Test 3 manufacturing
what is creep feed grinding
-deep grinding when external -wheel is continuously cutting
what are the treatments in surface hardening
1. carburizing 2. nitriding 3. carbonitriding
what are the two steps to form martensite
austenitizing and quenching
what are the 3 dimensions of a machining process
cutting speed, feed, depth of cut
specific energy in grinding is low or high
high
Name the 3 most common machining processes
turning, drilling, milling
Whats the difference between up and down milling
up milling- cuter speed direction is OPPSITE the feed direction down- cutter rotation direction is SAMe as feed direction
Identify the four forces that act upon the chip in the orthogonal metal cutting model but cannot be measured directly in an operation.
(1) Friction force(2) Normal force to friction(3) Shear force(4) Normal force to friction
what are the 5 principal heat treatments
-annealing -martensite formation in steel -tempering and martensite -precipitation hardening -surface hardening
what are the heat treatment objectives
-soften a metal prior forming -relieve strain hardening that occurs -strengthen and harden the metal near end
What are the 4 types of chips that occur in metal cutting?
1. Discontinuous 2. continuous 3. continuous with built-up edge 4.serrated
Identify the two forces that can be measured in the orthogonal metal cutting model.
1. cutting force 2. thrust force
what are the basic categrories of material removal processes
1.conventional 2. abrasive processes 3. nontraditional processes
what are 2 types of welding processes
1.fusion welding 2. solid state welding
3 steps of precipitation hardening
1.solution treatment 2. quenching 3.precipitation treatment
A shaping operation is best described by which one of the following: (a) a single-point tool moves linearly past a stationary work part, (b) a tool with multiple teeth moves linearly past a stationary work part, (c) a work part is fed linearly past a rotating cutting tool, or (d) a work part moves linearly past a single-point tool?
A
Most vertical boring machines are equipped for both turning and boring and are used for large, heavy work parts with large diameters: (a) true or (b) false?
A
Which one of the following types of grinding wheel wear involves dulling of the individual grains in the grinding wheel: (a) attritious wear, (b) bond failure, (c) crater wear, (d) flank wear, or (e) grain fracture?
A
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?
B
Grain size in the grinding wheel specification is indicated by a number system in which higher numbers indicate (a) larger grit size or (b) smaller grit size?
B
Manufacturing processes that create geometry are classified as basic or secondary processes; machining is classified as a (a) basic process or (b) secondary process?
B
The term deep grinding refers to which one of the following: (a) alternative name for any creep feed grinding operation, (b) external cylindrical creep feed grinding, (c) grinding operation performed at the bottom of a hole, (d) surface grinding that uses a large crossfeed, or (e) surface grinding that uses a large infeed?
B
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?
B
The three basic types of sawing, according to type of blade motion involved, are which of the following: (a) abrasive cutoff, (b) bandsawing, (c) circular sawing, (d) contouring, (e) friction sawing, (f) hacksawing, and (g) slotting?
B, C, F
Specific energy in grinding is higher than traditional machining due to which of the following: (a) feed speed, (b) bond failure, (c) size effect, (d) large crossfeed
C
Machined parts can be classified as rotational or nonrotational. Which two of the following are examples of operations that create nonrotational geometries: (a) boring, (b) drilling, (c) milling, (d) planing, and (e) turning?
C, D
A tap is a cutting tool used to create which one of the following geometries: (a) external threads, (b) flat planar surfaces, (c) holes in beer kegs, (d) internal threads, or (e) square holes?
D
Which one of the following is an example of combined generating and forming the work part geometry in machining: (a) broaching, (b) contour turning, (c) drilling, (d) profile milling, (e) taper turning, and (f) thread cutting?
F
What does the merchant equation tell us?
Shear plane angle increases when rake angle is increased and friction angle is decreased
Why are specific energy values so much higher in grinding than in traditional machining processes such as milling?
Size effect, negative rake angles, and ineffective grain actions
What is the relationship between the coefficient of friction and the friction angle in the orthogonal cutting model?
The coefficient of friction is the tangent of the friction angle
Boring and reaming share the common feature that they are both used to enlarge an existing hole: (a) true or (b) false?
a
Which of the following would tend to give higher material removal rates: (a) larger grain size, or (b) smaller grain size?
a
Which one of the following abrasive processes is capable of achieving the highest production rates: (a) external centerless grinding, (b) internal centerless grinding, (c) external cylindrical grinding, or (d) internal cylindrical grinding?
a
Which one of the following cutting tools cannot be used on a turret lathe: (a) broach, (b) cutoff tool, (c) drill bit, (d) single-point turning tool, or (e) threading tool?
a
§Soaking is a term that refers to which one of the following: (a) heating the metal to a suitable temperature and holding at that temperature for a certain time, (b) heating the metal to a suitable temperature, holding at that temperature for a certain time, and then quickly cooling the metal, (c) heating the metal to a suitable temperature, holding at that temperature for a certain time, and then slowly cooling the metal, (d) slowly cooling the metal from an elevated temperature, or (e) submersion of the heated metal in warm water?
a
§The advantage of laser-beam heating over electron-beam heating is that a vacuum is not required for best results: (a) True or (b) false?
a
§The faying surfaces are the part surfaces in contact or close proximity that are to be joined in the welding operation: (a) True or (b) false
a
Which of the following will improve surface finish in grinding (three best answers): (a) denser wheel structure, (b) higher wheel speed, (c) higher work speeds, (d) larger infeed, (e) lower infeed, (f) lower wheel speed, (g) lower work speed, and (h) more open wheel structure?
a, b, g
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?
a, c, f
what are the five basic parameters of a grinding wheel
abrasive material, grain size, bonding material, wheel grade, wheel structure
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?
b
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?
b
The basic milling machine is which one of the following: (a) bed type, (b) knee and column, (c) profiling mill, (d) ram mill, or (e) universal milling machine?
b
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?
b
Which of the following terms applies to the procedure of sharpening the grinding wheel and restoring the shape of its outside perimeter: (a) dressing or (b) truing?
b
friability refers to the capacity of the abrasive material to retain its sharpness during the grinding operation: (a) true or (b) false?
b
§All welding processes require sufficient external heat to melt the parts at the surfaces to be joined: (a) True or (b) false?
b
§For metallurgical reasons, it is desirable to melt the weld metal with minimum energy input. Which one of the following heat sources is most consistent with this objective: (a) high power, (b) high power density, (c) low power, or (d) low power density
b
§The hardness of steel increases with increasing carbon content, but the increase is achieved only through heat treatment: (a) True or (b) false
b
§Weld failures always occur in the fusion zone of the weld joint, because this is the part of the joint that has been melted: (a) True or (b) false
b
Which of the following are examples of generating the workpart geometry in machining, as opposed to forming the geometry (two best answers): (a) broaching, (b) contour turning, (c) drilling, (d) profile milling, and (e) thread cutting?
b, d
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?
b, d, e
Typical operations performed on a machining center include which of the following (two best answers): (a) boring, (b) drilling, (c) milling, (d) sawing, and (e) turning?
b,c
What is the geometric classification of nonrotational machined parts and an example of it?
block like and plate like; milling
how do you determine hardness in martensite
by seeing how much plain carbon steel percentage you started with
Smaller grain size in a grinding wheel tends to (a) degrade surface finish, (b) have no effect on surface finish, or (c) improve surface finish?
c
Which one of the following is not one of the five basic parameters of a grinding wheel: (a) abrasive material, (b) bonding material, (c) grain hardness, (d) grain size, (e) wheel grade, or (f) wheel structure?
c
Machined parts can be classified as rotational or nonrotational. Which of the following are examples of operations that create nonrotational geometries (two best answers): (a) boring, (b) drilling, (c) milling, (d) planing, and (e) turning?
c, d
whats the difference between carburizing and nitriding
carburizing= quench after heating nitriding=don't quench
whats the difference between consumable and nonconsumable electrodes
consumable=melts down and deposits on weld noncunsumable-doesnt melt down or deposit on weld
what is consumable electrodes
consumed during welding process; source of filler rmetal
what are the 3 types of grain action
cutting, plowing, rubbing
What is the geometric classification of rotational machined parts and an example of it?
cylindrical or dislike shape; turning or planing
A planing operation is best described by which one of the following: (a) a single-point tool moves linearly past a stationary workpart, (b) a tool with multiple teeth moves linearly past a stationary workpart, (c) a workpart is fed linearly past a rotating cutting tool, or (d) a workpart moves linearly past a single-point tool?
d
§A fillet weld has a cross‑sectional shape that is approximately which one of the following: (a) rectangular, (b) round, (c) square, or (d) triangular
d
§Tempering is a heat treatment applied to hardened steels that is best defined as which one of the following: (a) heating and soaking at a temperature above the austenitizing level followed by rapid cooling, (b) heating and soaking at a temperature above the austenitizing level followed by slow cooling, (c) heating and soaking at a temperature below the austenitizing level followed by rapid cooling, or (d) heating and soaking at a temperature below the austenitizing level followed by slow cooling?
d
what is a seam weld
does spot welding to weld continuous seams
Ways a work part can be held on a lathe
dog plate, chuck, collet, face plate
whats blind hole
drill doesnt exit opposite side
whats a through hole
drill exits opposite side of work
§The treatment in which the brittleness of martensite is reduced is called which one of the following: (a) aging, (b) annealing, (c) austenitizing, (d) normalizing, (e) quenching, or (f) tempering?
f
§Which three of the following are typical reasons to anneal a metal: (a) to heat the metal for hot working, (b) to increase strength and hardness, (c) to recrystallize strain-hardened metals, (d) to reduce brittleness, (e) to reduce ductility, and (f) to relieve stresses?
f,d,c
A live center is one way of holding a workpiece in the headstock of a lathe, whereas a dead center is used to hold the work in the tailstock: (a) True or (b) false?
false
The difference between up milling and down milling is that in down milling the direction of motion of the cutter teeth is opposite the feed direction when the teeth cut into the work: (a) True or (b) false?
false
What are example of forming to create shape?
form turning, drilling, and broaching
what is the differences between a fusion weld and a solid state weld
fusion- melting of the 2 surfaces takes place to obtain coalescence solid state- coalescence is achieved by hear or pressure
what are the causes of wheel wear?
grain fracture, attritious wear, bond fracture
parts of an engine lathe
head stock, soindle, toolpost, tailstock (live or dead) and all mounted on bed
whats precipitation hardening
heat treatment precipitates fine particles that block the movement of dislocation and harden metal
what is annealing
heating and soaking a metal at a suitable temp, for a certain time, and slowly cooling
3 steps of annealing
heating, soaking, slowly cooling
whats the surface temperature in grinding
high surface temps
what is the cutter tool on gear hobbing called?
hob
what is quenching
it affects cooling rate; brine, is the fastest, still fresh water, still oil, and air is the slowest
what does chromizing produce over others
it produces a casting that's hard, wear resistant, and heat and corrosion resistant
what is the most important heat treatment for hardening steels
martensite formation
what is nonconsumable electrodes
not consumed during welding process
Drilling is to ____ while milling is to _____
parallel; perpendicular
what is tapping
performed on a drilling machine and produces internal thread
what is threading
performed on a turning machine and produces external thread
what is the difference between peripheral and face milling
peripheral- cutter axis PARALLEL to surface being machined face- cutter axis PERPENDICULAR to surface being milled
types of sawing
power hacksaw, band saw vertical, circular saw
what is dressing
resharpening the wheel
what is honing
set of bonded abrasive sticks using combo of rotational and oscillatory motions
What are examples of generating shapes?
straight, contour, and taper turning; profile and plain milling
what is friability
the ability of the abrasive grain to fracture into smaller pieces
grinding is what
the most important abrasive process
what is faying surfaces in welding
the part surfaces in contact that are being joined by welding
what is surface hardening
thermochemical treatment applied to steels
What are examples of forming and generating put together?
thread cutting on a lathe and slot milling
why is tempering used
to reduce brittleness, increase toughness, and relieve stress
what is planing
tool doesnt move; work part is moving
The specific energy in a grinding operation is much greater than the specific energy in a conventional machining operation such as milling: (a) true or (b) false?
true
Wheel grade indicates the grinding wheel's ability to retain abrasive grits during cutting; it depends largely on the amount of bonding material present in the wheel: (a) True or (b) false?
true
What is the machining within using a single point cutting tool?
turning and boring
what is truing
use of a diamon pointed tool taht shapes the wheel and restores shape
what is superfinishing
uses bonded abrasive stick pressed against surface and reciprocating motion
what is lapping
uses fluid suspension of small abrasive particles between work piece and lap (tool)
what is a fillet weld
weld that has a triangular cross section
what is shaping
work part doesnt move; tool is moving
what is centerless grinding
workpiece kept between grinding wheel and moving wheel on work rest. -rest blade and regulating wheel
