MECH ENG 2653 Exam 4

What is the typical MRR for electrochemical machining?

0.1 in^3/min/1000 amps

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

150

Identify the type of milling cutter that would be used for each of the following milling operations 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 - Angle Cutter Finishing the top surface of a flat bar - Plain Cutter Deep, straight walled, narrow slots - Slitting saw cutter 1/4 radius, convex shape along the edge of a part - form cutter Milling wood to produce wood trim - form cutter Deep slots in a work piece - Staggered-too

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

To finish threading a blind hole you would first use a taper tap, followed by a plug tap, and finally a [x] tap.

Bottoming

The non-traditional machining process used to manufacture printed circuit boards is____.

Chemical Machining

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

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 - End Mill Finishing the top surface of a work piece - Face Mill Producing a groove with a 1/8 diameter concave bottom - Ball End Mill Bearing pocket in gearbox housing - Form Cutter Producing a pocket in a workpiece - End Mill Producing a flat-bottom groove in the surface of a part - end mill

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

False

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

False

The numeric control programming language used for computer-aided manufacturing (CAM) is called

G-Code

Which of the following statements is false regarding thread grinding?

Only coarse threads can be produced.

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.

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

Plowing/Rubbing/Cutting

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

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

What device is commonly used to quickly produce external threads on screw machines?

Self-opening die head

For the down milling process, complete the statements with the answers supplied

The mill cutter rotates ____ the direction of feed - with In slab milling operations, the direction of the cutting force is - vertically down The chip thickness is a _____ at the beginning of the chip formation - Maximum The chip thickness is a ____ at the end of the chip formation as the tool exits the work piece - Minimum

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

Thread rolling is a hot forming process.

Centerless grinding is a process that is performed quickly.

True

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

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

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

True

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

True

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

True

The use of a spiral fluted tap is to force chips up (rearward) and out of a hole during the threading process.

True

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

peripheral edge

A CNC milling machine ___.

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

The structure of a grinding wheel refers to ___.

the spacing of the abrasive grit in the wheel