mech 2653 test 4

rotary burrs

"Power filing" is frequently performed with ____ A. a filing machine B. band filing C. rotary burrs D. disk filing

Aluminum and aluminum alloys are:

"fabrication friendly".

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock for the process.

(1) multiple teeth (2) less

The accuracy that can be expected from the milling process is:

.0005 inches

The range of rise per tooth for internal broaching is (x) to (y) inches/tooth.

.001 .006

The range of rise per tooth for *internal* broaching is [x] to [y] inches/tooth.

.001 to .0025

The amount of material removed in lapping is usually less than _____ A. None of these B. 1 millionth of an inch C. 0.0005" D. 0.001"

.001"

The range of rise per tooth for external broaching is (x) to (y) inches/tooth.

.003 .006

The range of rise per tooth for *external* broaching is [x] to [y] inches/tooth

.003 to .006

What is the typical MRR for electrochemical machining? A. in^3/ min/ 1000 amps B. .1 in^3/min/1000 amps C. 100 in^3/min/1000 amps

.1 in^3/min/1000 amps

The accuracy that can be expected from the milling process is:

0.0005 inches

The range of rise per tooth for internal broaching is ______ inches/tooth

0.001 to 0.0025

The amount of material removed in lapping is usually less than _____

0.001"

The range of rise per tooth for internal broaching is ___ to ___ inches/tooth.

0.001, 0.0025

The range of rise per tooth for external broaching is ___ to ___ inches/tooth

0.003, 0.006

What is the typical MRR for electrochemical machining?

0.1 in^3/min/1000 amps

What is the typical MRR for electrochemical machining? 0.01 in^3/min/1000 amps 0.1 in^3/min/1000 amps 1 in^3/min/1000 amps 100 in^3/min/1000 amps

0.1 in^3/min/1000 amps

1) 45 degree, V shaped groove in the surface of a flat bar

1) angle cutter

1) Deep slots with straight side walls

1) end mill

The broaching processes is used in the manufacturing of

1. Pipe wrench jaw teeth 2. internal keyways 3. dovetail for a turbine blade 4. internal splines

Non-Traditional Machining produces parts by which of the following (mark all that apply)?

1. Removing material from a base using chemicals 2. Removing material from a base using a tool vibrated at ultrasonic frequencies 3. Removing material using ultra-high pressure water 4. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. 5. By an additive process where small, precise amounts of materaisl are built-up into a shape

Modular fixturing is frequently used ...

1. for prototyping and small jobs 2. because standard parts can be used to construct the fixture 3. to lower costs

The abrasive machining process is used for which of the following?

1. improving the surface finish of a part 2. accurately machining a part to a finished size with an excellent surface finish 3. cleaning the particle 4. Part seperation

CNC milling machines are used in machining operations becase

1. the part geometry can be more complex and 3D compound curves are possible 2. the part can be machined more accurately 3. the part can be machined faster

The milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches.

150

The milling process will produce a surface finish with a surface roughness measurement of 60 to ____ microinches.

150

2) finishing the top surface of a work piece

2) face mill

2) finishing the top surface of a flat bar

2) plain cutter

In the design of fixtures/jigs the principle of 3-2-1 uses location points to define:

3 perpendicular planes

In the design of fixtures/jigs the principle of 3-2-1 uses locaton points to define

3 perpendicular planes

3) producing a groove with a 1/8" diameter concave bottom

3) ball end mill

3) deep, straight walled, narrow slots

3) slitting saw cutter

The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.

30 40

The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.

30 to 40

The maximum operator force in loading/unloading a part should be less than ___ to ___ lbf.

30, 40

A good design consideration is to limit operator force in operating clamping mechanisms to ___ lbs

30-40

The surface finish obtained from the broaching process has a surface finish measurement of (x) to (y) microinches

32 125

The surface finish obtained from the broaching process has a surface finish measurement of [x] to [y] micro inches.

32 to 125

The surface finish obtained from the broaching process has a surface finish measurement of ___ to ___ microinches.

32, 125

4) Bearing pocket in gearbox housing

4) end mill

4) 1/4" radius, convex shape along the edge of the part

4) form cutter

5) Producing a flat-bottom groove in the surface of a part

5) end mill

5) milling wood to produce wood trim

5) form cutter

6) Deep slots in a work piece

6) Staggered- tooth cutter

Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations.

72

Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations. A. 100 B. 72 C. 48 D. 60

72

What percentage of EDM is used to produce tool and die sets? A.10-20% B. 80-90% C. 70-80% D. 50-60%

80-90

What percentage of EDM is used to produce tool and die sets?

80-90%

Provides for machining of more complex parts than a manual milling machine

A CNC milling machine ___. A. Requires highly trained operators to operate. B. Is used only in mass production operations. C. Can machine parts slower and more accurately than a manual milling machine D. Provides for machining of more complex parts than a manual milling machine

The honing process is a finishing process typically used to produce

A cross-hatch pattern on an internal cylindrical surface

accurate rotation of the work piece through any desired arc of rotation

A dividing head is an accessory used with a milling machine primarily to provide what operation? A. rotation of a part 90 degrees so that additional machining can be performed on it B. rotation of a part 180 degrees C. accurate rotation of the work piece through any desired arc of rotation D. rotation of a group of parts so that the next piece in the group can be machined

holds (x) size (y)

A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.

False

A fixture/jig should be design using the least number of standard elements as possible. True or False

True

A fixture/jig should be designed to tolerate variations in the workpiece. True or False

Which of the following describes the ultrasonic machining process? A harden steel tool is vibrated at low frequencies (<1000) with an small amplitude (~ 0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the materail being machined and the tool as a process to remove material. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

A harden steel tool is vibrated at high frequencies (>20,000 Hz) with a small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

Which of the following describes the ultrasonic machining process?

A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

Which of the following describes the ultrasonic machining process? A. A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the materail being machined and the tool as a process to remove material. B. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. C. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. D. A harden steel tool is vibrated at low frequencies (<1000) with an small amplitude (~ 0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

The milling process is characterized by

A high MRR, a good surface finish, and is used in mass production

location

A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.

The milling process typically involves

A non-rotating part and a rotating cutter

Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and rotating tooling B. A process involving a rotating tool and X-Y-Z linear movement of the work piece. C. A process involving a rotating work piece and X-Y-Z linear movement of the tooling D. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements.

A process involving a rotating tool and X Y Z linear movement of the work piece

Which of the following best describes the tool and workpiece movement for the milling process?

A process involving a rotating tool and X-Y-Z linear movement of the work piece

Which of the following statements applies to creep feed grinding?

A process with very slow t able feeds and deep depth-of-cut compared to conventional surface grinding

two

A requirement for broaching is that _____ teeth be in contact with the workpiece. A. two B. one C. three D. five

The broaching process can be described as

A single- stroke process using a multi-toothed cutter to remove small amounts of material with roughing and finishing operations performed in the single pass of the cutter

Which of the following statements for Electrical Discharge Machining is incorrect? A very specialized process for machining developed for machining parts for NASA rocket engine parts. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. Most frequently used of NTM processes. A matt finished is produced by the EDM process

A very specialized process for machining developed for machining parts for NASA rocket engine parts

Which of the following statements for electical discharge machining is incorrect? A. A matt finished is produced by the EDM process B. A very specialzied process for machining developed for machining parts for NASA rocket engine parts. C. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. D. Most frequently used of NTM processes.

A very specialized process for machining developed for machining parts for NASA rocket engine parts.

Which of the following statements for Electical Discharge Machining is incorrect?

A very specialzied process for machining developed for machining parts for NASA rocket engine parts.

Which of the following statements is false for rolled threads? A. The threads produced by thread rolling have a lower strength than cut threads. B. Rolled threads have a major diameter larger than the diameter of the base stock. C. Rolled threads have a hard, wear resistant, smooth surface.

A.

Which of the the following is not a common tooth form for saw blades? A. square B. regular C. skip D. claw

A.

What NTM process is used to cut composites?

Abrasive waterjet

True

Abrasive waterjet machining involves an abrasive grit carried with ultra high pressure water jet to cut metals and non-metals. True or False?

Which of the following does NOT apply to non-traditional machining? Removing material from a base using chemicals. Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra-high pressure water. Adding material to a base using high voltage electrical discharges. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. By an additive process where small, precise amounts of materials are built-up into a shape.

Adding material to a base using high voltage electrical discharges

Which of the following statements applies to creep feed grinding?

All of the these

Because of its FCC structure, it has the highest ductility of the lightweight metals.

Aluminum

Color anodizing is a surface finishing treatment that is somewhat unique to this metal.

Aluminum

Which of the following materials is not commonly used as a lap?

Aluminum

For American pattern files, the coarseness of a file is determined by:

An ASME standard that gives teeth per inch

dull (x) flattening (y)

Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit. A. dislodging B. sharp C. dull D. flattening

Which of the following is not a common material used for the teeth of a band saw blade? A. high speed steel B. CBN C. diamond D. tungsten carbide

B.

Which of the following is not an abrasive material used in commerical cleaning applications? A. dry ice B. aluminum chips C. walnut shells D. plastic media

B.

Which of the following statements is false regarding thread grinding? A. Threads in hardened steels can be produced B. Only coarse threads can be produced. C. Using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. Very accurate, fine pitched threads can be produced

B.

In mass-production operations, a milling machine with the capability of making heavy cuts, having 1,2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine?

Bed milling machine

Because this metal is considered to be toxic, processing often requires special precautions.

Beryllium

This metal is lighter than aluminum, but stiffer than steel.

Beryllium

This metal is sometimes used for nuclear applications because it is relatively transparent to the movement of neutrons.

Beryllium

False

Broaching is a process that can be used only in mass-production. True or False

internal keyways

Broaching was orginally developed for the production of ____. A. splines B. internal keyways C. flat surfaces D. external keyways

hard (m) glass(n) ceramics (o) carbides (p)

By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics

Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. mounted D. free

C.

Which of the following is not a type of broach construction? A. shell B. solid C. insert tooth D. segment

C.

Which of the following materials is not commonly used as a lap? A. Copper B. Cast iron C. Aluminum D. Cloth

C.

Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.

C.

Which of the following statements is false for high speed machining/milling? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. One or more axes are always accelerating in a 3-D cut. D. Cutting speed for steel is less than 1500 m/min E. A high material removal rate is obtained

C.

Which of the following statements is false regarding the thread rolling process? A. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second. B. Thread rolling can be used to form threads on tubular products. C. Thread rolling is a hot forming process.

C.

Which of the following is not a common material used for the teeth of a band saw blade?

CBN

Which of the following is not a common material used for the teeth of a band saw blade? A. tungsten carbide B. diamond C. high speed steel D. CBN

CBN

Which of the following is not an advantage of plasma arc cutting?

Can be used for cutting metal based composite materials

Which of the following is not an advantage of plasma arc cutting? Very fast cutting Smooth cuts free of contaminants are produced Can be used for cutting metal based composite materials small heat-affected zone

Can be used for cutting metal based composite materials

True

Centerless grinding is a process that is performed quickly. True or False

False

Centerless grinding is a process that must be performed manually by the machinist. True or False

False

Centerless grinding requires lots of operator skill to operate the machine. True or False

False

Centerless grinding requires that small grinding wheels be used in the grinding process. True or False

True

Centerless grinding requires the use of special, dedicated equipment to perform the grinding process. True or False

The NTM process used to manufacture printed circuit boards is ____.

Chemical Machining

The teeth of an end mill cutter are located on the ___.

Circumference and the face of the cutter

centrifugal gravity inertial cutting

Clamping forces must be greater than what four (4) forces? A. aerodynamic B. centrifugal C. frictional D. gravity E. inertial F. cutting

vise chuck

Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.

Two different types of monomers or reactants are required for this type of polymerization that involves the production of a small by-product molecule.

Condensation polymerization

False

Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder. True or False

True

Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs. True or False

Which of the following is not an application for laser beam machining?

Cutting thick materials

What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.

Cylindrical external

Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and X-Y-Z linear movement of the tooling B. A process involving a rotating work piece and rotating tooling C. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements. D. A process involving a rotating tool and X-Y-Z linear movement of the work piece.

D

Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. water B. oil C. grease D. air

D.

Inducing extensive branching of the chains would _______ the strength of a polymer.

Decrease

N=(12V)/(pi*D) f_m(table feed rate) = f_tNn(number of teeth) MRR = Wtf_m(table feed rate)

Determine the MRR in in^3/min, given the following data: Face milling 1020 steel, 55" long, 7" wide (W) 8" diameter, ? teeth, 9 tungsten carbide inserts Depth of cut (t) = 0.29" Feed/tooth (f_t) = 0.011 in/tooth Cutting speed (V) = 754 ft/min (ignore length of approach [L_a] and length of over-travel [L_o])

What device is used to manually produce external theads?

Die

What device is used to manually produce external threads?

Die

False

Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened. True or False

Which of the following is NOT a correct statement regarding magnesium?

Ductility and corrosion resistance are both good.

An adhesive example of this type of polymer would be flexible silicone bathtub caulk

Elastomeric

Extremely large elastic deformations are possible with this type of polymer.

Elastomeric

False

Electrochemical machining is deplating process using high DC voltage, high current for the process. True or False?

True

Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites). True or False?

vertical milling machine

End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. both vertical and horizontal milling machines C. vertical milling machine

Identify the type of cutter that would be used to machine a 12" wide, 48" long aluminum bar stock to produce a flat, smooth, and an excellent finish on the 12" wide surface of t he bare using a *vertical* knee-and- column milling machine

Face mill

Identify the type of cutter that would be used to machine a 12" wide, 48" long aluminum bar stock to produce a flat, smooth, and excellent finish on the 12" wide surface of the bar using as vertical knee-and-column milling machine.

Face mill

A fixture/jig should be design using the least number of standard elements as possible.

False

A fixture/jig should be design using the least number of standard elements as possible. True or False

False

A fixture/jig should be design using the least number of standard elements possible.

False

A high-strength aerospace aluminum alloy has strength equivalent to a quenched-and-tempered medium carbon steel. True/False

False

Adhesive bonding is an attractive means of joining materials that will be used at elevated temperature. True/False

False

Broaching is a process that can be used only in mass-production. True or False

False

Centerless grinding is a process that must be performed manually by the machinist.

False

Centerless grinding is a process that must be performed manually by the machinist. True or False

False

Centerless grinding requires lots of operator skill to operate the machine.

False

Centerless grinding requires lots of operator skill to operate the machine. True or False

False

Centerless grinding requires that small grinding wheels be used in the grinding process.

False

Centerless grinding requires that small grinding wheels be used in the grinding process. True or False

False

Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.

False

Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder. True or False

False

Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.

False

Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened. True or False

False

Electrochemical Machining is a deplating process using high DC voltage, high current for the process.

False

Electrochemical machining is deplating process using high DC voltage, high current for the process. True or False?

False

For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles. True or False

False

Good electrical and thermal conductivity is a characteristic or description of most polymeric materials. True/False

False

Good electrical and thermal conductivity is a property that is characteristic or descriptive of most ceramic materials. True/False

False

Good mechanical properties at elevated temperature is a characteristic or description of most polymeric materials. True/False

False

Good wear resistance is a characteristic or description of most polymeric materials. True/False

False

High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.

False

High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth. True or False?

False

In centerless grinding deep cuts are not possible due to the work support.

False

In centerless grinding deep cuts are not possible due to the work support. True or False

False

Low thermal expansion is a characteristic or description of most polymeric materials. True/False

False

Magnesium can be significantly strengthened by cold work. True/False

False

PVC piping is an approved material for compressed air lines.

False

The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.

False

The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes. True or False

False

The honing process used stones with a grit size of 1200 or more particles per inch.

False

The honing process used stones with a grit size of 1200 or more particles per inch. True or False

False

The lapping process must be performed only by hand without machinery

False

The lapping process must be performed only by hand without machinery.

False

The lapping process must be performed only by hand without machinery. True or False

False

The milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass-production, tool and die work, and prototype work.

False

The milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass-production, tool and die work, and prototype work. True of False

False

The surface finish produced by electrical discharge machining has a cross-hatch pattern with a roughness value of 32 to 120 microinches.

False

True or False: A fixture/jig should be design using the least number of standard elements as possible.

False

True or False: Broaching is a process that can be used only in mass-production.

False

True or False: Centerless grinding is a process that must be performed manually by the machinist.

False

True or False: Centerless grinding requires lots of operator skill to operate the machine.

False

True or False: Centerless grinding requires that small grinding wheels be used in the grinding process.

False

True or False: Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.

False

True or False: Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.

False

True or False: Electrochemical Machining is a deplating process using high DC voltage, high current for the process.

False

True or False: For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.

False

True or False: High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.

False

True or False: In centerless grinding deep cuts are not possible due to the work support.

False

True or False: The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.

False

True or False: The honing process used stones with a grit size of 1200 or more particles per inch.

False

True or False: The lapping process must be performed only by hand without machinery.

False

True or False: The milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass-production, tool and die work, and prototype work.

False

True or False: Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.

False

True or False: With centerless grinding tubes will automatically have concentric inside and outside diameters.

False

True or False: Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.

False

Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent. True or False?

False

With centerless grinding tubes will automatically have concentric inside and outside diameters.

False

With centerless grinding tubes will automatically have concentric inside and outside diameters. True or False

False

With centerless grinding, tubes will automatically have concentric inside and outside diameters.

False

Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.

False

Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool. True or False

False

Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.

False (Water jets are used to cut non-metal materials. To cut metals, an abrasive is added to the water stream)

Tapered end mills are used for ____

Finish cutting on molds to produce a desired angle

Which of the following is a function of the dielectric in the electrical discharge machining process?

Flushing agent

the tooth pattern and the length of the file

For American pattern files, the coarseness of the file cut is given by: A. xx teeth/ inch B. the tooth pattern and the length of the file C. tooth pattern of the file D. the length of the file

False

For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles. True or False

vertically down

For the DOWN milling process, complete the statements with the answers supplied: In slab milling operations, the direction of the cutting force is _______.

maximum

For the DOWN milling process, complete the statements with the answers supplied: The chip thickness is a _______ at the beginning of the chip formation.

with

For the DOWN milling process, complete the statements with the answers supplied: The mill cutter rotates _______ the direction of feed.

Up

For the UP milling process, complete the statements with the answers supplied: In the slab milling operations, the direction of the cutting force is ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

maximum

For the UP milling process, complete the statements with the answers supplied: The chip thickness is a ____ at the end of the chip formation as the tool exits the work piece. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

minimum

For the UP milling process, complete the statements with the answers supplied: The chip thickness is a _____ at the beginning of the chip formation. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

minimum

For the UP milling process, complete the statements with the answers supplied: The chip thickness is a _______ at the end of the chip formation as the tool exits the work piece.

toward the part

For the UP milling process, complete the statements with the answers supplied: The direction of the cutting forces are ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

against

For the UP milling process, complete the statements with the answers supplied: The mill cutter rotates ____ the direction of feed. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

True

For the honing process the amount of material removed is less than 0.005" from the surface. True or False

____ is the property referring to the ability of the abrasive material to fracture producing new, sharp edges

Friability

fracture, producing new, sharp edges

Friability refers to the ability of the abrasive material to ____. A. form chips B. withstand high temperatures C. withstand exposure to water and cutting oils D. fracture, producing new, sharp edges

Which of the following is not an asset of aluminum?

Good elevated temperature strength

Which of the following statements applies to centerless grinding

Heavy cuts and accurate size control are possible because the workpiece is supported at the grinding location

which of the following statements applies to centerless grinding

Heavy cuts and accurate size control is possible because the workpiece is supported at the grinding location

Two teeth less smoother (lower surface roughness value)

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface. A. one tooth B. multiple teeth C. more D. less E. rougher (higher surface roughness value) F. smoother (lower surface roughness value)

Bandsaw blades are frequently made with teeth of what material

High Speed Steel

False

High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth. True or False?

Slab milling is typically performed using what type of knee-and-column milling machine?

Horizontal milling machine

Match the following surface grinder types with the description / property / application. (answers may be used more than once). The most common type of surface grinding machine. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

Horizontal spindle, reciprocating table

Surface grinder not typically used due to limited type of work which it will accommodate.

Horizontal spindle, reciprocating table

The most common type of surface grinder is a

Horizontal spindle, reciprocating table

The most common type of surface grinding machine is ___.

Horizontal spindle, reciprocating table

The most common type of surface grinding machine.

Horizontal spindle, reciprocating table

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

form cutter

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

face mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

ball end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

form cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 1/4" radius, convex shape along the edge of a part A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

angle cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 45 degree, V shaped groove in the surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

staggered-tooth cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Deep slots in a work piece A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

form cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Milling wood to produce wood trim A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

slitting saw cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) deep, straight walled, narrow slots A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

plain cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) finishing the top surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

plastic

In ___ products, threads are frequently produced by casting.

False

In centerless grinding deep cuts are not possible due to the work support. True or False

rotating speed and axial feed of the work piece

In centerless grinding, the regulating wheel controls _____ in the grinding process. A. rotating speed of the grinding wheel B. axial feed of the workpiece C. rotating speed of the workpiece D. rotating speed and axial feed of the work piece

True

In centerless grinding, the work piece must be round and not include flats or keyways. True or False

Peripheral edge

In face milling, most of the cutting occurs at what area of the cutter? A. Equal amount of cutting both at the center and peripheral edge B. Peripheral edge C. center

bed milling machine

In mass-production opeations, a milling machine with the capability of making heavy cuts, having 1,2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine? A. knee-and-column milling machine B. universal milling machine C. bed milling machine D. gantry milling machine

many (x) excellent (y)

In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish. A. Rough B. excellent (y) C. many (x) D. few E. two F.three

Parallel (x) horizontal (y)

In the slab milling process, the finished surface is ____ to the axis of rotation of the cutter and is normally performed on a ____ spindle milling machine. A. perpendicular B. Parallel C. horizontal D. vertical

Increasing the length of the average chain would _______ the strength of a polymer.

Increase

Inducing "crystallization" during cooling would _______ the strength of a polymer.

Increase

Replacing hydrogen side atoms with chlorine would _______ the strength of a polymer.

Increase

The milling machine was invented in approximately 1816 by Simeon North to machine

Interchangeable parts for rifles for the US Gov.

The cutting process during the milling operation is a(n)___ process

Interrupted

Which of the following does not apply to the thread milling process?

It is a process performed on a manually-operated milling machine

The slot cut in the material by a saw blade is called ____.

Kerf

charged

Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material. A. charged B. mounted C. lapped D. pasted

more than the machining operation

Loading and unloading of a fixture will often abuse the fixture ____ . A. less than the machining operation B. more than the machining operation C. equal to the machining operation

The table has ___ movement on the saddle ways.

Longitudinal (X- axis)

Which of the following would not be a desirable property of a wrought alloy?

Low melting point

Attractive properties for casting alloys include:

Low melting point, Good fluidity, High as-solidified strength

It has the lowest density of all of the engineering metals (i.e. is the lightest engr. metal).

Magnesium

People specifying the use of this metal are driven by a desire for light weight, and are willing to accept the numerous negative properties and characteristics.

Magnesium

The designation system for this metal consists of two letters followed two or three numbers, such as AZ61 or AM100.

Magnesium

This metal can be very difficult to fabricate. It is brittle at room temperature; machining chips can burn: and molten metal must be kept under protective atmospheres.

Magnesium

surface grinders

Magnetic chucks are commonly used on what type of machinery? A. Lathes B. Surface grinders C. Micro-drill presses D. Milling machines

vertical (z axis)

Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

transverse (y axis)

Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

longitudinal (x axis)

Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

Head

Match the part numbers on the schematic diagram with the names. Part 1

Table

Match the part numbers on the schematic diagram with the names. Part 2

Workpiece

Match the part numbers on the schematic diagram with the names. Part 3

Saddle

Match the part numbers on the schematic diagram with the names. Part 4

Knee

Match the part numbers on the schematic diagram with the names. Part 5

Base

Match the part numbers on the schematic diagram with the names. Part 6

Column Ways

Match the part numbers on the schematic diagram with the names. Part 7

Spindle

Match the part numbers on the schematic diagram with the names. Part 8

Column

Match the part numbers on the schematic diagram with the names. Part 9

More flat surfaces are produced by the _______ process than any other milling process.

Milling

negative 3-5

Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter. A. positive B. negative C. 10-15 D. 3-5

True

More flat surfaces are produced by the milling process than any other machining process. True or False

Removing material from a base using chemicals Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra high pressure water By an additive process where small, precise amounts of materials are built up into a shape

Non-traditional machining produces parts by which of the following (mark all that apply)? A. removing material from a base using chemicals B. Removing material from a base using a tool vibrated at ultrasonic frequencies. C. Removing material using ultra high pressure water. D. By an additive process where small, precise amounts of materials are built up into a shape E. Adding material to a base using high voltage electrical discharges.

Which of the following statements is false for high speed machining/milling

One or more axes are always accelerating in a 3-D cut

Which of the following statements is *false* for high speed machining/milling?

One or more axes are always accelerating in a 3-D cut.

Which of the following statements is false regarding thread grinding?

Only course threads can be produced

In the slab milling process, the finished surface is ____ to the axis of rotation of the cutter and is normally performed on a ____ spindle milling machine. A. perpendicular B. Parallel C. horizontal D. vertical

Parallel (x) horizontal (y)

In face milling, most of the cutting process occurs at the ___ portion of the cutter

Peripheral

In face milling, most of the cutting occurs at what area of the cutter? A. Equal amount of cutting both at the center and peripheral edge B. Peripheral edge

Peripheral edge

straight helical

Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter. A. straight B. pointed C. spiral D. helical

Which of the following applies to plasma arc cutting?

Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

Which of the following applies to plasma arc cutting? Plasma arc cutting involves superheated gas for cutting only steel plates. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals. Plasma arc cutting involves super-high pressure gas propelled at mach 30 for cutting conductive metals.

Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

Which of the following applies to plasma arc cutting? A. Plasma arc cutting involves superheated gas for cutting only steel plates B. Plasma cutting involves super high pressure gas propelled at mach 30 for cutting conductive metals. C. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

Which of the following is not a limitation of magnesium and magnesium alloys?

Poor machinability

Which of the following is not a limitation of aluminum?

Poor thermal conductivity

A CNC milling machine ___. A. Requires highly trained operators to operate. B. Is used only in mass production operations. C. Can machine parts slower and more accurately than a manual milling machine D. Provides for machining of more complex parts than a manual milling machine

Provides for machining of more complex parts than a manual milling machine

In the equation fm = ftNn, N refers to :

RPM of the spindle

Which of the following is a correct statement for rapid prototyping?

Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.

Which of the following is a correct statement for rapid prototyping? Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes. Rapid prototyping is used only for medical applications. Rapid prototyping is a very expensive process and has very limited applications. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.

Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.

Which of the following is a correct statement for rapid prototyping? A. Rapid prototyping is an additive manufacturing process that can be produce parts fro various materials using various processes. B. Rapid prototyping is very expensive process and has very limited applications C. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.

Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.

In centerless grinding, the ___ controls the rotation and longitudinal motion of the workpiece

Regulating wheel

Non-traditional machining produces parts by which of the following (mark all that apply)? A. removing material from a base using chemicals B. Removing material from a base using a tool vibrated at ultrasonic frequencies. C. Removing material using ultra high pressure water. D. By an additive process where small, precise amounts of materials are built up into a shape E. Adding material to a base using high voltage electrical discharges.

Removing material from a base using chemicals Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra high pressure water By an additive process where small, precise amounts of materials are built up into a shape

In centerless grinding, the regulating wheel controls _____ in the grinding process.

Rotating speed and axial feed of the work piece

What device is used to produce external threads with lathes, screw machines, and threading machines?

Self-opening die head

The milling machine was invented in approximately 1816 by ___.

Simeon North

The milling machine was invented in approximately 1816 by ____. A. Thomas Edison B. Simeon North C. James Watt D. Eli Whitney

Simeon North

horizontal milling machine

Slab milling is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. vertical milling machine C. both horizontal and vertical milling machines

Identify the type of cutter that would be used to mill deep narrow slots in a part using a *horizontal* knee-and-column milling machine

Slitting saw cutter

What is the milling of two parallel surfaces with side cutters called ?

Straddle Milling

What is the milling of two parallel surfaces with side cutters called ?

Straddle milling

Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter.

Straight or Helical

honing

Superfinishing is a variation of what process to finish flat surfaces. A. lapping B. None of these C. surface grinding D. honing

Magnetic chucks are commonly used on what type of machinery?

Surface grinders

What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ? A. L-Slot milling cutter B. T-slot milling cutter C. Staggered-tooth mill cutter D. Plain milling cutter

T slot milling cutter

What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ?

T-slot milling cutter

finish cutting on molds to produce a desired angle

Tapered end mills are used for ____ A. rough cutting in the machining of molds B. both rough and finished cutting in the machining of molds C. Finish cutting on molds to produce a desired angle D. machining a chamfer on finished parts

fool proofing

The ability to load a part into a fixture only one way is called? A. proofing B. fool proofing C. robotic design D. auto loading

plowing (x) rubbing (y) cutting (z)

The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips. A. Cutting (z) B. digging C. plowing (x) D. rubbing (y) E. scrapping F. planning

True

The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process. True or False?

.001"

The amount of material removed in lapping is usually less than _____ A. None of these B. 1 millionth of an inch C. 0.0005" D. 0.001"

radius

The blade width of the saw blade determines the minimum ____ that can be cut with a bandsaw blade A. depth of cut B. radius C. rate of cutting D. thickness

single-stroke (x) multi (y) a single pass (z)

The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter. A. single-stroke B. multi-stroke C. single D. multi E. a single pass F. multiple passes

True

The chemical machining process is used in mass-production of parts True or False?

Which of the following statements is false for clamping forces?

The clamping forces should be spread over a small area

True

The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials. True or False

True

The creep feed grinding process is used to grind deep slots with straight parallel sides into parts. True or False

False

The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes. True or False

True

The filing process is used to remove small amounts of material from a part. True or False

sewing machines

The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device? A. revolvers B. sewing machines C. bicycle bearings D. steam engines

The strength of the bonds between the abrasive grits

The grade of a grinding wheel refers to ____. A. the ratio of bonding material volume to abrasive material volume B. the strength of the bonds between the abrasive grits C. the spacing of the abrasive particles in the wheel D. the ratio of bonding material weight to abrasive material weight

crosshatch

The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole? A. no defined pattern B. circular C. crosshatch

Truing of holes

The honing process is not used for which of the following: A. truing of holes B. removing taper, waviness, and tool marks from the boring process C. sizing and finishing of bored holes D. removing tooling marks

False

The honing process used stones with a grit size of 1200 or more particles per inch. True or False

False

The lapping process must be performed only by hand without machinery. True or False

Which of the following statements correctly describes the purpose of the mask in chemical machining? A. The mask is applied to the area of the part that is desired to not remove material from the part B. The mask is applied to the area of the part that it is desired to removal material from the part. C. The mask enhances the chemical machining process. D. None of the above.

The mask is applied to the area of the part that is desired to not remove material from the part

Which of the following statements correctly describes the purpose of the mask in chemical machining?

The mask is applied to the area of the part that is is desired to not remove material from the part

Which of the following statements correctly describes the purpose of the mask in chemical machining? The mask is applied to the area of the part that is is desired to not remove material from the part. The mask is applied to the area of the part that it is desired to removal material from the part. The mask enhances the chemical machining process. None of the above.

The mask is applied to the area of the part that it is desired to not remove material from the part.

30 40

The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.

Simeon North

The milling machine was invented in approximately 1816 by ____. A. Thomas Edison B. Simeon North C. James Watt D. Eli Whitney

False

The milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass-production, tool and die work, and prototype work. True of False

multi tooth cutting tool interrupted

The milling process uses [x] and involves [y] cutting. a) single-point tool b) multi-tooth cutter c) continuous d) interrupted

150

The milling process will produce a surface finish with a surface roughness measurement of 60 to ____ microinches.

vertical

The most common type of broaching machine construction is ____. A. vertical B. Horizontal

bandsaw

The most common type of sawing machine for cutting metal is : A. cold saw B. power hacksaw C. bandsaw D. milling machine

True

The operator should not have to reach past the tool to load/unload parts for machining. True or False

set

The pattern used to offset the saw blade teeth from the centerline of the blade is called ____. A. pitch B. rake C. set

three perpendicular planes

The principle of 3-2-1 uses location points to define ___. A. three (3) intersecting planes B. 6 points C. 3 axis, 2 rotations, 1 point D. three (3) perpendicular planes

Thread milling

The process for machining threads which requires a CNC machining center capable of circular interpolation is ____.

.003 .006

The range of rise per tooth for external broaching is (x) to (y) inches/tooth.

.001 .0025

The range of rise per tooth for internal broaching is (x) to (y) inches/tooth. A. 0.0015 B. 0.001 C. 0.0005 D. 0.003 E. 0.0025 F. 0.005

kerf

The slot cut int eh material by a saw blade is called ____. A. slot B. groove C. kerf D. gullet

lap

The soft material used in the lapping process is called _______. A. felt B. rouge C. lap D. None of these

The grade of a grinding wheel refers to ____. A. the ratio of bonding material volume to abrasive material volume B. the strength of the bonds between the abrasive grits C. the spacing of the abrasive particles in the wheel D. the ratio of bonding material weight to abrasive material weight

The strength of the bonds between the abrasive grits

the spacing of the abrasive grit in the wheel

The structure of a grinding wheel refers to ____. A. the strength of the bonds between the abrasive grit in the wheel B. The ratio of the bonding material volume to the abrasive material volume C. The ration of the bonding material weight to the abrasive material weight D. the spacing of the abrasive grit in the wheel

32 (x) 125 (y)

The surface finish obtained from the broaching process has a surface finish measurement of (x) to (y) microinches

circumference and the face of the cutter

The teeth of an end mill cutter are located on the ___. A. circumference and the face of the cutter B. circumference of the cutter C. face of the cutter

Which of the following statements is false for rolled threads?

The threads produced by thread rolling have a lower strenghth than cut threads

True

The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel. True or False

An adhesive example of this type of polymer would be hot-melt glue.

Thermoplastic

Extremely large plastic deformations are possible with this type of polymer.

Thermoplastic

In this type of polymer, heating softens, cooling hardens, and the cycle can be repeated.

Thermoplastic

These polymers are the most easily recycled variety

Thermoplastic

An adhesive example of this type of polymer would be two-part epoxy.

Thermosetting

The highest rigidity is found in this type of polymer.

Thermosetting

The highest strength polymers would most likely be of this type.

Thermosetting

The process for machining threads which requires a CNC machining center capable of circular interpolation is ____.

Thread milling

Which of the following statements is false regarding the thread rolling process?

Thread rolling is a hot forming process

Which of the following statements is false regarding the thread rolling process? A. Thread rolling is a hot forming process B. Thread rolling can be used to form threads on tubular products C. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second.

Thread rolling is a hot forming process

Because it is allotropic (BCC at elevated temp and HCP at room temp), this material can be heat treated by both age hardening and phase transformation processes

Titanium

It is often used in place of steel for weight saving, or in place of aluminum when use involves elevated temperatures.

Titanium

It is the only high temperature, lightweight metal, retaining useful strength up to 900F (500C).

Titanium

Since it is strong, light weight and corrosion resistant to body fluids, orthopedic implants and bone-repair screws and plates often use this material.

Titanium

This metal offers the strength of a heat-treated medium-carbon steel at a little more than half the weight.

Titanium

taper plug bottom

To thread a blind hold the three types of taps used, in order are ___, ___, and ___. A. plug B. spiral C. fluteless D. taper E. bottom

A fixture/jig should be designed to tolerate variations in the workpiece.

True

A fixture/jig should be designed to tolerate variations in the workpiece. True or False

True

Abrasive waterjet machining involves an abrasive grit carried with ultra high pressure water jet to cut metals and non-metals. True or False?

True

Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.

True

Adhesive bonding is an attractive means of joining dissimilar materials. True/False

True

Adhesive joints often compensate for their lower strength by increasing the area of the bond. True/False

True

Brittleness is a property that is characteristic or descriptive of most ceramic materials. True/False

True

Can have integral color is a characteristic or description of most polymeric materials. True/False

True

Casting alloys can be heat-treated after casting for added strength.

True

Centerless grinding is a process that is performed quickly.

True

Centerless grinding is a process that is performed quickly. True or False

True

Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.

True

Centerless grinding requires the use of special, dedicated equipment to perform the grinding process. True or False

True

Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs.

True

Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs. True or False

True

Ease of fabrication is a characteristic or description of most polymeric materials. True/False

True

Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)

True

Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites). True or False?

True

For the honing process the amount of material removed is less than 0.005" from the surface.

True

For the honing process the amount of material removed is less than 0.005" from the surface. True or False

True

Good chemical and thermal stability is a property that is characteristic or descriptive of most ceramic materials.

True

Good corrosion resistance is a characteristic or description of most polymeric materials. True/False

True

Good elevated temperature creep resistance is a property that is characteristic or descriptive of most ceramic materials. True/False

True

High compressive strength is a property that is characteristic or descriptive of most ceramic materials. True/False

True

High elastic modulus is a property that is characteristic or descriptive of most ceramic materials. True/False

True

High hardness is a property that is characteristic or descriptive of most ceramic materials. True/False

True

High melting temperature is a property that is characteristic or descriptive of most ceramic materials. True/False

True

In centerless grinding, the work piece must be round and not include flats or keyways.

True

In centerless grinding, the work piece must be round and not include flats or keyways. True or False

True

Light weight is a characteristic or description of most polymeric materials. True/False

True

Low thermal expansion is a property that is characteristic or descriptive of most ceramic materials true/false

True

Magnesium can be cast to final shape provided special mold materials are used and the molten metal and hot solid is isolated from oxygen by some form of protective atmosphere. True/False

True

More flat surfaces are produced by the milling process than any other machining process

True

More flat surfaces are produced by the milling process than any other machining process. True or False

True

The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.

True

The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process. True or False?

True

The chemical machining process is used in mass-production of parts True or False?

True

The chemical machining process is used in mass-production of parts.

True

The corrosion resistance of titanium is due to an adherent oxide, much like aluminum True/False

True

The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.

True

The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials. True or False

True

The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.

True

The creep feed grinding process is used to grind deep slots with straight parallel sides into parts. True or False

True

The filing process is used to remove small amounts of material from a part.

True

The filing process is used to remove small amounts of material from a part. True or False

True

The operator should not have to reach past the tool to load/unload parts for machining.

True

The operator should not have to reach past the tool to load/unload parts for machining. True or False

True

The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.

True

The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel. True or False

True

True or False: A fixture/jig should be designed to tolerate variations in the workpiece.

True

True or False: Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.

True

True or False: Centerless grinding is a process that is performed quickly.

True

True or False: Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.

True

True or False: Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs.

True

True or False: Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)

True

True or False: For the honing process the amount of material removed is less than 0.005" from the surface.

True

True or False: In centerless grinding, the work piece must be round and not include flats or keyways.

True

True or False: More flat surfaces are produced by the milling process than any other machining process.

True

True or False: The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.

True

True or False: The chemical machining process is used in mass-production of parts.

True

True or False: The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.

True

True or False: The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.

True

True or False: The filing process is used to remove small amounts of material from a part.

True

True or False: The operator should not have to reach past the tool to load/unload parts for machining.

True

True or False: The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.

True

True or False: With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions.

True

True or False: Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.

True

Waterjet machining is used to cut nonmetals.

True

When magnesium is the material of choice, it is almost always for weight reduction. true/False

True

With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions.

True

With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions. True or False

True

Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly

True

Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.

True

Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly. True or False

True

The honing process is not used for which of the following:

Truing of holes

The honing process is not used for which of the following: A. truing of holes B. removing taper, waviness, and tool marks from the boring process C. sizing and finishing of bored holes D. removing tooling marks

Truing of holes

3) In slab milling operations, the direction of the cutting force is _____.

Up

For the up milling process, complete the statements with the answers supplied: In the slab milling operations, the direction of the cutting force is ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

Up

72

Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations. A. 100 B. 72 C. 48 D. 60

End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?

Vertical milling machine

Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder where the wheel diameter must exceed the width of the part being ground.A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

Vertical spindle reciprocating table

Surface grinder where the wheel diameter must exceed the width of the part being ground

Vertical spindle, reciprocating table

A surface grinder that can be equipped with multiple heads, ad automatic loading, and unloading is a

Vertical spindle, rotary table

Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

Vertical spindle, rotary table

Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.

Vertical spindle, rotary table

Surface grinding machine used in production operations.

Vertical spindle, rotary table

False

Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent. True or False?

die

What device is used to manually produce external threads? A .file B. taps C. Die D. grinding wheel

self opening die head

What device is used to produce external threads with lathes, screw machines, and threading machines? A. self closing die head B. self opening die head C. die attachment D. threader

straddle milling

What is the milling of two parallel surfaces with side cutters called? A. saddle milling B. twin milling C. parallel milling D. straddle milling

aluminum oxide

What is the most common material used for abrasives? A. plastic media B. silicon carbide C. diamond D. aluminum oxide E. dry ice F. CBN

T slot milling cutter

What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ? A. L-Slot milling cutter B. T-slot milling cutter C. Staggered-tooth mill cutter D. Plain milling cutter

.1 in^3/min/1000 amps

What is the typical MRR for electrochemical machining? A. in^3/ min/ 1000 amps B. .1 in^3/min/1000 amps C. 100 in^3/min/1000 amps

taps

What is used to produce internal threads?

80-90

What percentage of EDM is used to produce tool and die sets? A.10-20% B. 80-90% C. 70-80% D. 50-60%

cylindrical external

What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4. A. cylindrical external B. surface grinder C. None of these D. cylindrical internal

woodruff keyseat milling cutter

What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment? A. end mill cutter B. T-slot milling cutter C. woodruff keyseat milling cutter D. Slitting saw cutter

bonded

Which is the most frequently used mounting system for abrasives? A. free B. bonded C. mounted D. coated

Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

Which of the following applies to plasma arc cutting? A. Plasma arc cutting involves superheated gas for cutting only steel plates B. Plasma cutting involves super high pressure gas propelled at mach 30 for cutting conductive metals. C. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.

A process involving a rotating tool and X Y Z linear movement of the work piece

Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and rotating tooling B. A process involving a rotating tool and X-Y-Z linear movement of the work piece. C. A process involving a rotating work piece and X-Y-Z linear movement of the tooling D. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements.

A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

Which of the following describes the ultrasonic machining process? A. A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the materail being machined and the tool as a process to remove material. B. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. C. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. D. A harden steel tool is vibrated at low frequencies (<1000) with an small amplitude (~ 0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.

mounted

Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. free D. mounted

Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.

Which of the following is a correct statement for rapid prototyping? A. Rapid prototyping is an additive manufacturing process that can be produce parts fro various materials using various processes. B. Rapid prototyping is very expensive process and has very limited applications C. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.

flushing agent

Which of the following is a function of the dielectric in the electical discharge machining process? A. Flushing agent B. heating agent C. lubricant D. protective coating for the finished part

CBN

Which of the following is not a common material used for the teeth of a band saw blade? A. tungsten carbide B. diamond C. high speed steel D. CBN

square

Which of the following is not a common tooth for saw blades? A. square B. regular C. skip

insert tooth

Which of the following is not a type of broach construction? A. segment B. shell C. insert tooth D. solid

aluminum chips

Which of the following is not an abrasive material used in commercial cleaning applications? A. walnut shells B. dry ice C. aluminum chips D. plastic media

can be used for cutting metal based composite materials

Which of the following is not an advantage of plasma arc cutting? A. small heat-affected zone B. Can be used for cutting metal based composite materials C. very fast cutting D. smooth cuts free of contaminants are produced

cutting thick materials

Which of the following is not an application for laser beam machining? A. welding B. cutting thin materials C. Drilling micro-sized holes D. cutting thick materials

Horizontal spindle, reciprocating table

Which of the following is the most common type of surface grinding machine? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

aluminum

Which of the following materials is not commonly used as a lap? A. Aluminum B. Copper C. Cloth D. Cast iron

air

Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. grease B. oil C. water D. air

The mask is applied to the area of the part that is desired to not remove material from the part

Which of the following statements correctly describes the purpose of the mask in chemical machining? A. The mask is applied to the area of the part that is desired to not remove material from the part B. The mask is applied to the area of the part that it is desired to removal material from the part. C. The mask enhances the chemical machining process. D. None of the above.

A very specialized process for machining developed for machining parts for NASA rocket engine parts.

Which of the following statements for electical discharge machining is incorrect? A. A matt finished is produced by the EDM process B. A very specialzied process for machining developed for machining parts for NASA rocket engine parts. C. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. D. Most frequently used of NTM processes.

one or more axes are always accelerating in a 3D cut

Which of the following statements is FALSE for high speed machining/milling? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. Cutting speed for steel is less than 1500 m/min D. One or more axes are always accelerating in a 3-D cut. E. A high material removal rate is obtained

the threads produced by thread rolling have a lower strength than cut threads

Which of the following statements is FALSE for rolled threads? A. Rolled threads have a hard, wear resistance, smooth surface. B. the threads produced by thread rolling have a lower strength than cut threads. C. Rolled threads have a major diameter larger than the diameter of the base stock.

Thread rolling is a hot forming process

Which of the following statements is FALSE regarding the thread rolling process? A. Thread rolling is a hot forming process B. Thread rolling can be used to form threads on tubular products C. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second.

only coarse threads can be produced

Which of the following statements is FALSE regarding thread grinding? A. only coarse threads can be produced B. threads in hardened steels can be produced C. using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. very accurate, fine pitched threads can be produced

the clamping forces should be spread over a small area

Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.

Vertical spindle, reciprocating table

Which of the following surface grinder requires the wheel diameter to exceed the width of the part being abrasively machined? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

horizontal spindle, rotary table

Which of the following surface grinder types is typically NOT used due to limited type of work which it will accommodate? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

vertical spindle, rotary table

Which of the following surface grinding machines is frequently used in production operations? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

Vertical spindle, rotary table

Which surface grinder can be equipped with multiple grinding heads and automatic loading and unloading of the parts? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

False

With centerless grinding tubes will automatically have concentric inside and outside diameters. True or False

True

With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions. True or False

True

Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly. True or False

False

Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool. True or False

electrostatic chuck

You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice? A. electrostatic chuck B. vise C. toggle clamps D. magnetic chuck

The surface finish of a mold or plastic injection molding can be damaged by

a finger print

Cermets gain their enhanced toughness through:

a metal matrix.

The aluminum designation system identifies metal chemistry. An aluminum alloy with a four-digit designation would be considered to be:

a wrought alloy.

A dividing head is an accessory used with a milling machine primarily to provide what operation?

accurate rotation of the work piece through any desired arc of rotation

A dividing head is an accessory used with a milling machine primarily to provide what operation? A. rotation of a part 90 degrees so that additional machining can be performed on it B. rotation of a part 180 degrees C. accurate rotation of the work piece through any desired arc of rotation D. rotation of a group of parts so that the next piece in the group can be machined

accurate rotation of the work piece through any desired arc of rotation

1) The mill cutter rotates ___ the direction of feed.

against

For the up milling process, complete the statements with the answers supplied The mill cutter rotates ___ the direction of feed.

against

For the up milling process, complete the statements with the answers supplied: The mill cutter rotates ____ the direction of feed. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

against

In up milling, the cutter rotates ___ the direction of the feed

against

In up milling, the cutter rotates _____ the direction of the feed.

against

The most effective strengthening method for aluminum alloys is:

age hardening

Which of the following materials is not used a a carrier to charge the lap with abrasive particles?

air

Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. grease B. oil C. water D. air

air

CNC milling machines are used in machining operations because:

all of the above

Which of the following materials is not commonly used as a lap? A. Aluminum B. Copper C. Cloth D. Cast iron

aluminum

Which of the following is not an abrasive material used in commercial cleaning application?

aluminum chips

Which of the following is not an abrasive material used in commercial cleaning applications?

aluminum chips

Which of the following is not an abrasive material used in commercial cleaning applications? A. walnut shells B. dry ice C. aluminum chips D. plastic media

aluminum chips

What is the most common material used for abrasives?

aluminum oxide

What is the most common material used for abrasives? A. plastic media B. silicon carbide C. diamond D. aluminum oxide E. dry ice F. CBN

aluminum oxide

In the color anodizing process, the material being colored is:

aluminum oxide.

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 45 degree, V shaped groove in the surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

angle cutter

Type of milling cutter: 45 degree, V shaped groove in the surface of a flat bar

angle cutter

The chips formed during the broaching process

are trapped in the gullet until the cutting edge exits the workpiece

The chips formed during the broaching process:

are trapped in the gullet until the cutting edge exits the workpiece

The crystal structures of ceramic materials are often quite complex because:

atoms of different sizes are in the same structure,covalent structures often have a limited number of nearest neighbors,charge neutrality must be maintained throughout ionic structures

The "degree of polymerization" refers to the:

average number of mers per molecule

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

ball end mill

Which cutter is best: producing a groove with a 1/8" diameter concave bottom

ball end mill

What is the type of mill cuter used to produce a grove with a 1/8" diameter concave bottom in a vertical milling machine?

ball nose end mill

The most common sawing machine is

band saw

The most common type of sawing machine for cutting metal is : A. cold saw B. power hacksaw C. bandsaw D. milling machine

bandsaw

The most common type of sawing machine for cutting metal is____.

bandsaw

In mass-production opeations, a milling machine with the capability of making heavy cuts, having 1,2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine? A. knee-and-column milling machine B. universal milling machine C. bed milling machine D. gantry milling machine

bed milling machine

In mass-production operations, a milling machine capable of making heavy cuts, having 1,2, or 3 spindles, and without vertical tale motion is often used. This is a

bed milling machine

In mass-production operations, a milling machine with the capability of making heavy cuts, having 1,2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine?

bed milling machine

Titanium has a density that is:

between steel and aluminum.

Which is the most frequently used mounting system for abrasives?

bonded

Which is the most frequently used mounting system for abrasives? A. free B. bonded C. mounted D. coated

bonded

While it is unlikely that we will be able to change the ___ of ceramic materials, it may be possible to impart significant amounts of ___.

brittleness, toughness

Which of the following is not an advantage of plasma arc cutting? A. small heat-affected zone B. Can be used for cutting metal based composite materials C. very fast cutting D. smooth cuts free of contaminants are produced

can be used for cutting metal based composite materials

The threads on plastic flood containers are formed by:

casting

Clamping forces must be greater than what four (4) forces? A. aerodynamic B. centrifugal C. frictional D. gravity E. inertial F. cutting

centrifugal gravity intertial intertial cutting

Clamping forces must be greater than what four (4) forces?

centrifugal, gravity, cutting, inertial

The cemented carbide on a carbide-tipped drill is actually carbide particles bonded by cobalt metal. This is an example of a:

cermet

Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material.

charged

Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material. A. charged B. mounted C. lapped D. pasted

charged

The teeth of an end mill cutter are located on the ___.

circumference and the face of the cutter

The teeth of an end mill cutter are located on the ___. A. circumference and the face of the cutter B. circumference of the cutter C. face of the cutter

circumference and the face of the cutter

The teeth of an end mill cutter are located on the___.

circumference and the face of the cutter

The suffix (the letter or letter and number that appear after the hyphen) in the aluminum designation system designates the material:

condition (past processing history).

The bonding mechanism between the atoms along the spine of linear polymers is:

covalent

The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole?

crosshatch

The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole? A. no defined pattern B. circular C. crosshatch

crosshatch

The equilibrium structure in ceramic materials (lowest energy) would be:

crystalline

The abrasive machining process is a mixture of processes, which of the processes produces the *chips* are formed by the grit?

cutting

The abrasive machining process is a mixture of processes. Which of the processes produces the chips formed by the grit?

cutting

Which of the following is not an application for laser beam machining? Welding Drilling micro-sized holes Cutting thick materials Cutting thin materials

cutting thick materials

Which of the following is not an application for laser beam machining? A. welding B. cutting thin materials C. Drilling micro-sized holes D. cutting thick materials

cutting thick materials

Clamping forces must be greater than what four (4) forces?

cutting, gravity, inertial, and centrifugal

What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.

cylindrical external

What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4. A. cylindrical external B. surface grinder C. None of these D. cylindrical internal

cylindrical external

Increasing the amount of initiator or activator in an addition polymerization reaction will ___ the length of the chains and ___ the strength of the resulting polymer.

decrease, decrease

The fracture resistance of a ceramic can be best improved by:

decreasing the flaw size.

What device is used to manually produce external threads? A .file B. taps C. Die D. grinding wheel

die

Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit.

dull flattening

Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit. A. dislodging B. sharp C. dull D. flattening

dull (x) flattening (y)

Attrition refers to the material property regarding the wearing action of the abrasive, resulting in ___ edges and ___ of the abrasive grit.

dull, flattening

Beryllium is unique among the engineering metals because of its extremely high:

elastic modulus

You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice?

electrostatic chuch

You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice?

electrostatic chuck

You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice? A. electrostatic chuck B. vise C. toggle clamps D. magnetic chuck

electrostatic chuck

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

end mill

Producing a flat-bottom groove in the surface of a part

end mill

Which cutter is best: Deep slots with straight side walls

end mill

Which cutter is best: producing a pocket in a workpiece

end mill

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

face mill

Which cutter is best: finishing the top surface of a work piece

face mill

Broaching is a process that can be used only in mass-production.

false

For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.

false

In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish.

few excellent

Tapered end mills are used for ____ A. rough cutting in the machining of molds B. both rough and finished cutting in the machining of molds C. Finish cutting on molds to produce a desired angle D. machining a chamfer on finished parts

finish cutting on molds to produce a desired angle

Tapered end mills are used for ____.

finish cutting on molds to produce a desired angle

Which of the following is a function of the dielectric in the electical discharge machining process? A. Flushing agent B. heating agent C. lubricant D. protective coating for the finished part

flushing agent

Which of the following is a function of the dielectric in the electrical discharge machining process? Flushing agent Lubricant Protective coating for the finished part Heating agent

flushing agent

The ability to load a part into a fixture only one way is called?

fool proofing

The ability to load a part into a fixture only one way is called? A. proofing B. fool proofing C. robotic design D. auto loading

fool proofing

Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter

form cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 1/4" radius, convex shape along the edge of a part A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

form cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Deep slots in a work piece A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

form cutter

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Milling wood to produce wood trim A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

form cutter

Type of milling cutter: 1/4" radius, convex shape along the edge of a part

form cutter

Type of milling cutter: Milling wood to produce wood trim

form cutter

Which cutter is best: bearing pocket in gearbox housing

form cutter

While crystalline ceramic materials contain dislocations, they do not exhibit plastic deformation because:

fracture occurs at a lower stress than dislocation movement

Friability refers to the ability of the abrasive material to ____.

fracture, producing new, sharp edges

Friability refers to the ability of the abrasive material to ____. A. form chips B. withstand high temperatures C. withstand exposure to water and cutting oils D. fracture, producing new, sharp edges

fracture, producing new, sharp edges

By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics

hard glass, ceramics, carbides

By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics

hard (m) glass(n) ceramics (o) carbides (p)

By using extremely ___ materials for abrasives, it is possible to machine hardened steel, ___, ___, and ___. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics

hard, glass, ceramics, carbides

Synthetic abrasive materials are commonly used in manufacturing instead of natural abrasive materials because synthetic materials

have more uniform physical properties

The highest strength aluminum alloys are:

heat-treatable.

Bandsaw blades are frequently made with teeth of what material

high speed steel

A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.

holds size

A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.

holds (x) size (y)

A fixture is a special workholding device that ___ during machining or assembly operations

holds the workpiece and determines size demensions

A fixture is a special workholding device that ___ the workpiece during machining or assembly operations and establishes ___ dimensions.

holds, size

Superfinishing is a variation of what process to finish flat surfaces.

honing

Superfinishing is a variation of what process to finish flat surfaces. A. lapping B. None of these C. surface grinding D. honing

honing

Slab milling is typically performed using what type of knee-and-column milling machine?

horizontal milling machine

Slab milling is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. vertical milling machine C. both horizontal and vertical milling machines

horizontal milling machine

Which surface grinder type: The most common type of surface grinding machine.

horizontal spindle, reciprocating table

Which surface grinder type: Surface grinder not typically used due to limited type of work which it will accommodate.

horizontal spindle, rotary table

Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder not typically used due to limited type of work which it will accommodate. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

horizontal spindle, rotate table

Which of the following is not a type of broach construction?

insert tooth

Which of the following is not a type of broach construction? A. segment B. shell C. insert tooth D. solid

insert tooth

Broaching was orginally developed for the production of ____.

internal keyways

Broaching was orginally developed for the production of ____. A. splines B. internal keyways C. flat surfaces D. external keyways

internal keyways

Broaching was originally developed for the production of ____.

internal keyways

Ceramic materials have ___ atomic bonding.

ionic or covalent

The slot cut in the material by a saw blade is called ____.

kerf

The slot cut int eh material by a saw blade is called ____. A. slot B. groove C. kerf D. gullet

kerf

The soft material used in the lapping process is called _______.

lap

The soft material used in the lapping process is called _______. A. felt B. rouge C. lap D. None of these

lap

For elevated temperature creep resistance, a crystalline ceramic should have ___ crystals.

large

A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.

location

Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways.

longitudinal (X-axis)

Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

longitudinal (x axis)

In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish. A. Rough B. excellent (y) C. many (x) D. few E. two F.three

many (x) excellent (y)

In the abrasive machining process, ___ edges are cutting simultaneously resulting in a(n) ___ surface finish.

many, excellent

3) The chip thickness is a ___ at the beginning of the chip formation.

maximum

5) The chip thickness is a ___ as the end of the chip formation as the tool exits the work piece

maximum

For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.

maximum

For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ as the end of the chip formation as the tool exits the work piece

maximum

For the up milling process, complete the statements with the answers supplied: The chip thickness is a ____ at the end of the chip formation as the tool exits the work piece. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

maximum

4) The chip thickness is a ___ at the beginning of the chip formation.

minimum

4) The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.

minimum

For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.

minimum

For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.

minimum

For the up milling process, complete the statements with the answers supplied: The chip thickness is a _____ at the beginning of the chip formation. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

minimum

Loading and unloading of a fixture will often abuse the fixture ____ .

more than the machining operation

Loading and unloading of a fixture will often abuse the fixture ____ . A. less than the machining operation B. more than the machining operation C. equal to the machining operation

more than the machining operation

Which of the following is NOT a type of mounting method that is used with the abrasive machining process?

mounted

Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. free D. mounted

mounted

The milling process uses [x] and involves [y] cutting. a) single-point tool b) multi-tooth cutter c) continuous d) interrupted

multi tooth cutter interrupted

The milling process typically uses

multi-point tools

The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter. A. single-stroke B.multi-stroke C.single D.multi (y) E.a single pass F.multiple passes

multi-stroke (x) multi (y)

The milling process uses __ and involves __ cutting

multi-tooth cutter interrupted

The milling process uses _____ and involves _____ cutting.

multi-tooth cutter, interrupted

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface. A. one tooth B. multiple teeth C. more D. less E. rougher (higher surface roughness value) F. smoother (lower surface roughness value)

multiple teeth less smoother (lower surface roughness value)

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface.

multiple teeth less smoother (lower surface roughness value)

A plain arbor helical-toothed cutter is preferred over straight-toothed cutters because

multiple teeth contact the work during the milling operation

Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface.

multiple teeth, less, smoother (lower surface roughness value)

Mill cutters manufacturing from carbide and ceramic have a ____ rake angle

negative

Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter. A. positive B. negative C. 10-15 D. 3-5

negative 3-5

Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter.

negative 3 to 5

Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter.

negative, 3 to 5

The best corrosion resistance is found in alloys that are

non-heat-treatable

Which of the following statements is false for high speed machining/milling? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. Cutting speed for steel is less than 1500 m/min D. One or more axes are always accelerating in a 3-D cut. E. A high material removal rate is obtained

one or more axes are always accelerating in a 3D cut

Which of the following statements is false regarding thread grinding? A. only coarse threads can be produced B. threads in hardened steels can be produced C. using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. very accurate, fine pitched threads can be produced

only coarse threads can be produced

In the slab milling process, the finished surface is _____ to the axis of rotation of the cutter and is normally performed on a ____ spindle milling machine.

parallel horizontal

In the slab milling process, the finished surface is _____ to the axis of rotation of the cutter and is normally performed on a ____ spindle milling machine.

parallel, horizontal

Which of the following is not an abrasive material used in commercial cleaning applications?

peanuts

In face milling, most of the cutting occurs at what area of the cutter?

peripheral edge

Ceramic materials excel when:

physical properties dominate the selection process.

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) finishing the top surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

plain cutter

Type of milling cutter: finishing the top surface of a flat bar

plain cutter

In ___ products, threads are frequently produced by casting.

plastic

In _____ products, threads are frequently produced by casting.

plastic

The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips.

plowing rubbing cutting

The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips. A. Cutting B. digging C. plowing (x) D. rubbing (y) E. scrapping F. planning

plowing (x) rubbing (y)

The abrasive machining process is a mixture of three processes; ___ moves material, ___ causes friction and ___ forms chips.

plowing, rubbing, cutting

Crystalline ceramic products are usually fabricated by

pressing and firing solid particles

A CNC milling machine ___.

provides for machining of more complex parts than a manual milling machine

Tempered glass has enhanced fracture resistance because it incorporates:

quenching to produce compressive residual stresses on the surface

The blade width determines the minimum ___ that can be cut with a bandsaw for contour cutting

radius

The blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade

radius

The blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade.

radius

The blade width of the saw blade determines the minimum ____ that can be cut with a bandsaw blade A. depth of cut B. radius C. rate of cutting D. thickness

radius

Conventional abrasive machine involves

rapid movement of abrasive grit at a shallow depth of cut

Ceramic materials that are used for applications like the containment of molten metals are:

refractories

In centerless grinding, the ____ controls the rotation and longitudinal motion of the workpiece

regulating wheel

"Power filing" is frequently performed with ___.

rotary burrs

"Power filing" is frequently performed with ____ A. a filing machine B. band filing C. rotary burrs D. disk filing

rotary burrs

Powered filing is most frequently performed with

rotary burrs

In centerless grinding, the regulating wheel controls _____ in the grinding process.

rotating speed and axial feed of the work piece

In centerless grinding, the regulating wheel controls _____ in the grinding process. A. rotating speed of the grinding wheel B. axial feed of the workpiece C. rotating speed of the workpiece D. rotating speed and axial feed of the work piece

rotating speed and axial feed of the work piece

The abrasive machining process is a mixture of processes. Which of the processes produces friciton?

rubbing

What device is used to produce external threads with lathes, screw machines, and threading machines? A. self closing die head B. self opening die head C. die attachment D. threader

self opening die head

What device is used to produce external threads with lathes, screw machines, and threading machines?

self-opening die head

The pattern used to offset the saw blade teeth from the center-line of the blade is called ___.

set

The pattern used to offset the saw blade teeth from the centerline of the blade is called ___.

set

The pattern used to offset the saw blade teeth from the centerline of the blade is called ____. A. pitch B. rake C. set

set

The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?

sewing machine

The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?

sewing machines

The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device? A. revolvers B. sewing machines C. bicycle bearings D. steam engines

sewing machines

Wrought alloys are shaped how

shaped as a solid

What process is used to manufacture the jaw teeth on a pipe wrench as discussed in class?

shaping

The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter.

single stroke multi a single pass

The broaching process can be described as: A _____ process using a _____-tooth cutter to remove material with roughing and finishing operations performed in _____ of the cutter.

single-stroke, multi, a single pass

Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) deep, straight walled, narrow slots A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter

slitting saw cutter

Type of milling cutter: deep, straight walled, narrow slots

slitting saw cutter

The clamping forces should be:

spread over a large area to avoid distorting the part

Which of the following is not a common tooth for saw blades? A. square B. regular C. skip

square

Which of the the following is not a common tooth form for saw blades?

square

Type of milling cutter: Deep slots in a work piece

staggered-tooth cutter

What is the milling of two parallel surfaces with side cutters called?

straddle milling

Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter. A. straight B. pointed C. spiral D. helical

straight helical

Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter.

straight helical

Magnetic chucks are commonly used on what type of machinery?

surface grinders

Magnetic chucks are commonly used on what type of machinery? A. Lathes B. Surface grinders C. Micro-drill presses D. Milling machines

surface grinders

To thread a blind hole the threes types of taps used, in order are [x], [y], and [z].

taper plug bottom

To thread a blind hole the threes types of taps used, in order are ___, ___, and ___.

taper, plug, bottom

To thread a blind hold the three types of taps used, in order are ___, ___, and ___.

tapered plug bottoming

Internal threads are produced using

taps

What is used to produce internal threads?

taps

Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.

the damping forces should be spread over a small area

In the equation fm=ftNn, n refers to

the number of teeth on the cutter

The coarseness of a file is determined by

the pattern of cut and length of the file

For grinding wheels, dressing refers to ____.

the process to clean the grinding wheel and sharpen the abrasive particles

The structure of a grinding wheel refers to ___.

the spacing of the abrasive grit in the wheel

The structure of a grinding wheel refers to ____.

the spacing of the abrasive grit in the wheel

The structure of a grinding wheel refers to ____. A. the strength of the bonds between the abrasive grit in the wheel B. The ratio of the bonding material volume to the abrasive material volume C. The ration of the bonding material weight to the abrasive material weight D. the spacing of the abrasive grit in the wheel

the spacing of the abrasive grit in the wheel

The structure of a grinding wheel refers to

the spacing of the abrasive particles

The grade of a grinding wheel refers to ___.

the strength of the bonds between the abrasive grits

The grade of a grinding wheel refers to ____.

the strength of the bonds between the abrasive grits

Which of the following statements is false for rolled threads? A. Rolled threads have a hard, wear resistance, smooth surface. B. the threads produced by thread rolling have a lower strength than cut threads. C. Rolled threads have a major diameter larger than the diameter of the base stock.

the threads produced by thread rolling have a lower strength than cut threads

For American pattern files, the coarseness of the file cut is given by:

the tooth pattern and the length of the file

For American pattern files, the coarseness of the file cut is given by: A. xx teeth/ inch B. the tooth pattern and the length of the file C. tooth pattern of the file D. the length of the file

the tooth pattern and the length of the file

in up milling, the chip starts out ___ and is ____ as the tool exists the workpeice

thin/thick

The process for machining threads which requires a CNC machining center capable of circular interpolation is ___.

thread milling

The principle of 3-2-1 uses location points to define ___.

three (3) perpendicular planes

The functionality of polymer reactants that form 3-dimensional network polymers is

three or more

The principle of 3-2-1 uses location points to define ___. A. three (3) intersecting planes B. 6 points C. 3 axis, 2 rotations, 1 point D. three (3) perpendicular planes

three perpendicular planes

The designation scheme for cast aluminum alloys involves a:

three-digit number.

2) The direction of the cutting forces are ____.

toward the part

For the up milling process, complete the statements with the answers supplied The direction of the cutting forces are ____.

toward the part

For the up milling process, complete the statements with the answers supplied: The Direction of the cutting forces are ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up

toward the part

Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways

transverse (Y-axis)

The saddle provides ___ movement on the knee ways

transverse (Y-axis)

Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

transverse (y axis)

The honing process is not used for which of the following:

truing of holes

A requirement for broaching is that ___ teeth be in contact with the work piece.

two

A requirement for broaching is that ___ teeth be in contact with the workpiece.

two

A requirement for broaching is that _____ teeth be in contact with the workpiece. A. two B. one C. three D. five

two

The functionality of polymer reactants that form linear or chain-type polymers is: #

two

For the up milling process, complete the statements with the answers supplied In slab milling operations, the direction of the cutting force is _____.

up

The wide variation in mechanical properties for nominally "identical" ceramic components (same material and same processing) can be attributed to:

variation in the size, shape and location of flaws

The most common type of broaching machine construction is ____.

vertical

The most common type of broaching machine construction is ____. A. vertical B. Horizontal

vertical

Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways.

vertical (Z-axis)

Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)

vertical (z axis)

The knee provides ____ movement on the column ways.

vertical (z-axis)

End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?

vertical milling machine

End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. both vertical and horizontal milling machines C. vertical milling machine

vertical milling machine

Which surface grinder type: Surface grinder where the wheel diameter must exceed the width of the part being ground

vertical spindle, reciprocating table

Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinding machine used in production operations. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table

vertical spindle, rotary table

Which surface grinder type: Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.

vertical spindle, rotary table

Which surface grinder type: Surface grinding machine used in production operations.

vertical spindle, rotary table

2) In slab milling operations, the direction of the cutting force is ____.

vertically down

For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.

vertically down

Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.

vise chuck

Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.

vise chuch

Common base elements for fixtures are a ___ for milling and a ___ for lathe operations.

vise, chuck

1) The mill cutter rotates ____ the direction of feed.

with

For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.

with

In down milling, the cutter rotates _____ the direction of the feed.

with

What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment?

woodruff keyseat milling cutter

What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment? A. end mill cutter B. T-slot milling cutter C. woodruff keyseat milling cutter D. Slitting saw cutter

woodruff keyseat milling cutter