Material Processing
A lathe can be used to perform which of the following machining operations
(a) boring (c) drilling (f) turning
Ceramic matrix composites are designed to overcome which of the following weaknesses of ceramics (two best answers)
tensile strength, toughness
A circular sheet metal slug produced in a hole punching operation will have the same diameter as a. the die opening or b. the punch?
the die opening
Wood is which one of the following composite types
PMC
A copolymer is a mixture consisting of macromolecules of two different homopolymers: (a) true or(b) false.
false
The basic milling machine is which one of the following
b) knee-and-column
µ stands for?
µ = coefficient of friction
A facing operation is normally performed on which one of the following machine tools
(b) lathe
A tap is a cutting tool used to create which one of the following geometries
(d) internal threads
As the degree of crystallinity in a given polymer increases, the polymer becomes denser and stiffer,and its melting temperature decreases: (a) true or (b) false
Answer. (b) Melting temperature increases with higher degree of crystallinity.
Identify some of the reasons why machining is commercially and technological important.
Applicability to most materials; it can produce a variety of geometries to a part; it can achieve closer tolerances than most other processes; and it can create good surface finishes
From which of the following ores is aluminum derived: (a) alumina, (b) bauxite, (c) cementite, (d) hematite, or (e) scheelite?
Bauxite
Which of the following is the chemical formula for the repeating unit in polyethylene? (a) CH2, (b)C2H4, (c) C3H6, (d) C5H8, or (e) C8H8.
C2H4
A lathe is used to perform which one of the following manufacturing operations: a. broaching, b. drilling, c. lapping, d. milling, and e. turning.
Lathes are used to perform TURNING
Diamond is the hardest material known: (a) true or (b) false?
true
A broaching operation is best described by which one of the following
(b) a tool with multiple teeth moves linearly past a stationary workpart
Which of the following are examples of generating the workpart geometry in machining, asopposed to forming the geometry
(b) contour turning (d) profile milling
Reaming is used for which of the following functions
(b) enlarge a drilled hole, (c) improve surface finish on a hole, (d) improve tolerance on hole diameter
Gear hobbing is a special form of which one of the following machining operations:
(b) milling
Which of the following most closely typifies the sintering temperatures in PM: ( Tm = melting temperature of the metal)
.8Tm
The strength and hardness of steel increases as carbon content (a) increases or (b) decreases?
Increases
Which one of the three polymer types is not normally considered to be a plastic? (a) thermoplastics,(b) thermosets, or (c) elastomers.
elastomers.
Glass ceramics are polycrystalline ceramic structures that have been transformed into the glassy state: (a) true or (b) false?
false
The reinforcing phase is the matrix within which the secondary phase is imbedded
false
Which one of the following is fired at the highest temperatures: (a) china, (b) earthenware, (c) porcelain, or (d) stoneware?
porcelain
Which of the following metals has the highest density: (a) gold, (b) lead, (c) platinum, (d) silver, or (e) tungsten?
Platinum
In an electrolytic cell, the anode is the electrode that is (a) positive or (b) negative.
Positive EXTRA -> cathode is negative
Which one of the following is a machine used toperform extrusion: (a) forge hammer, (b) millingmachine, (c) rolling mill, (d) press, (e) torch?
Press
Particulate processing of metals and ceramics involveswhich of the following steps:(a) adhesive bonding, (b) deformation,(c) forging, (d) material removal, (e) melting,(f) pressing, and, (g) sintering?
Pressing, Sintering
Which one of the following is the most common element in the earth's crust: (a) aluminum, (b) calcium, (c) iron, (d) oxygen, or (e) silicon?
oxygen
An outside micrometer would be appropriate for measuring which of the following (two correct answers)
part length, shaft diameter
Surface texture includes which of the following characteristics of a surface (three correct answers)
deviations from the nominal surface, feed marks of the tool that produced the surface, surface cracks
Which one of the following manufacturing processes will likely result in the worst surface finish
sand casting
22.17 How many elements of tool geometry are required to completely specify a single-point tool (one correct answer): (a) two, (b) five, (c) seven, (d) eight, or (e) ten?
seven
Glass products are based primarily on which one of the following minerals: (a) alumina, (b) corundum, (c) feldspar, (d) kaolinite, or (e) silica?
silica
Hooke's Law defines which one of the following regions of the stress strain relationship for engineering materials: (a) elastic region, (b) plastic region, or (c) neither?
elastic region
The reinforcing phase is the matrix within which the secondary phase is imbedded: (a) true or (b)false.
false
Which one of the following reinforcing geometries offers the greatest potential for strength and stiffness improvement in the resulting composite material
fibers
Which one of the following cutting tools cannot be used on a turret lathe
(a) broach
Plain carbon steels are designated in the AISI code system by which of the following: (a) 01XX, (b) 10XX, (c) 11XX, (d) 12XX, or (e) 30XX?
10XX
Synthetic diamonds date to (a) ancient times, (b) 1800s, (c) 1950s, or (d) 1980.
1950s
A product's total manufacturing costs typically constitute what proportion of the product's selling price: (a) 10%, (b) 20%, (c) 40%, (d) 60%, or (e) 80%?
40%
In the Boeing 787 Dreamliner, what percentage of the aircraft consist of composite materials (two correct answers)
80% by volume, 50% by weight
Which of the following industries are classifiedas secondary industries?(a) beverages (b) financial services, (c) fishing,(d) mining, (e) power utilities, (f) publishing(g) transportation
Beverages, publishing, power utilities
The chemical formula for polyisoprene in natural rubber is which of the following: (a) CH2, (b)C2H4, (c) C3H6, (d) C5H8, or (e) C8H8.
C5H8
22.12 If you had to select a cemented carbide for an application involving finish turning of steel, which C grade would you select (one best answer): (a) C1, (b) C3, (c) C5, or (d) C7?
C7
Copper is generally considered easy to weld because of its high thermal conductivity: (a) true or (b) false?
False Copper is generally difficult to weld because its high thermal conductivity allows heat to be conducted from the energy source into the work too rapidly, inhibiting heat buildup for melting at the joint.
The plastic region of the stress-strain curve for a metal is characterized by a proportional relationship between stress and strain: (a) true or (b) false?
False It is the elastic region that is characterized by a proportional relationship between stress and strain. The plastic region is characterized by a power function - the flow curve
The thermal diffusivity of a material is its thermal conductivity divided by its specific heat: (a) true or (b) false?
False The thermal diffusivity of a material is its thermal conductivity divided by its volumetric specific heat.
Viscosity can be defined as the ease with which a fluid flows: (a) true or (b) false?
False Viscosity can be defined as the resistance with which a fluid flows:
The strength-to-weight ratio of a material is its yield strength divided by its density: (a) true or (b) false?
False the strength-to-weight ratio of a material is its tensile strength divided by its density:
The thermal expansion properties of polymers are generally (a) greater than, (b) less than, or (c) the same as those of metals?
Greater than those of metals
Which of the following descriptions applies to a V-bending operation as compared to an edge-bending operation: a. costly tooling, b. inexpensive tooling, c. limited to 90 degree bends or less, d. used for high production, e. used for low production, and f. uses a pressure pad to hold down the sheet metal. (2 best answers)
Inexpensive tooling and used for low production
High-volume production of assembled products ismost closely associated with which one of the followinglayout types: (a) cellular layout, (b) fixed positionlayout, (c) process layout, or, (d) product layout?
Product layout
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.
ROUND HOLE
The formation of new strain-free grains in a metal that has been heated to an elevated temperature is called which one of the following: (a) hot hardness, (b) recrystallization, (c) strain hardening, or (d) strain softening?
Recrystallization*
The term vulcanization is associated with which one of the following: (a) adhesives, (b) bronze, (c) fire, (d) rubber, or (e) wood?
Rubber
Most hardness tests involve pressing a hard object into the surface of a test specimen and measuring the resulting indentation or its effect: (a) true or (b) false?
True Most hardness tests involve pressing a hard object into the surface of a test specimen and measuring the resulting indentation or its effect.
Viscoelasticity can be defined as the property of a material that determines the strain it experiences when subjected to combinations of stress and temperature over time: (a) true or (b) false?
True Viscoelasticity can be defined as the property of a material that determines the strain it experiences when subjected to combinations of stress and temperature over time: (a) true or (b) false?
The electrical conductivity of a material is the reciprocal of its resistivity: (a) true or (b) false?
True conductivity X resistivity = 1
Solid solution alloying is the principal strengthening mechanism in high-strength low-alloy (HSLA) steels: (a) true or (b) false?
True Solid solution alloying is the principal strengthening mechanism in high-strength low-alloy (HSLA)steels.
If engineering stress and true stress were measured simultaneously during a tensile test, which would have the higher value: (a) engineering stress or (b) true stress?
True stress
The specific gravity of a material is the ratio of its density relative to the density of water: (a) true or (b) false?
True*
Which one of the following materials has the highest specific heat: (a) aluminum, (b) concrete, (c) polyethylene, or (d) water?
Water
The modulus of elasticity is also known as which one of the following: (a) elastic limit, (b) strain hardening exponent, (c) strength coefficient, or (d) Young's modulus?
Young's modulus
A superconductor is characterized by which one of the following: (a) high conductivity, (b) resistivity properties between those of conductors and semiconductors, (c) very low resistivity, or (d) zero resistivity?
Zero resistivity
Which one of the following is not a common alloying ingredient in steel: (a) chromium, (b) manganese,(c) nickel, (d) vanadium, (e) zinc?
Zinc
Which of the following polymers are normally thermoplastic (more than one): (a) acrylics, (b)cellulose acetate, (c) nylon, (d) polychloroprene, (e) polyethylene, or (f) polyurethane.
acrylics, cellulose acetate, nylon, and polyethylene
Which one of the following turning machines permits very long bar stock to be used
c) screw machine
Which of the following two geometric terms have the same meaning
circularity, roundness
22.6 As an alloying ingredient in high-speed steel, tungsten serves which of the following functions (two best answers): (a) depth hardenability during heat treatment, (b) forms hard carbides to resist abrasion, (c) improves strength and hardness, (d) increases corrosion resistance, (e) increases hot hardness, and (f) increases toughness?
forms hard carbides to resist abrasion, increases hot hardness
22.1 Of the three possible modes by which a cutting tool can fail during a machining operation, which one is most preferable: (a) fracture failure, (b) gradual wear, or (c) temperature failure?
gradual wear
Anisotropic means which one of the following
properties vary depending on the direction in which they are measured
Of the three polymer types, which one is the most important commercially? (a) thermoplastics, (b) thermosets, or (c) elastomers.
thermoplastics
Which one of the following is the correct definition of ultimate tensile strength, as derived from the results of a tensile test on a metal specimen: (a) the stress encountered when the stress-strain curve transforms from elastic to plastic behavior, (b) the maximum load divided by the final area of the specimen, (c) the maximum load divided by the original area of the specimen, or (d) the stress observed when the specimen finally fails?
The maximum load divided by the original area of the specimen
How is power required in a cutting operation related to the cutting force?
The power required in a cutting operation is equal to the cutting force multiplied by the cutting speed.
What does the term size effect mean in metal cutting?
The size effect refers to the fact that the specific energy increases as the cross-sectional area of the chip (to x w in orthogonal cutting or f x d in turning) decreases.
Describe in words what the Merchant equation tell us
This equation states that the shear plane angle increases when the rake angle is increased and friction angle is decreased
Which one of the following metals has the lowest melting point: (a) aluminum, (b) lead, (c) magnesium,(d) tin, or (e) zinc?
Tin
Which one of the following metals has the lowest density: (a) aluminum, (b) magnesium, (c) tin, or (d) titanium?
Magnesium
End milling is most similar to which one of the following
(a) face milling
Knurling is performed on a lathe, but it is not a metal cutting operation
(a) true
The twist drill is the most common type of drill bit
(a) true
A production planning and control departmentaccomplishes which of the following functions inits role of providing manufacturing support (twobest answers):(a) designs and orders machine tools,(b) develops corporate strategic plans, (c) ordersmaterials and purchased parts, (d) performs qualityinspections, and, (e) schedules the order of productson a machine?
- Orders materials and purchased parts- Schedules the order of productson a machine
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) .50 mm?
.12 mm, smallest chip thickness would have greatest specific energy in machining
Which of the following best characterizes the structure of glass-ceramics: (a) 95% polycrystalline, (b) 95% vitreous, or (b) 50% polycrystalline?
95% polycrystalline
Which one of the following comes closest to expressing the chemical composition of clay: (a) Al2O3, (b) Al2(Si2O5)(OH)4, (c) 3AL2O3-2SiO2, (d) MgO, or (e) SiO2?
Al2(Si2O5)(OH)4
22.9 Which of the following is not a common ingredient in cemented carbide cutting tools (two correct answers): (a) Al2O3, (b) Co, (c) CrC, (d) TiC, and (e) WC?
Al2O3, CrC
Which one of the following materials has the highest hardness: (a) alumina ceramic, (b) gray cast iron, (c) hardened tool steel, (d) high carbon steel, or (e) polystyrene?
Alumina ceramic
Which one of the metallic elements is the most abundant on the earth: (a) aluminum, (b) copper, (c) iron, (d) magnesium, or (e) silicon?
Aluminum
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?
Aluminum would have the lowest unit horsepower in a machining operation
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 elements is the mostimportant alloying ingredient in steel: (a) carbon,(b) chromium, (c) nickel, (d) molybdenum, or(e) vanadium?
Carbon
Ferrous metals include which of the following:(a) aluminum, (b) cast iron,(c) copper, (d) gold, and, (e) steel?
Cast iron, steel
Deformation processes include which of the following:(a) casting, (b) drilling,(c) extrusion, (d) forging, (e) milling, (f) painting,and, (g) sintering?
Forging, Extrusion (metal that is pressed out and extruding from chamber)
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. press working, and i. spinning.
GRINDING and MACHINING are material removal processes
Which of the following is the most important cast iron commercially: (a) ductile cast iron, (b) gray cast iron, (c) malleable iron, or (d) white cast iron?
Gray cast iron
Which of the following operations are classified as material removal processes (a) anodizing, (b) brazing, (c) forging, (d) grinding, (e) milling, (f) sintering, and (g) turning?
Grinding, milling, turnging
Which of the following properties or characteristics are inconsistent with the metals (two correctanswers): (a) good thermal conductivity, (b) high strength, (c) high electrical resistivity, (d) high stiffness, and (e) ionic bonding?
High electrical resistivity, ionic bonding
Identify which of the following applications are point‑to‑point and not continuous path operations (three correct answers):
Hole punching in sheet material, drilling, spot welding
The transverse rupture strength is a property usually associated with which one of the following material types: (a) ceramics, (b) metals, (c) plastics, or (d) rubber?
Metals*
Which one of the following press types is usually associated with the highest production rates in sheet metal stamping operations: a. adjustable bed, b. open back inclinable, c. press brake, d.. solid gap, or e. straight-sided?
Open back inclinable
Which of the following materials are not composites (two correct answers)
Portland cement, 1020 steel
A typical production cycle time consists of which of the following elements (three best answers): (a) actual processing time, (b) inspection time, (c) rest breaks for the worker, (d) time to withdraw starting materials from storage, (e) tool fabrication time, (f) tool handling time, and (g) work handling time?
actual processing time, tool handling time, work handling time.
Polyurethanes can be which of the following (more than one): (a) thermoplastic, (b) thermosetting, or (c) elastomeric
all of them
Which of the following contains significant amounts of aluminum oxide (three correct answers): (a) alumina, (b) bauxite, (c) corundum, (d) feldspar, (e) kaolinite, (f) quartz, (g) sandstone, and (h) silica?
alumina, bauxite, and corundum
22.15 Most ceramic cutting tools are fabricated from which one of the following materials: (a) aluminum oxide, (b) cubic boron nitride, (c) titanium carbide, (d) titanium nitride, or (e) tungsten carbide?
aluminum oxide
22.16 Sialon is a cutting tool material containing which of the following as its principal ingredients (two correct answers): (a) aluminum oxide, (b) cubic boron nitride, (c) silicon carbide, (d) silicon nitride, (e) titanium nitride, and (e) tungsten carbide?
aluminum oxide, and silicon nitride
Which of the following materials are used as fibers in fiber-reinforced plastics (four best answers)
aluminum oxide, boron, E-glass, Kevlar 49
Which of the following ceramics are commonly used as abrasives in grinding wheels (two best answers): (a) aluminum oxide, (b) calcium oxide, (c) carbon monoxide, (d) silicon carbide, and (e) silicon dioxide?
aluminum oxide, silicon carbide
Which of the following metals are used as the matrix material in fiber-reinforced MMCs (two best answers)
aluminum, magnesium
Degree of polymerization is which one of the following? (a) average number of mers in the molecule chain; (b) proportion of the monomer that has been polymerized; (c) sum of the molecule weights of the mers in the molecule; or (d) none of the above.
average number of mers in the molecule chain
In a turning operation, the change in diameter of the workpart is equal to which one of thefollowing
b) 2 x depth of cut
The three basic types of sawing, according to type of blade motion involved, are
b) bandsawing, (c) circular sawing (f) hacksawing
The standard coordinate system for numerical control machine tools is based on which one of the following
cartesian coordinates
The fiber rayon used in textiles is based on which of the following polymers: (a) cellulose, (b) nylon,(c) polyester, (d) polyethylene, or (e) polypropylene.
cellulose
In a GO/NO-GO gage, which one of the following best describes the function of the GO gage
checks maximum material condition
22.13 Which of the following processes are used to provide very thin coatings on the surface of coated carbide inserts (two best answers): (a) chemical vapor deposition, (b) electroplating, (c) physical vapor deposition, (d) pressing and sintering, and (e) spray painting?
chemical vapor deposition, physical vapor deposition
Which of the following metals are used as the matrix metals in nearly all WC cemented carbides and TiC cermets (two correct answers)
cobalt, nickel
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, work material
Which one of the following is generally the most porous of the clay-based pottery ware: (a) china, (b) earthenware, (c) porcelain, or (d) stoneware?
earthenware
Properties and characteristics of the glass-ceramics include which of the following (two best answers): (a) efficiency in processing, (b) electrical conductor, (c) high thermal expansion, and (d) strong, relative to other glasses?
efficiency in processing, and strong, relative to other glasses
The leading commercial synthetic rubber is which of the following: (a) butyl rubber, (b) isoprene rubber, (c) polybutadiene, (d) polyurethane, (e) styrene-butadiene rubber, or (f) thermoplastic elastomers.
styrene-butadiene rubber
Which answers complete the following sentence correctly (more than one): As the temperature of an amorphous thermoplastic polymer is gradually reduced, the glass transition temperature Tg is indicated when (a) the polymer transforms to a crystalline structure, (b) the coefficient of thermal expansion increases markedly, (c) the slope of specific volume versus temperature changes markedly, (d) the polymer becomes stiff, strong, and elastic, or (e) the polymer solidifies from the molten state.
the slope of specific volume versus temperature changes markedly, and the polymer becomes stiff, strong, and elastic
Which one of the three polymer types does not involve cross- linking? (a) thermoplastics, (b)thermosets, or (c) elastomers.
thermoplastics
Which one of the following polymer types are most commonly used in polymer matrix composites
thermosets
The shear strength of a metal is commonly determined in which one of the following tests: (a) bending test, (b) compression test, (c) flexure test, (d) tensile test, or (e) torsion test?
torsion test thin-walled tubular specimen is subjected to a torque. As torque is increased, the tube deflects by twisting, which is a shear strain for this geometry.
A tolerance is which one of the following
total permissible variation from a specified dimension
22.18 Chip breakers are frequently used with single-point tools. They work by forcing the chips to curl more tightly than they would naturally be inclined to curl, thus causing them to fracture: (a) true or (b) false?
true
A branched molecular structure is stronger in the solid-state and more viscous in the molten state than a linear structure for the same polymer: (a) true or (b) false.
true
In a sheet metal cutting operation used to produce a flat part with a hole in the center, the part itself is called a blank, and the scrap piece that is cut out to make the hole is called a slug. T or F
true
Polystyrene (without plasticizers) is amorphous, transparent, and brittle: (a) true or (b) false.
true
Surface texture is included within the scope of surface integrity
true
The basic difference between low density polyethylene and high density polyethylene is that thelatter has a much higher degree of crystallinity: (a) true or (b) false.
true
Name three most common machining processes.
turning, drilling, and milling
What does gamma (γ) represent
γ = shear strain
Which of the following processes start with a materialthat is in a fluid or semi fluid state and solidifiesthe material in a cavity:(a) casting, (b) forging, (c) machining, (d) molding,(e) pressing, and, (f) turning?
Casting (for molten metal), molding (for hot polymer)
Which one of the following engineering materials isdefined as a compound containing metallic andnonmetallic elements: (a) ceramic, (b) composite,(c) metal, or, (d) polymer?
Ceramic
Which of the following alloying elements are most commonly associated with stainless steel: (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e) tungsten?
Chromium and Nickel
22.11 Steel-cutting grades of cemented carbide are typically characterized by which of the following ingredients (three correct answers): (a) Co, (b) CrC, (c) Mo, (d) Ni, (e) TiC, and (f) WC?
Co, TiC, and WC
Which one of the following stamping dies is the most complicated: a. blanking die, b. combination die, c. compound die, d. edge-bending die, e. progressive die, or f. V-bending die?
Compound die
Which of the following are the three basic types of static stresses to which a material can be subjected: (a) compression, (b) hardness, (c) reduction in area, (d) shear, (e) tensile, (f) true stress, and (f) yield?
Compression, tensile, shear
The mass diffusion rate dm/dt across a boundary between two different metals is a function of which of the following variables (four best answers): (a) concentration gradient dc/dx, (b) contact area, (c) density, (d) melting point, (e) thermal expansion, (f) temperature, and (g) time?
Concentration gradient dc/dxContact areaTemperatureTime.EXTRA -> temperature affects diffusion coefficient of the metal.
What are the three basic categories of material removal processes?
Conventional machining, abrasive processes, and nontraditional processes
Which of the following metals is noted for its good electrical conductivity: (a) copper, (b) gold, (c) iron, (d) nickel, or (e) tungsten?
Copper
Traditional brass is an alloy of which of the following metallic elements (two correct answers): (a) aluminum, (b) copper, (c) gold, (d) tin, and (e) zinc?
Copper, Zinc
What are the parameters of a machining operation that are included within the scope of cutting conditions?
Cutting conditions include speed, feed, depth of cut, and whether or not a cutting fluid is used.
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 bue, c) discontinuous, or d) serrated?
DISCONTINUOUS
Which one of the following materials has the highest modulus of elasticity: (a) aluminum, (b) diamond, (c) steel, (d) titanium, or (e) tungsten?
Diamond
Name and briefly describe the four types of chips that occur in metal cutting.
Discontinuous—chip is formed into separated segmentsContinuous—chip does not segment and is formed from a ductile materialContinuous with built-up edge (BUE)---same as continuous above, except the friction at the tool-chip interface causes adhesion of a small portion of work material to the tool rake faceSerrated---semi-continuous in the sense that they possess a saw-tooth appearance that is produced by a cyclical chip formation of alternating high shear strain followed by low shear strain.
Which one of the following types of stress strain relationship best describes the behavior of metals at temperatures above their respective recrystallization points: (a) elastic and perfectly plastic, (b) elastic and strain hardening, (c) perfectly elastic, or (d) none of the above?
Elastic and perfectly plastic
Which one of the following types of stress strain relationship best describes the behavior of most metals at room temperature: (a) elastic and perfectly plastic, (b) elastic and strain hardening, (c) perfectly elastic, or (d) none of the above?
Elastic and strain hardening
Springback in a sheet metal bending operation is the result of which one of the following: a. elastic modulus of the metal, b. elastic recovery of the metal, c. overbending, and d. overstraining, or e. yield strength of the metal?
Elastic recovery of the metal
Which of the following processes are classified a high-energy rate forming processes: a. electrochemical machining, b. electromagnetic forming, c. electron beam cutting, d. explosive forming, e. Guerin process, f. hydroforming, g. redrawing, and h. shear spinning? (2 best answers)
Electromagnetic and explosive forming
If engineering strain and true strain were measured simultaneously during a tensile test, which would have the higher value: (a) engineering strain or (b) true strain?
Engineering strain
The coefficient of thermal expansion measures the change in volume of a material per degree of temperature: (a) true or (b) false?
FalseThe coefficient of thermal expansion measures the change in length of a material per degree of temperature.
In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut t corresponds to which one of the following cutting conditions in turning: a) depth of cut d, b) feed f, or c) speed v?
Feed rate f
The predominant phase in the iron-carbon alloy system for a composition with 99% Fe at room temperatureis which one of the following: (a) austenite, (b) cementite, (c) delta, (d) ferrite, or (e) gamma?
Ferrite
A steel with 1.0% carbon is known as which one of the following: (a) eutectoid, (b) hypoeutectoid,(c) hypereutectoid, or (d) wrought iron?
Hypereutectoid
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 ins hear plane angle?
INCREASE in rake angle would result in a DECREASE in power requirements and increase in shear plane angle.Merchant equation:Phi = 45 + α/2 - β/2phi: shear plane angleα: rake angle of cutting toolβ: friction angle
A Newtonian fluid is a fluid best defined by which one of the following: (a) its viscosity decreases as shear rate increases, (b) its viscosity decreases as temperature increases, (c) its viscosity increases as shear rate increases, (d) its viscosity increases as temperature increases, (e) its viscosity remains constant as shear rate changes, or (f) its viscosity remains constant as temperature changes?
Its viscosity remains constant as shear rate changes.
A roughing operation generally involves which one of the following combination of cutting conditions: a). high v, f, and d, b). high v, low f and d, c). low v, high f and d, d). low v, f, and d, where v=cutting speed, f=feed, and d=depth?
LOW cutting speedHIGH feed rate and depth of cut
Which one of the following is the best definition of bend allowance: a. amount by which the die is larger than the punch, b. amount of elastic recovery experienced by the metal after bending, c. safety factor used in calculating bending force, or d. length before bending of the straight sheet metal section to be bent?
Length before bending of the straight sheet metal section to be bent
The shear strength of a metal is usually (a) greater than or (b) less than its tensile strength?
Less than it's tensile strengthS=0.7(TS)
Which one of the following metals has the lowest density: (a) aluminum, (b) copper, (c) iron, (d) magnesium, or (e) tin?
Magnesium
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 machine tools in a factory, (d) personal computers used to schedule production, or (e) shop floor control?
Mainframe computers used to remotely control machine tools in a factory
What is an orthogonal cutting operation
Orthogonal cutting involves the use of a wedge-shaped tool in which the cutting edge is perpendicular to the direction of speed motion into the work material
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 sing-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?
Orthogonal cutting model:Only two dimensions play an active role in the analysis, The cutting edge is perpendicular to the direction of cutting speed, The two elements of tool geometry are rake and relief angle
Which one of the following types of stress strain relationship best describes the behavior of brittle materials such as ceramics and thermosetting plastics: (a) elastic and perfectly plastic, (b) elastic and strain hardening, (c) perfectly elastic, or (d) none of the above?
Perfectly elastic
Mining is classified in which one of the followingindustry categories: (a) agricultural industry,(b) manufacturing industry, (c) primary industry,(d) secondary industry, (e) service industry, or,(f) tertiary industry?
Primary industry
Hardness is best defined as which one of the following: (a) energy absorbed by a material when an object strikes its surface, (b) resistance to bending, (c) resistance to permanent indentation, or (d) resistance to scratching?
Resistance to permanent indentation
Which of the following pure metals is the best conductor of electricity: (a) aluminum, (b) copper, (c) gold, or (d) silver?
Silver
In the heating of most metal alloys, melting begins at a certain temperature and concludes at a higher temperature. In these cases, which of the following temperatures marks the beginning of melting: (a) liquidus or (b) solidus?
Solidus
Volumetric specific heat is best defined by which one of the following: (a) capability of a material to transfer heat through itself, (b) density divided by specific heat, (c) specific heat divided by density, or (d) specific heat multiplied by density?
Specific heat multiplied by density
Which of the following cutting conditions has the strongest effect on cutting temperature: a) feed or b) speed?
Speed
Inventions of the Industrial Revolution include whichone of the following: (a) automobile, (b) cannon,(c) printing press, (d) steam engine, or, (e) sword?
Steam engine
The flow curve describes the property of metals known as which one of the following: (a) ductility, (b) engineering strain, (c) fracture stress, (d) strain hardening, or (e) tensile strength?
Strain hardening
A unit operation is defined as a single manufacturing step in the sequence of steps required to transform a starting material into a final part or product: (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
Identify the four forces that act upon the chip in the orthogonal metal cutting model but cannot be measured directly in an operation
The four forces that act upon the chip are friction force, normal force to friction, shear force, and the normal force to shear force.
Which of the following are referred to as thin film deposition processes (two correct answers): (a) chemical vapor deposition, (b) electroplating, (c) extrusion, (d) painting, and (e) physical vapor deposition?
chemical vapor deposition, physical vapor deposition
22.8 Cast cobalt alloys typically contain which of the following as their main ingredients (three best answers): (a) aluminum, (b) cobalt, (c) chromium, (d) iron, (e) nickel, (f) steel, and (g) tungsten?
cobalt, chromium, tungsten
Sheet metal bending involves which of the following stresses and strains: a compressive, b. shear, and c. tensile? (2 correct answers)
compressive and tensile
which of the following pure metals is the best thermal conductor
copper
22.2 Which of the following are the two main types of gradual wear on a cutting tool: (a) clearance wear, (b) crater wear, (c) flank wear, (d) nose wear, and (e) notch wear?
crater wear,flank wear
22.14 Which one of the following materials has the highest hardness: (a) aluminum oxide, (b) cubic boron nitride, (c) high-speed steel, (d) titanium carbide, or (e) tungsten carbide?Answer. (b).
cubic boron nitride
Which one of the following materials is closest to diamond in hardness: (a) aluminum oxide, (b) carbon dioxide, (c) cubic boron nitride, (d) silicon dioxide, or (e) tungsten carbide
cubic boron nitride
22.4 Of the following cutting conditions, which one has the greatest effect on tool wear: (a) cutting speed, (b) depth of cut, or (c) feed?
cutting speed
22.3 The basic Taylor tool life equation defines the relationship between which two of the following variables: (a) cutting speed, (b) depth of cut, (c) feed, (d) feed rate, (e) tool life, and (f) work material hardness?
cutting speed, tool life
A planing operation is best described by which one of the following
d) a workpart moves linearly past a single-point tool
As temperature of a polymer increases, its density (a) increases, (b) decreases, or (c) remains fairly constant.
decreases
22.10 An increase in cobalt content has which of the following effects on WC Co cemented carbides (two best answers): (a) decreases hardness, (b) decreases transverse rupture strength, (c) increases hardness, (d) increases toughness, and (e) increases wear resistance?
decreases hardness, increases toughness
22.7 As an alloying ingredient in high-speed steel, chromium serves which of the following functions (three best answers): (a) depth hardenability during heat treatment, (b) forms hard carbides to resist abrasion, (c) improves strength and hardness, (d) increases corrosion resistance, (e) increases hot hardness, and (f) increases toughness?
depth hardenability during heat treatment, forms hard carbides to resist abrasion, increases corrosion resistance,
Which of the following are variations of sheet metal bending operations: a. coining, b. flanging, c. hemming, d. ironing, e. notching, f. shear spinning, g. trimming, and h. tube bending? (two best answers)
flanging and hemming
A surface plate is most typically made of which one of the following materials
granite
Which one of the following manufacturing processes will likely result in the best surface finish
grinding
Thermal energy is normally associated with which of the following changes in the altered layer (three best answers)
hardness variations, heat affected zone, recrystallization
The holding force in drawing is most likely to be a. greater than, b. equal to, or c. less than the maximum drawing force?
holding force most likely to be LESS than maximum drawing force
22.5 Which of the following are the three most important properties of a tool material that are suggested by the three modes of tool failure: (a) ductility, (b) hot hardness, (c) impact resistance, (d) tensile strength, (e) toughness, and (f) wear resistance?
hot hardness, toughness, and wear resistance
As sheet metal stock hardness increases in a blanking operation, the clearance between punch and die should be a. decreased, b. increased, or c. remain the same?
increased
Which of the following are likely to be GO/NO-GO gages (three correct answers)
limit gage, plug gage, snap gage
Which of the following features and terms are associated with batch production: (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, setup time between batches is a disadvantage
Most sheet metalworking operations are performed as which one of the following: a. cold working, b. hot working, or c. warming working.
most sheet metalworking operations are performed using COLD WORKING
Which of the following design features would be difficult or impossible to achieve by conventional pressing and sintering? (three best answers):
outside rounded corners, side holes, threaded holes
The three components of a NC system are (three correct answers):
part program, the machine control unit, processing equipment
Among the thermosetting polymers, the most widely used commercially is which of the following:(a) epoxies, (b) phenolics, (c) silicones, or (d) urethanes.
phenolics
Which of the following plastics has the highest market share? (a) phenolics, (b) polyethylene, (c)polypropylene, (d) polystyrene, or (e) polyvinylchloride.
polyethylene
Anisotropic means which one of the following: (a) composite materials with composition consisting of more than two materials, (b) properties are the same in every direction, (c) properties vary depending on the direction in which they are measured, or (d) strength and other properties as a function of curing temperature.
properties vary depending on the direction in which they are measured
In the context of production equipment in a factory, the term availability is best defined by which one of the following: (a) downtime proportion, (b) hourly operating cost, (c) proportion of good products, (d) proportion uptime, or (e) utilization?
proportion uptime
Impregnation refers to which of the following (two best answers):
putting polymers into the pores of a PM part, soaking oil by capillary action into the pores of a PM part
What is the chip thickness ratio?
r = to/tc where r: chip thickness ratioto: original chip thickness/depth of cuttc: final chip thickness after separation
22.20 Which of the following are the two main functions of a cutting fluid in machining (two best answers): (a) improve surface finish on the workpiece, (b) reduce forces and power, (c) reduce friction at the tool chip interface, (d) remove heat from the process, and (e) wash away chips?
reduce friction at the tool chip interface, remove heat from the process
22.19 Which of the following drill types would be the most likely choice to drill a hole with a 100 mm (4.0 in) diameter (one best answer): (a) gun drill, (b) spade drill, (c) straight-flute drill, (d) twist drill?
spade drill
The cutting force in a sheet metal blanking operation depends on which mechanical property of the metal: a. compressive strength, b. modulus of elasticity, c. shear strength, d. strain rate, e. tensile strength, or f. yield strength. (1 correct answer)
strain rate
Ohm's Law is expressed by which one of the following relationships: (a) current = voltage divided by resistivity, (b) current = voltage multiplied by resistance, (c) power = current multiplied by voltage, (d) resistance = voltage multiplied by current, or (e) voltage = current multiplied by resistance?
voltage = current multiplied by resistance
