Manufacturing Processes: Theory of Metal Machining (CH. 20)

Which of the following cutting conditions has the strongest effect on cutting temperature: (a) feed or (b) speed?

Answer. (b).

Specific energy in metal machining is a measure of the amount of energy required to remove a unit volume of material: (a) true or (b) false?

Answer. (a).

The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry: (a) true or (b) false?

Answer. (a).

Which one of the following cutting conditions has the strongest effect on cutting temperature: (a) cutting speed, (b) depth of cut, or (b) feed?

Answer. (a).

Which one of the following metals would usually have the lowest unit horsepower in a machining operation: (a) aluminum, (b) brass, (c) cast iron, or (d) steel?

Answer. (a).

According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers): (a) decrease in friction angle, (b) decrease in power requirements, (c) decrease in shear plane angle, (d) increase in cutting temperature, and (e) increase in shear plane angle?

Answer. (b) and (e).

Machining is noted for which of the following characteristics relative to other manufacturing processes: (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?

Answer. (b) and (f).

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?

Answer. (b), (d), and (g).

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?

Answer. (b).

The chip thickness ratio is which one of the following: (a) tc/to, (b) to/tc, (c) f/d, or (d) to/w, where tc = chip thickness after the cut, to = chip thickness before the cut, f = feed, d = depth, and w = width of cut?

Answer. (b).

A roughing operation generally involves which one of the following combinations of cutting conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d, where v = cutting speed, f = feed, and d = depth?

Answer. (c).

A single-point cutting tool is used for which one of the following operations: (a) drilling, (b) milling, or (c) turning?

Answer. (c).

For which one of the following values of chip thickness before the cut to would you expect the specific energy in machining to be the greatest: (a) 0.010 inch, (b) 0.025 inch, (c) 0.12 mm, or (d) 0.50 mm?

Answer. (c).

For which one of the following values of chip thickness before the cut to would you expect the specific energy in machining to be the greatest: (a) 0.010 inch, (b) 0.025 inch, (c) 0.12 mm, or (d) 0.50 mm?

Answer. (c).

Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material: (a) continuous, (b) continuous with built-up edge, (c) discontinuous, or (d) serrated?

Answer. (c).

With which one of the following geometric forms is the drilling operation most closely associated: (a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads, or (e) sphere?

Answer. (c).

Which of the following are characteristics of the orthogonal cutting model (three best answers): (a) a circular cutting edge is used, (b) a multiple-cutting-edge tool is used, (c) a single-point tool is used, (d) only two dimensions play an active role in the analysis, (e) the cutting edge is parallel to the direction of cutting speed, (f) the cutting edge is perpendicular to the direction of cutting speed, and (g) the two elements of tool geometry are rake and relief angle?

Answer. (d), (f), and (g).

If the cutting conditions in a turning operation are cutting speed = 300 ft/min, feed = 0.010 in/rev, and depth of cut = 0.100 inch, which one of the following is the material removal rate: (a) 0.025 in3/min, (b) 0.3 in3/min, (c) 3.0 in3/min, or (d) 3.6 in3/min?

Answer. (d).

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?

Answer. (e) and (f).

A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, or (e) turning?

Answer. (e).