ME2653 Exam 4

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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 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 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 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.

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 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 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

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

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: 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

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

against

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

angle cutter

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

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

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

cylindrical external

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

dull, flattening

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

Which cutter is best: producing a pocket in a workpiece

end mill

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

face mill

Tapered end mills are used for ____.

finish cutting on molds to produce a desired angle

Type of milling cutter: Milling wood to produce wood trim

form cutter

Which cutter is best: bearing pocket in gearbox housing

form cutter

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

fracture, producing new, sharp edges

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

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

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

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 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

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

more than the machining operation

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.

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

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

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

plain cutter

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

plowing, rubbing, cutting

A CNC milling machine ___.

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

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

radius

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

Magnetic chucks are commonly used on what type of machinery?

surface grinders

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

taper, plug, bottom

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

the tooth pattern and the length of the file

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

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

toward the part

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

150

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

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 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.

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

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

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

horizontal milling machine

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

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

ball end mill

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

many, excellent

The milling machine was invented in approximately 1816 by ___.

Simeon North

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

False

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

0.001"

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

80-90%

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

A.

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

True

What is the most common material used for abrasives?

aluminum oxide

Which is the most frequently used mounting system for abrasives?

bonded

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

end mill

What is used to produce internal threads?

taps

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 ___ for milling and a ___ for lathe operations.

vise, chuck

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

with

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

30, 40

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

32, 125

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

72

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.

What device is used to manually produce external threads?

Die

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

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

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.

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

True

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

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

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

centrifugal, gravity, cutting, inertial

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

charged

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

circumference and the face of the cutter

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

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

form cutter

Broaching was originally developed for the production of ____.

internal keyways

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

kerf

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

lap

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)

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

peripheral edge

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

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

slitting saw cutter

Type of milling cutter: Deep slots in a work piece

staggered-tooth cutter

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? 0.01 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

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.

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

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

True

"Power filing" is frequently performed with ___.

rotary burrs

The structure of a grinding wheel refers to ___.

the spacing of the abrasive grit in the wheel

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

set

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

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 workpiece.

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 most common type of broaching machine construction is ____.

vertical

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

vertical (Z-axis)

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

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

bandsaw

Which cutter is best: Deep slots with straight side walls

end mill

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

sewing machine

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.

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

True

In _____ products, threads are frequently produced by casting.

plastic

The grade of a grinding wheel refers to ____.

the strength of the bonds between the abrasive grits

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

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


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