Precision Machining Midterm Exam

What are torx screwdrivers?

6-point star shaped pattern hand tool

What is a hex key wrench?

a tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal socket in the head

The jaws of _____ chucks are advanced and retracted independently of each other and allow for fine-tuning the position of the workpiece for maximum accuracy. a. independent b. three-jaw c. universal d. jaw-type

a. independent

A(n) _____ chuck is a device used to clamp a workpiece in the lathe spindle by applying pressure on multiple sides. a. jaw-type b. collet c. indexable d. independent

a. jaw-type

You should preform a _____ test to be sure the wheel is not defective. a. ring b. blotter c. mount d. spindle

a. ring

The _____ slide sits atop the saddle and provides cutting-tool movement perpendicular to the ways. a. clutch b. cross c. stock d. latitudinal

b. cross

What are needle nose pliers?

both cutting and holding pliers, with long edges

What is a file card?

brushes used to clean files

What is the abrasive cutoff saw?

chop saw, high speed motor that has an abrasive cutting disc mounted to its shaft

What is the cold saw?

circular-type saw, cuts cooler, very little blade "walking" or flexing

The letter D is used for what type of grinding wheel?

diamond

What are straight/slotted screwdrivers?

flat tipped hand tool

What is a spanner wrench?

hand tool that fits threaded fasteners with holes or slots that are used for turning the fastener

What is a socket wrench?

hand tool with a 6 to 12 point socket shape in a hollow cylinder on one end and a square hole for attachment to a handle in the other hand

What are side cutting pliers?

hand tools that have broad, flat jaws for gripping as well as cutting edges for cutting small diameter wire and pins

What is a soft face hammer?

hand tools used to strike surfaces that can easily be damaged by hard hammers

What is a ball peen hammer?

have two heads for striking face on one end, and a rounded end that can be used for peening rivet heads or rough forming metal

Define carbon steel.

least expensive blades, run at a slower speed than blades made of harder materials, used for vertical contour sawing of small radii

What is a straight filing?

moving the file from tip to heel across the surface in a straight or angled motion

What is draw filing?

moving the file in the direction of its width

What is deburring?

neatening and smoothing the rough edges or ridges of a workpiece

What is an open end wrench?

one-piece wrench with a u-shaped opening that grips two opposite faces of the bolt or nut

What is pinning?

particles of the material being filed called pins embedding in the teeth

What are slip joint pliers?

pliers whose pivot point or fulcrum can be moved to increase the size range of their jaws

What is an offset screwdriver?

screwdriver used at a perpendicular angle, used for the requirement of torque or power

Define rake.

the angle of the saw tooth's cutting face

What is loading?

the clogging of a file with material you are removing

Define gullet.

the curved area at the root of a saw tooth in which the metal chips are formed into curls

What is a diagonal cutter?

used for light cutting of wire and pins, edge angle allows for flush cut with work surface

What is a rawhide?

used for some soft hammers, made from tightly rolled and shaped material

What is a nylon hammer?

used when a soft, yet more durable striking surface is needed, typically rebound after striking

What are locking pliers?

very high griping power, adjusted to desired jaw opening size by rotating an adjusting screw in the handle

_____ grinders are used to grind diameters, shoulders, and faces much like the lathe is used for turning, facing, and boring operations. a. cylindrical b. tool and cutter c. jig d. surface

a. cylindrical

On a _____ lathe, a small portion of the lathe bed can be removed to allow larger-diameter workpieces to be machined. a. gap bed b. gear box c. feed rod d. spindle nose

a. gap bed

Green wheels are the purest form of _____ wheels. a. silicon carbide b. ceramic aluminum oxide c. aluminum oxide d. silicon oxide

a. silicon carbide

The headstock _____ is used to attach various workholding devices to the spindle. a. spindle nose b. spindle clutch lever c. swing d. saddle

a. spindle nose

_____ collets are very accurately ground cylindrical sleeves. a. spring b. follower c. steady rest d. fkex

a. spring

A _____ clamps directly to the lathe's ways and acts as a brace to surround and support the workpiece. a. steady rest b. follower rest c. mandrel d. spring collet

a. steady rest

_____ collets are used to grip on short workpieces whose diameters are too large to fit within the envelope of standard spring collets. a. step b. spring c. drive d. flex

a. step

_____ are used in grinding wheels that are used to grind extremely hard materials. a. superabrasives b. bonds c. abrasive d. grits

a. superabrasives

The primary purpose of a ____ grinder is to produce flat surfaces. a. surface b. horizontal spindle surface c. jig d. tool

a. surface

The top of the lathe bed contains precision-ground flat and v-shaped rails known as the _____. a. ways b. swing c. gib d. rod

a. ways

Define teeth per inch (TPI).

another way to quantify pitch, determining the number of teeth per inch

Define wavy set.

appears as a wave of tooth set with groups of teeth set to one side and with the next group gradually changing to the other side (used for crossectional area consisting of varying thickness common to structural materials)

_____ wheels are second in hardness after diamond wheels. a. resinoid b. CBN c. vitrified d. silicate

b. CBN

Define hook tooth form.

positive rake angle (shaped like a hook), large gullet area

List the steps to be performed before any surface grinding is started.

ring test, dress and true, make sure wheel is right fit

Define horizontal band saw.

saw with a horizontal oriented blade, capable of cutting off large pieces of stock both quickly and accurately

What is a c-clamp?

shaped like a c, made with steel or cast iron, typically to hold a wood or metal workpiece

What do you use to true an Aluminum Oxide and Silicon Carbide wheel?

single point or cluster dresser

Define raker set.

small groups of teeth with an alternate tooth set, but places a tooth with neutral set in between them (used for large round stock or thick steel)

What is a dead blow hammer?

soft face hammers that are frequently used by machinists to seat workpieces on parallels

Define tooth set.

staggered arrangement of the saw teeth

Define regular tooth form.

standard blade, large radii in the gullet area of the saw teeth and a zero rake angle

Define alternate set.

teeth set in a pattern in which every other tooth switches the side of the blade it is set to

While mounting the material in the lathe the tool bit should be: a. against the material b. away from material c. against the chuck d. on the center line of the cut

b. away from material

When filing on the lathe you should file: a. toward the chuck b. away from the chuck c. on the chuck d. close to the cutting bit

b. away from the chuck

Production grinding of the outside shafts and tubes can be performed with the _____ grinder. a. HSS b. centerless c. cylindrical d. chuck

b. centerless

Aluminum oxide and silicon carbide wheels are dressed and trued simultaneously using a _____ dresser. a. grinding b. dressing c. milling d. clamping

b. dressing

Superabrasive wheels should first be trued eliminate runout using a brake truing device and then dressed using a ______ stick. a. grinding b. dressing c. milling d. clamping

b. dressing

A(n) _____ is a specially designed plate that is mounted on the spindle nose. a. steady rest b. drive plate c. drawtube d. indexable tool post

b. drive plate

A _____ is mounted to the headstock spindle and is generally made of cast iron with a series of slots machined into its face. a. tool post b. faceplate c. steady rest d. workholding device

b. faceplate

_____ sizes from 46 to 60 are commonly used for general-purpose surface grinding operations. a. grade b. grain c. bond d. structure

b. grain

A(n) tool post consists of a T-nut, clamping stud, and a multi-sided tool block with either removable or integral toolholders. a. drive dog b. indexable c. live center d. quick-change

b. indexable

The _____ grinder provides more precise x- and y-axis movements than a vertical milling machine for extremely accurate positioning. a. spindle b. jig c. cutter d. cylindrical

b. jig

The _____ is a very long threaded rod supported by the bearings at both ends. a. headstock b. leadscrew c. tailstock d. headscrew

b. leadscrew

Where should the tool holder be when setting up the cutter on the carriage? a. right side b. left side c. back d. bottom

b. left side

_____ workholding devices contain alternating segments of ferrous and nonferrous materials that are mounted together to form a single unit. a. chuck b. magnetic c. parallels d. v-block

b. magnetic

The _____ supports the lathe cutting tool and provides the tool with the movement needed to perform machining operations. a. gap box b. carriage c. spindle d. feed rack

b. qcarriage

The _____ tool post consists of a T-nut, clamping stud, and tool post. a. jaw-type b. quick-change c. rocker-type d. drive dog

b. quick-change

What should be done with the chuck key when finished with it? a. throw it away b. remove and store it away c. lay it on the bed d. leave it in the chuck

b. remove and store it away

Precision angles can be ground using a magnetic ______ chuck. a. plate b. sine c. parallel d. collet

b. sine

The _____ is the part of the machine that holds and rotates work during machining. a. apron b. spindle c. carriage d. bed

b. spindle

_____ wheels are probably the most widely used wheel for surface and cylindrical grinding operations. a. type 13 saucers b. type 1 straight c. type 11 flaring cup d. type 12 dish

b. type 1 straight

The jaws of _____ chucks advance and retract simultaneously. a. dead center b. universal c. independent d. flex

b. universal

While turning between centers the operator should not cut: a. on the right side b. toward the headstock c. all the way through the materials d. toward the tailstock

c. all the way through the material

The lathe _____ is located on the right side of the headstock and is the foundation of the entire machine. a. rest b. rack c. bed d. carriage

c. bed

The jaws are closed and opened by inserting a special wrench called a _____ into a socket on the chuck. a, chuck mandrel b. chuck tool c. chuck key d. chuck collet

c. chuck key

The apron also contains the ____ lever that is used to switch between longitudinal and cross feed. a. spindle nose b. feed rod c. feed change d. step cone

c. feed change

The _____ is a bar that spans the length of the bed and contains gear teeth. a. gap rack b. gib c. feed rack d. apron

c. feed rack

A _____ material is simply a material that is attracted to a magnet. a. parallel b. chuck c. ferromagnetic d. sine

c. ferromagnetic

_____ is the ability of the individual abrasive grains to fracture during grinding to create new, sharp cutting edges. a. permeability b. structurability c. friability d. grading

c. friability

The _____ of a grinding wheel refers to its hardness or strength of the bond and ranges from A to Z. a. structure b. grit c. grade d. friability

c. grade

The _____ is located at the upper left side of the engine lathe. a. leadscrew b. saddle c. headstock d. gib

c. headstock

The sliding motion of the saddle is parallel to the ways and is called _____ feed. a. vertical b. horizontal c. longitudinal d. latitudinal

c. longitudinal

The _____ hand wheel is rotated to move the table left and right. a. horizontal-feed b. downfeed c. longitudinal-feed d. cross-feed

c. longitudinal-feed

Magnetic _____ are not magnetic by themselves but are designed to extend the magnetic field of the chuck to the workpiece. a. chucks b. blocks c. parallels d. sines

c. parallels

_____ is the spacing between the individual grains of the grinding wheel and is identified by the numbers 1 through 16. a. grain b. grade c. structure d. bond

c. structure

A _____ grinder is used for tool sharpening while the cutting tools are held in workholding devices and machine slides provide movement for much greater control and flexibility. a. surface b. centerless c. tool and cutter d. jig

c. tool and cutter

Making adjustments, measurements and cleaning chips should be done: a. with the machine on b. with the machine coasting c. with the machine at a dead stop d. when finished

c. with the machine at a dead stop

The chips cut by the lathe should not be removed by: a. a brush b. a rag c. your fingers d. a stick

c. your fingers

Define carbide tooth.

can be operated at very high speeds and cut very tough materials, have tungsten carbide brazed to a carbon steel bod, very expensive

Define vertical band saw.

common in almost every shop, very useful, blade of vertical orientation supported by two wheels

Define power hacksaw.

cutting action is achieved by drawing a saw blade back and forth, very similar to the hand hacksaw

_____ tool posts and holders have been largely replaced since they do not offer as much rigidity as newer toolholding methods. a. Three-jaw b. Spring-type c. Quick-change d. Rocker-type

d. Rocker-type

After mounting the material and setting up the machine: a. check speed of chuck b. check cutting bit c. remove all tools d. all of the above

d. all of the above

_____ have holes in their centers to match the size and shape of the workpiece to be held. a. drawtubes b. chucks c. mandrels d. collets

d. collets

Most _____ chucks move independently of each other, and each has its own adjusting screw. a. one-jaw b. two-jaw c. three-jaw d. four-jaw

d. four-jaw

Where do you set the height of the cutting bit on the lathe? a. at the bottom b. at the top c. above the center line d. on the center line

d. on the center line

_____ wheels are identified by the letter E. a. rubber b. silicone c. resinoid d. shellac

d. shellac

_____ grinding should be performed when it is not possible to grind two perpendicular surfaces by re positioning the workpiece. a. angled b. parallel c. magnetic d. side

d. side

The chuck or face plate must be tightened on what part on the lathe? a. tailstock b. carriage c. knee d. spindle

d. spindle

The _____ of the lathe is determined by the biggest diameter workpiece that can be mounted in the spindle without touching the ways. a. bed b. saddle c. spindle d. swing

d. swing

When turning between centers make sure to tighten: a. the headstock b. the carriage c. the cross slide d. the tail stock

d. the tail stock

Define tooth forms.

the shape and pattern of the saw teeth

Define pitch.

the spacing of teeth from one tooth to the next

Define skip tooth form.

zero rake angle, every other took on this has been omitted

When turning between centers adjust the centers to hold the material: a. loosely b. tight enough so the material cannot be turned c. any way you want d. tight enough for support, but can be turned freely

d. tight enough for support, but can be turned freely

_____ grinders typically use the periphery of a solid wheel to grind workpiece surfaces. a. cylindrical b. horizontal spindle surface c. cutter d. vertical spindle surface

d. vertical spindle surface

_____ grinders typically use the side of a grinding wheel to grind workpiece surfaces. a. horizontal spindle surface b. jig c. tool d. vertical spindle surface

d. vertical spindle surface

Just under the headstock is another gear train called the quick-change _____. a. feed box b. saddle box c. tailstock d. gear box

d.gear box

What is a combination wrench?

double-ended wrench with one box end and one open end of the same size

A magnetic V-block can be used to hold a workpiece at a _____-degree angle and extend the magnetism of a check to the workpiece. a. 45 b. 90 c. 120 d. 145

a. 45

Aluminum oxide and ceramic aluminum oxide wheels are identified by the letter _____. a. A b. C c. O d. X

a. A

When do you set the lathe speed on a no variable speed machine? a. before starting b. with machine on c. whenever you need to d. never

a. before starting

_____ act as the glue that holds the individual abrasives together in the shape of a wheel. a. bonding agents b. superabrasives c. grades d. grits

a. bonding agents

To prevent breakage and chatter of the cutter bit it should be clamped: a. close to the holder b. as far out as possible c. anywhere d. on the right side

a. close to the holder

A _____-type indexing fixture can be used to spin a workpiece beneath the grinding wheels to grind diameters. a. collet b. sine c. v-block d. magnetic

a. collet

Define kerf.

the width of the slot produced by the saw blade in the workpiece

What is a box-end wrench?

used when more torque must be applied to the fastener, end completely encircles the bolt or nut, giving the wrench more strength

What is an adjustable wrench?

versatile tool that must be properly adjusted to fit the fastener snugly in order to avoid damage to equipment, come in many different sizes

List 5 surface grinder safety guidelines.

wear safety goggles, tie up long hair, wear proper clothes, wear proper shoes, don't use locked or tagged-out machines