
A sheet-metal cutting operation that cuts out a portion of metal from the interior of a sheet or strip that will become part of the outline of the blanking is called which one of the following:
seminotching
The cutting force in a sheet-metal blanking operation depends on which mechanical property of the metal:
shear strength
The most common work material used in microsystem technology is which one of the following:
silicon
The data contained in a compact disc are coded as which one of the following:
small pits in a helical track
Vapor degreasing is a form of which one of the following:
solvent cleaning - wrong, but should be emulsion cleaning - right
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:
standoff distance
Shot peening uses a high-velocity stream of which one of the following media:
steel pellets
Which one of the following rapid prototyping processes uses a photosensitive liquid polymer as the starting material?
stereolithography
Which of the following RP technologies uses molten material as the starting material (two correct answers)?
stereolithography droplet deposition manufacturing....1 of these is correct not sure which one is wrong
The advantage of reactive ion etching is
straight walls can be produced
To reduce residual stresses and warping in long seam welds, the parts are sometimes welded at multiple points along their lengths prior to continuous seam welding; this is called which one fo the following:
tack welding
The treatment in which the brittleness of martensite is reduced is called which one of the following:
tempering
Overcut in EDM is defined as which one of the following:
the distance by which the machined cavity in the work part exceeds the size of the tool on each side
In a blanking die, the device that clears the sheet metal from the punch after blanking is called which one of the following:
the stripper
Which one of the following is not a physical form of the starting material in additive manufacturing:
three-dimensional volumes
In an organic coating process, the proportion of paint supplied to the process that is actually deposited onto the work surface is called which one of the following:
transfer efficiency
A manufacturing system can be defined as a collection of integrated equipment and human resources that performs one or more processing and/or assembly operations on a starting work material, part, or set of parts.
true
Numerical control is a form of programmable automation in which the mechanical actions of a piece of equipment are controlled by a program containing coded alphanumeric data, the data representing relative positions between a work head and a work part.
true
Rapid prototyping and additive manufacturing are two terms that refer to fabrication technologies that add layers of material to an existing part or substrate: (a) true or (b) false?
true
Which one of the following is the name of the casting process in which molten metal is poured into a rotating mold to produce a tubular part:
true centrifugal casting
Tumbling is a mass finishing process that is also known by which one of the following names:
tumble finishing - wrong... barrel finishing?-correct
As work material hardness increases, material removal rates in ECM are
unaffected
Along the penetration into the work, etching also occurs sideways under the protective coating; this is called which one of the following:
undercut
Physical vapor deposition must be carried out in which one of the following types of equipment:
vacuum chamber
The fused zone between the two parts in a resistance spot weld is called which one of the following:
weld nugget
Which one of the following plating metals is associated with the term galvanizing?
zinc
Which one of the following metals has the lowest melting point:
zinc?-wrong!