Combo with "Chapter 18" and 1 other
Which of the following stress or strength parameters is used in the computation of the maximum force in a forging operation (one best answer): (a) average flow stress, (b) compression strength, (c) final flow stress, (d) tensile strength, or (e) yield strength?
Final flow stress
What is a factory that performs casting operations usually called?
Foundry
In a turning operation, the change in diameter of the workpart is equal to which one of the following: (a) 1 x depth of cut, (b) 2 x depth of cut, (c) 1 x feed, or (d) 2 x feed?
2 x depth of cut
Which of the following are basic bulk deformation processes in metal forming (three correct answers): (a) bar drawing, (b) blanking, (c) deep drawing, (d) extrusion, (e) forging, and (f) stamping?
Bar drawing, extrusion, forging
Which of the following are the three most common machining operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, (e) planing, (f) shaping, or (g) turning?
Drilling, milling, and turning
Machining is noted for which of the following characteristics relative to other manufacturing processes (two best answers): (a) creates three-dimensional geometries, (b) good dimensional accuracy, (c) net shape process, (d) poor surface finish, (e) wasteful of energy, (f) wasteful of material?
Good dimensional accuracy and wasteful of material
According to the empirical relationship in the previous question, total solidification time is proportional to which one of the following quantities: (a) (A/V)n, (b) Hf, (c) Tm, (d) V, (e) V/A, or (f) (V/A)2; where A = surface area of casting, Hf = heat of fusion, Tm = melting temperature, and V = volume of casting?
(V/A)2
A facing operation is normally performed on which one of the following machine tools: (a) drill press, (b) lathe, (c) milling machine, (d) planer, or (e) shaper?
A Lathe
When the drill bit in a drilling operation exits the opposite side of the work, the resulting hole is called which one of the following: (a) a blind hole or (b) a through hole?
A Through Hole
In casting processes, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity, (b) worker who moves the molten metal to the mold, or (c) vertical channel into which molten metal is poured into the mold?
A channel in the mold leading from the downsprue to the main mold cavity
Products purchased by companies to produce products or provide services are called which one of the following: (a) assembled products, (b) capital goods, (c) consumer goods, (d) final products, or (e) manufactured products?
Capital goods
Which one of the following casting metals is most important commercially: (a) aluminum and its alloys, (b) bronze, (c) cast iron, (d) cast steel, or (e) zinc alloys?
Cast Iron
Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast iron, (c) copper, (d) gold, and (e) steel?
Cast Iron and Steel
Identify some of the important advantages of shape-casting processes.
Casting can be used to create complex geometries, including internal and external shapes. Casting can produce final product 'net shapes' or 'near net' Can be used to create large parts ( over 100 tons) Can be mass produced Can be used on any metal that can become a liquid.
In a GO/NO GO gage, which one of the following best describes the function of the GO gage: (a) checks the limit of maximum tolerance, (b) checks the maximum material condition, (c) checks the maximum size, (d) checks the minimum material condition, or (e) checks the minimum size?
Checks the maximum material condition
The empirical relationship that determines total solidification time in casting is known as which one of the following: (a) Bernoulli's theorem, (b) Chvorinov's rule, (c) continuity law, (d) flow curve, (e) Hooke's law, or (f) Ohm's law?
Chvorinov's Rule
Which of the following rolling mill types are associated with relatively small diameter rolls in contact with the work (two correct answers): (a) cluster mill, (b) continuous rolling mill, (c) four high mill, (d) reversing mill, and (e) three high configuration?
Cluster mill, four high mill
What is the difference between deep drawing and bar drawing?
Deep drawing is a sheet metal forming process used to fabricate cup-shaped parts; bar drawing is a bulk deformation process used to reduce the diameter of a cylindrical work part Deep drawing is a sheet metal forming process used to fabricate cup shapes parts while bar drawing is a bulk deformation part used to reduce the diameter of a cylinder.
Surface texture includes which of the following characteristics of a surface (three correct answers): (a) deviations from the nominal surface, (b) feed marks of the tool that produced the surface, (c) hardness variations, (d) oil films, and (e) surface cracks?
Deviations from the nominal surface, feed marks of the tool that produced the surface, and surface cracks
What is meant by the term superheat?
Difference between temperature at pouring and temperature at solidification
One of the first applications of digital computers in manufacturing was direct numerical control, which is best described by which one of the following: (a) computers used to count work units on a production line, (b) flexible manufacturing, (c) mainframe computers used to remotely control
Mainframe computers used to remotely control machine tools in a factory
List some of the products produced on a rolling mill.
Products made by shape rolling include construction shapes such as I-beams, L-beams, and U-channels; rails for railroad tracks; and round and square bars and rods
Which casting process is the most important commercially?
Sand Casting
One way to classify forging operations is by the degree to which the work is constrained in the die. By this classification, name the three basic types.
open die, flashless die, impression die forging
During solidification of an alloy when a mixture of solid and liquid metals is present, the solid-liquid mixture is referred to as which one of the following: (a) eutectic composition, (b) ingot segregation, (c) liquidus, (d) mushy zone, or (e) solidus?
solidus
The upper half of a sand-casting mold is called which of the following: (a) cope or (b) drag?
Cope
The upper half of a sand-casting mold is called which one of the following: (a) cope, (b) drag, (c) flask, or (d) pattern?
Cope
Which one of the following cutting conditions has the strongest effect on cutting temperature: (a) cutting speed, (b) depth of cut, or (c) feed?
Cutting speed
Which of the following cost categories are considered to be variable costs rather than fixed costs (two correct answers): (a) direct labor, (b) equipment, (c) insurance, (d) maintenance, (e) work material, and (f) research and development?
Direct Labor and Work material
Direct V Indirect Excursion
Direct, pushed through die indirect, die is part of ramming mechanism
Reaming is used for which of the following functions (three correct answers): (a) accurately locate a hole position, (b) create a stepped hole, (c) enlarge a drilled hole, (d) improve surface finish on a hole, (e) improve tolerance on hole diameter, and (f) provide an internal thread?
Enlarge a drilled hole, improve surface finish on a hole, and improve tolerance on a hole diameter
Sand casting is which of the following types: (a) expendable mold or (b) permanent mold?
Expendable
. Name the two basic mold types that distinguish casting processes.
Expendable Mold Casting - Broken off and shape is saved Permanent Mold Casting - Mold can be used several times
Sand casting is which of the following types of casting process: (a) expendable mold or (b) permanent mold?
Expendable mold
With which one of the following geometric forms is the turning operation most closely associated: (a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads, or (e) sphere?
External Cylinder
Johnson's formula is associated with which one of the four bulk deformation processes: (a) bar and wire drawing, (b) extrusion, (c) forging, and (d) rolling?
Extrusion
Which of the following are bulk deformation processes (three correct answers): (a) bending, (b) deep drawing, (c) extrusion, (d) forging, (e) rolling, and (f) shearing?
Extrusion - compression process in which metal is forced to flow through die opening and cross section takes dimensions of die opening Deep drawing - reduction in diameter of a cylindrical part Rolling - thickness of slab is reduced with 2 rollers
Production of pipes and tubes is associated with which of the following bulk deformation processes (three correct answers): (a) extrusion, (b) hobbing, (c) ring rolling, (d) roll forging, (e) roll piercing, (f) tube sinking, and (g) upsetting?
Extrusion, roll piercing, tube sinking
What is a two-high rolling mill?
A shape rolling process in which two opposing rollers are used to achieve compression.
A broaching operation is best described by which one of the following: (a) a rotating tool moves past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary workpart, (c) a workpart is fed past a rotating cutting tool, or (d) a workpart moves linearly past a stationary single-point tool?
A tool with multiple cutting teeth moving linearly past a stationary workpart
What is a reverse mill in rolling?
A two-high rolling process in which the rollers can go in reverse as well to compress the work piece from either side
In rolling of steel, what are the differences between a bloom, a slab, and a billet?
Abloom has a square cross section 150 mm 150 mm (6 in 6 in) or larger. A slab is rolled from an ingot or a bloom and has a rectangular cross section of width 250mm (10 in) or more and thickness 40 mm (1.5 in) or more.Abillet is rolled froma bloomand is square with dimensions 40mm(1.5 in) on a side or larger.
Which one of the following metals would usually have the lowest specific energy in a machining operation: (a) aluminum, (b) brass, (c) cast iron, or (d) steel?
Aluminum
Which of the following are advantages of die casting over sand casting (four best answers): (a) better surface finish, (b) closer tolerances, (c) higher melting temperature metals can be cast, (d) higher production rates, (e) larger parts can be cast, and (f) mold can be reused?
Better surface finish, closer tolerances, higher production rates, and mold can be reused
A lathe can be used to perform which of the following machining operations (three correct answers): (a) boring, (b) broaching, (c) drilling, (d) milling, (e) planing, and (f) turning?
Boring, Drilling, and Turning
Cupolas are furnaces used to melt which of the following metals (one best answer): (a) aluminum, (b) cast iron, (c) steel, or (d) zinc?
Cast Iron
Which of the following are classified as forging operations (four correct answers): (a) coining, (b) fullering, (c) impact extrusion, (d) roll piercing, (e) swaging, (f) thread rolling, (g) trimming, and (h) upsetting?
Coining, fullering, swaging, upsetting
Extrusion is a fundamental shaping process. Describe it.
Compression process in which the work metal is passed through a die, thereby taking the shape of the die opening
In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity: (a) true or (b) false?
False (cold chamber)
In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning: (a) depth of cut d, (b) feed f, or (c) speed v?
Feed, f
Indicate some of the advantages of cold working relative to warm and hot working.
Greater accuracy resulting in smaller tolerances Better surface finishes Higher strength and hardening due to strength hardening Cast savings from reduced heat energy usage
Which one of the following manufacturing processes is likely to result in the best surface finish: (a) arc welding, (b) grinding, (c) machining, (d) sand casting, or (e) sawing?
Grinding
Which of the following manufacturing processes are classified as material removal processes (two correct answers): (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) molding, (h) pressworking, and (i) spinning?
Grinding and Machining
Which of the following operations are classified as material removal processes (three correct answers): (a) anodizing, (b) brazing, (c) forging, (d) grinding, (e) milling, (f) sintering, and (g) turning?
Grinding, Milling, and Turning
. What are the two basic types of forging equipment
Hammer and Presses
What are the reasons why the bulk deformation processes are important commercially and technologically?
Hot working operations can significantly change the shape of the starting piece Strength-hardening can be achieved through cold working Produce little to no waste and final products a near or net shape which saves on secondary processing energy
What are the differences between bulk deformation processes and sheet metal processes?
In bulk deformation there are significant changes and shape and a low surface area to volume ratio. In sheet metal processes there is a high surface area to volume ratio.
How does increasing temperature affect the parameters in the flow curve equation?
Increases K and n
Increasing strain rate tends to have which one of the following effects on flow stress during hot forming of metal: (a) decreases flow stress, (b) has no effect, or (c) increases flow stress?
Increases flow stress
Describe the effect of strain rate in metal forming
Increases in strain rate increase resistance to deformation.
Why is friction generally undesirable in metal forming operations?
Increases wearing of tools, increases force and energy required and causes residual stress and product defects.
A tap is a cutting tool used to create which one of the following geometries: (a) external threads, (b) flat planar surfaces, (c) holes used in beer kegs, (d) internal threads, or (e) square holes?
Internal Threads
Which of the following qualifies as a precision-casting process (two correct answers): (a) ingot casting, (b) investment casting, (c) plaster-mold casting, (d) sand casting, and (e) shell molding?
Investment casting and shell molding
Which of the following casting processes are expendable mold operations (four correct answers): (a) centrifugal casting, (b) die casting, (c) investment casting, (d) low pressure casting, (e) sand casting, (f) shell molding, (g) slush casting, and (h) vacuum molding?
Investment casting, Sand casting, Shell molding, and Vacuum molding
Turbulence during pouring of the molten metal is undesirable for which of the following reasons (two best answers): (a) it causes discoloration of the mold surfaces, (b) it dissolves the binder used to hold together the sand mold, (c) it increases erosion of the mold surfaces, (d) it increases the formation of metallic oxides that can become entrapped during solidification, (e) it increases the mold filling time, and (f) it increases total solidification time?
It increases erosion of the mold surfaces It increases the formation of metallic oxides that can become entrapped during solidification
Identify the three sources of contraction in a metal casting after pouring.
Liquid contraction due to cooling prior to solidification Contraction during the phase change from liquid to solid thermal contraction of the solid as it goes to room temp
Investment casting is also known by which one of the following names: (a) fast payback molding, (b) full mold process, (c) lost foam process, (d) lost-pattern process, or (e) lost wax process?
Lost wax process
In inspection, which procedure provides more information: (a) gaging or (b) measurement?
Measurement
The internal surfaces of a casting are determined during the casting process by means of which one of the following: (a) core, (b) gating system, (c) parting line, (d) pattern, or (e) sprue?
The core
What is the continuity law as it applies to the flow of molten metal in casting?
The volume rate of flow remains constant throughout the liquid.
Total solidification time is defined as which one of the following: (a) time between pouring and complete solidification, (b) time between pouring and cooling to room temperature, (c) time between solidification and cooling to room temperature, or (d) time to give up the heat of fusion?
Time between pouring and complete solidification
A tolerance is which one of the following: (a) clearance between a shaft and a mating hole, (b) measurement error, (c) total permissible variation from a specified dimension, or (d) variation in manufacturing?
Total permissible variation from a specified dimension
Accuracy is the degree to which the measured value agrees with the true value of the quantity of interest: (a) true or (b) false?
True
Boring and reaming share the common feature that they are both used to enlarge an existing hole: (a) true or (b) false?
True
Precision is the degree of repeatability in the measurement process: (a) true or (b) false?
True
The expanded polystyrene casting process uses a mold of sand packed around a polystyrene foam pattern that vaporizes when the molten metal is poured into the mold: (a) true or (b) false?
True
The term plant capacity refers to the maximum rate of production that a factory can achieve under assumed labor manning levels, hours of operation per week, and other operating conditions: (a) true or (b) false?
True
The twist drill is the most common type of drill bit: (a) true or (b) false?The twist drill is the most common type of drill bit
True
A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, or (e) turning?
Turning
A single-point cutting tool is used for which one of the following operations: (a) drilling, (b) milling, or (c) turning?
Turning
What are some of the factors that affect the fluidity of a molten metal during pouring into a mold cavity?
Viscosity of the molten metal Heat transfer to surroundings Metal composition Pouring temperature relative to melting point
What is sticking in shape rolling?
When the hot work piece surface adhere to the rollers on contact
What are wire and bar drawing
Wire and bar drawing are bulk deformation processes in which the cross section of a wire or bar is reduced by pulling (drawing) it through a die opening.
Which of the following are advantages and characteristics of hot working relative to cold working (four correct answers): (a) fracture of workpart is less likely, (b) friction is reduced, (c) increased strength properties, (d) isotropic mechanical properties, (e) less overall energy is required, (f) lower deformation forces is required, (g) more significant shape changes are possible, and (h) strain-rate sensitivity is reduced?
fracture of workpart is less likely isotropic mechanical properties lower deformation forces required more significant shape changes possible
Besides flat rolling and shape rolling, identify some additional bulk forming processes that use rolls to effect the deformation.
gear rolling, threaded rolling, ring rolling
Which of the following is typical of the starting work geometry in sheet metal processes: (a) high volume-to-area ratio or (b) low volume-to-area ratio?
low volume to area ratio high area to volume ratio
The coefficient of friction between the part and the tool in cold working tends to be (a) higher, (b) lower, or (c) no different relative to its value in hot working?
lower
Why is flash desirable in impression die forging
metal in die completely fills cavity
What is draft in a rolling operation?
the amount of thickness in which the workpiece is reduced
Casting
the flow of molten metal through gravity or some other force into a mold where it solidifies into the shape of the mold cavity.
What is sticking friction in metalworking?
Tendency for two surfaces moving in relative motion to adhere to each other rather than slide.
Theoretically, the maximum reduction possible in a wire drawing operation, under the assumptions of a perfectly plastic metal, no friction, and no redundant work, is which one of the following: (a) zero, (b) 0.63, (c) 1.0, or (d) 2.72?
0.63
Hot working of metals refers to which one of the following temperature regions relative to the melting point of the given metal on an absolute temperature scale: (a) room temperature, (b) 0.2Tm, (c) 0.4Tm, or (d) 0.6Tm?
0.6Tm
Name the four basic bulk deformation processes.
1) Rolling 2) Bar Drawing 3) Excursion 4)Forging
Identify some of the ways in which force in flat rolling can be reduced
1) Use hot rolling 2) Reduce the draft between each pass 3) Use rolls with smaller diameter
In foundry work, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity, (b) foundryman who moves the molten metal to the mold, or (c) vertical channel into which molten metal is poured into the mold?
A channel in the mold leading from the downsprue to the main mold cavity
What is a chill in casting?
A chill is a heat sink placed to encourage rapid freezing in certain regions of the cast.
Which of the following features and terms are associated with batch production (two correct answers): (a) cellular manufacturing, (b) mass production, (c) medium quantity production, (d) production equipment is dedicated to one product, and (e) setup time between batches is a disadvantage?
Medium Quantity Production and Setup time between batches is a disadvantage
A misrun is which one of the following defects in casting: (a) globules of metal becoming entrapped in the casting, (b) metal is not properly poured into the downsprue, (c) metal solidifies before filling the cavity, (d) microporosity, and (e) "pipe" formation?
Metal solidifies before filling the cavity
A riser in casting is described by which of the following (three correct answers): (a) an insert in the casting that inhibits buoyancy of the core, (b) gating system in which the sprue feeds directly into the cavity, (c) metal that is not part of the casting, (d) source of molten metal to feed the casting and compensate for shrinkage during solidification, and (e) waste metal that is usually recycled?
Metal that is not part of the casting, a source of molten metal to feed the casting and compensate for shrinkage during solidification, and waste metal that is usually recycled
Gear hobbing is a special form of which one of the following machining operations: (a) grinding, (b) milling, (c) planing, (d) shaping, or (e) turning?
Milling
Why is the term pressworking often used for sheet metal processes?
Most sheet metal operations are performed on presses
During solidification of an alloy when a mixture of solid and liquid metals is present, the solid liquid mixture is referred to as which one of the following: (a) eutectic composition, (b) ingot segregation, (c) liquidus, (d) mushy zone, or (e) solidus?
Mushy zone
What is the difference between an open mold and a closed mold?
Open mold is like a container of the shape with an open top where the metal is poured into. Will likely have at least one flat surface Closed mold uses a gating system to allow the pouring of metal into, a cavity of the shape housing the molten metal through solidification. More popular and important
What is isothermal forming?
Operations carried out to reduce surface cooling and temperature gradients that result from it.
A production planning and control department accomplishes which of the following functions in its role of providing manufacturing support (two best answers): (a) designs and orders machine tools, (b) develops corporate strategic plans, (c) orders materials and purchased parts, (d) performs quality inspections, and (e) schedules the order of products on a machine?
Orders materials and purchased parts and schedules the order of products on a machine
The pattern that determines the geometry of the casting in expendable mold processes is usually made (a) oversized, (b) the same size, or (c) undersized relative to the dimensions of the casting?
Oversized
An outside micrometer is appropriate for measuring which of the following (two correct answers): (a) hole depth, (b) hole diameter, (c) part length, (d) shaft diameter, and (e) surface roughness?
Part length and Shaft diameter
What is the difference between a pattern and a core in sand molding
Pattern has the shape of the cast while a core is something within the cavity to define internal geometries
The flow curve expresses the behavior of a metal in which of the following regions of the stress-strain curve: (a) elastic region or (b) plastic region?
Plastic Region
What are some of the limitations and disadvantages of casting?
Poor dimensional accuracy and surface finish on with some casting processes Porosity Limitation on mechanical properties Risks associated with handling hot molten metal Environmental problems
Which one of the following is a type of machine used to perform extrusion: (a) forge hammer, (b) milling machine, (c) rolling mill, (d) press, or (e) torch?
Press
Particulate processing of metals involves which two of the following steps: (a) adhesive bonding, (b) deformation, (c) forging, (d) material removal, (e) melting, (f) pressing, and (g) sintering?
Pressing and Sintering
How does solidification of alloys differ from solidification of pure metals?
Pure metals solidify at a constant temperature equal to the melting point while alloys differ in the temperatures at which they solidify.
In metal extrusion, the extrusion ratio is also known by which of the following terms (one best answer): (a) area reduction, (b) draft, (c) reduction, or (d) reduction ratio?
Reduction ratio
What is rolling in the context of the bulk deformation processes?
Rolling is a compression process in which the thickness of a workpiece is reduced by using two metal rollers. As they rotate they stretch and squeeze the work slap.
Which one of the following casting processes is the most widely used: (a) centrifugal casting, (b) die casting, (c) investment casting, (d) sand casting, or (e) shell casting?
Sand Casting
Which one of the following manufacturing processes is likely to result in the worst surface finish: (a) cold rolling, (b) grinding, (c) machining, (d) sand casting, or (e) sawing?
Sand Casting
The mechanism of chip formation in machining is best described by which one of the following: (a) compression, (b) fracture failure, (c) shear deformation, or (d) tensile failure?
Shear Deformation
What is trimming in die forging
Shearing of flash after process
The starting workpiece in hot rolling of steel plate and sheet stock is which one of the following: (a) bar stock, (b) billet, (c) bloom, (d) slab, or (e) wire stock?
Slab
Which of the following measurement instruments are considered to be graduated measuring devices (three correct answers): (a) divider, (b) limit gage, (c) sine bar, (d) slide caliper, (e) snap gage, (f) steel rule, and (g) vernier caliper?
Slide Caliper, Steel Rule, and Vernier Caliper
Furnaces used to heat cast steel ingots to achieve a uniform temperature throughout prior to rolling are called which of the following (one best answer): (a) annealing furnaces, (b) heat treating ovens, (c) soaking pits, or (d) tempering furnaces?
Soaking pits
What does heat of fusion mean in casting?
The amount of heat required to solidify the metal from the liquid state
In casting, a flask is which one of the following: (a) beverage bottle for foundrymen, (b) box which holds the cope and drag, (c) container for holding liquid metal, or (d) metal which extrudes between the mold halves?
box which holds cope and drag
