Milling

During tool confirmation, visually examine the machine magazine to make sure the necessary tools are loaded. A True B False

A

Homing the machine, is the process of moving the primary axes to the zero position. A True B False

A

Identify the appropriate drilling operation for cutting a recess for a socket head cap screw: a) Counterboring b) Spotfacing c) Countersinking d) Recessing

A

If the proper feeds, speeds, and power are not available, the machine process may fail. A True B False

A

If you are standing in front of a vertical machining center, what direction doe the X-axis travel? A Left to Right B Front to Back C Up and Down D None of the above

A

It is always a good idea when running a program for the first time to reduce the rapid rates to a minimum. A True B False

A

Only lubricating fluids recommended by the manufacturer should be used. A True B False

A

Part Zero, must be captured, for each particular Job Setup. A True B False

A

Programs may be written with word processors. A True B False

A

Proper feed rates, may be determined by referring to a Machinist Handbook. A True B False

A

Surface finish can be checked with a: a) Comparison chart b) Toolmaker microscope c) Eye loupe d) Depth micrometer

A

The air in the pressure tank and hoses must be kept as dry as possible to prevent lubrication problems. A True B False

A

The best cutting fluid for tapping aluminum is: a) Heavy duty soluble oil b) Sulfur based chlorinated oil c) Mineral spirits d) No fluid at all

A

The cutting speed (in surface feet per minute) is determined by: a) The type of material being machined b) The size of the vertical milling machine c) The rigidity of the workholding device d) Number of cutting edges on the tool

A

The dimension of a hole is stated as 9/16 ± 1/64 inches. Which of the following statements is true if a 0.584-inch diameter pin slips into the hole? a) The hole is oversize b) The hole is to size c) The hole is undersize d) A fractional hole cannot be measured with pins

A

The first time running a program, it is always a good idea to run it in SINGLE BLOCK mode. A True B False

A

The hand dial found on the table of a vertical milling machine has a resolution of: a) 0.001 inches b) 0.0001 inches c) 0.010 inches d) 0.100 inches

A

The included angle on the point of a general purpose drill is: a) 118° b) 39.5° c) 59° d) 135°

A

The most commonly used holding device for a drill applied on a vertical mill is a: a) Drill chuck b) Collet properly fit to the straight shank portion of the drill c) Style A toolholder d) Tailstock attachment

A

The optimum thread percentage that most tap drill charts are based on is: a) 75% b) 65% c) 55% d) 85%

A

This is the standard formula to calculate RPM: SFPM X 4 (3.82) divided by the diameter = RPM A True B False

A

Tool Radius (R) is half of Tool Diameter (D). Diameter / 2 = Radius A True B False

A

What do M.S.D.S. (Material Safety Data Sheets) indicate? A The chemical and materials used in shop B Instructions to setup machine C Maintenance manual D None of the above

A

What does a boxed letter represent? A Datum B Tolerance C Basic D None of the above

A

What is the code G00? A Rapid position B Linear interpolation C Circular interpolation D Dwell

A

What is the correct code for canceling cutter compensation? A G40 B G80 C G43 D M28

A

When manually maneuvering the programmable elements of the machine, an operator has the ability to control what two elements? A Axis Motion B Axis Limits C Axis Resistance D Rate at Which The Axis Moves

A D

An edge finder has a tip diameter of 0.200 inches. What distance must the table move to align the center of the edge finder to the edge of the workpiece? a) 0.200 inches b) 0.100 inches c) 0.400 inches d) 0.050 inches

B

Changing the spindle RPM on a vertical milling machine with a belt and pulley drive differs from changing the spindle RPM on a machine with a variable speed drive because the: a) Variable speed drive must be adjusted while the machine is running while the belt and pulley drive requires complete disassembly of the motor and pulley b) Variable speed drive must be adjusted while the machine is running while the belt and pulley drive requires adjustment while the machine is stopped c) Variable speed drive must be adjusted while the machine is stopped while the belt and pulley drive requires adjustment while the machining is running d) Variable speed drive must be adjusted with differential gearing while the machine is stopped and a belt and pulley drive requires no differential gearing

B

EOB stands for: A Early of Block B End of Block C End of Blank D None of the above

B

G41 through G59, are used for standard Work or Part Offsets. A True B False

B

Identify the appropriate drilling operation for cutting a recess for a flat head screw: a) Spotfacing b) Countersinking c) Counterboring d) Trepanning

B

Name the three types of taps found in a tap set: a) Taper, truncated, topping b) Taper, plug, bottoming c) Bottoming, truncated, dry seal d) Plug, dry seal, bottoming

B

Surface finish can be measured in: a) Millimeters b) Microinches c) Kilomicrons d) Centiinches

B

The X-axis on a vertical mill represents ______________ table movement. The Y-axis on a vertical mill represents ________________ table movement. The Z-axis represents _______________ movement of the spindle. a) Longitudinal, vertical, Crossfeed b) Longitudinal, Crossfeed, vertical c) Vertical, Crossfeed, longitudinal d) Crossfeed, longitudinal, vertical

B

The ________ should be emptied prior to start up. A OIL B CHIP BIN C COOLANT TANK

B

The correct RPM for a 0.750 diameter high speed steel end mill machining O1 tool steel at 50 sfm is: a) 533 RPM b) 266.7 RPM c) 133.3 RPM d) 150 RPM

B

The most commonly used workholding device on the vertical milling machine is a: a) Hold down clamp b) Vise c) Rotary table d) Dividing head

B

The tap drill for a 3/8-16 UNC internal thread is ______ inches in diameter and provides a _______ thread engagement. a) 0.356, 90% b) 0.3125, 75% c) 0.257, 65% d) 0.375, 100%

B

To ensure even seating and to combat any tipping action caused by the moveable jaw, the best practice is to: a) Use gage pins underneath the parallels b) Strike the workpiece softly with a dead blow hammer and test the parallels for movement c) Use paper shims underneath the parallels and underneath the workpiece d) Mount the workpiece on parallels and tighten the vise very tightly with a leverage bar

B

To remove a collet from the spindle of a vertical milling machine, the drawbar should be: a) Tighten the drawbar one-quarter turn and tapped with a dead blow hammer b) Loosen the drawbar a few turns and tap the top of the drawbar with a dead blow hammer to release the taper then unscrew the drawbar c) Unscrew the drawbar completely and pry the collet out with a small pry bar d) Loosen the collet and tighten the drawbar then hit the top of the drawbar with a dead blow hammer

B

What is the code G01? A Rapid position B Linear interpolation C Circular interpolation D Dwell

B

What is the code M30? A Spindle ON clockwise B Program End and Reset C Spindle OFF D Coolant ON

B

What is the proper procedure for tapping under power on a vertical milling machine? a) Use the rpm for milling, lock the quill and reverse the motor b) Use a low rpm, leave the quill unlocked, use both the forward and reverse motions of the motor c) Use 150 rpm for all tapping, lock the quill, use both the forward and reverse motions of the motor d) Use 350 rpm for all tapping exceeding 1/4 inch, leave the quill unlocked, use only the forward motion of the motor

B

When using hold down clamps to clamp work on the milling machine, the best setup that provides even clamping pressure is to: a) The T-bolt is closer to the work than to the step block and at a 3 degree angle tilted down b) The T-bolt is the same distance from the work and the step block parallel to the table c) The T-bolt is closer to the step block than to the work and the clamp is angle up toward the work for maximum pressure d) The T-bolt is the same distance from the work and the step block and is set at a three degree angle titled up

B

Which of the following describes the safest procedure for measuring a part on the milling machine? a) Raise the table and check the dimension b) Stop the machine, deburr, brush chips clear, check the dimension c) Raise the tool, check the dimension, deburr, blow chips off the table d) Take the part out of the machine, deburr, brush chips clear, stop the machine

B

Which of the following tools is the most accurate tool for making the preparatory setup for milling an angle on a workpiece? a)Machinist square b)Sine bar c)Angle set d)Combination set e) Adjustable parallels

B

Which of the following vertical milling machine components is labeled as 11? a) Head b) Knee c) Vertical traverse handle d) Table

B

Which of the following vertical milling machine components is labeled as 9? a) Quill feed hand lever b) Vertical traverse lever c) Crossfeed handle d) Table traverse handle

B

A right-hand end mill rotates __________ in the spindle and ___________ when viewed from the front end (cutting edges). a) Counterclockwise, clockwise b) Clockwise, clockwise c) Clockwise, counterclockwise d) Counterclockwise, counterclockwise

C

If solid material becomes lodged in the eye, the first step for proper first aid is to: a) Use a magnet to attract the material out of the eye b) Rub the eye in a circular motion c) Pull the top lid over the bottom lid d) Close the eyelid and rub from left to right to dislodge the material

C

If you are standing in front of a vertical machining center, what direction doe the Z-axis travel? A Left to Right B Front to Back C Up and Down D None of the above

C

Machine motion, is always relative to the movement of the what? A Table B X Axis C Spindle D Y Axis

C

Productions parts are considered rejected when: a) The process plan is changed b) The production run continues through two shifts c) Dimensions are out of tolerance d) All the dimensions are made to the print tolerances

C

Program lines are separated by what character? Multiple Choice (select the best answer) A / B > C ; D ()

C

Proper disposal of oily rags and wipes prevents fires by preventing: a) Aqueous emulsion b) Spontaneous response c) Spontaneous combustion d) Aqueous oxidation

C

Removing any part of the Fire Triangle extinguishes the fire. The three components of the Fire Triangle are: a) Oxygen, hydrogen, fuel b) Heat, hydrogen, ashes c) Oxygen, fuel, heat d) Heat, fuel, water

C

The best cutting fluid for tapping gray cast iron is: a) Mineral spirits b) Kerosene c) No cutting fluid at all d) Heavy duty mineral oil

C

The table of a vertical milling machine rests on the: a) Column b) Spindle c) Saddle d) Head

C

The type of tap that is best suited for finish tapping a blind hole is a: a) Taper tap b) Plug tap c) Bottoming tap d) Blind hole tap

C

To accurately align a vise mounted on a table of a vertical milling machine perpendicular to the column, the vise should be aligned with: a) Machinists square b) Dowel pins c) Dial indicator against the fixed jaw d) Dial indicator against the moveable jaw e) Dowel pins against the hold down slots

C

To bore a hole perpendicular to the face of the workpiece, the machine table should be _____________ to the spindle. a) Tangent b) Parallel c) Perpendicular d) Offset at 45 degrees

C

What is the code M06? A Coolant ON B Coolant OFF C Tool Change D Spindle STOP

C

What type of spindle taper is most commonly found on a Bridgeport milling machine for hold collets? a) Jarno taper b) Morse taper c) R-8 d) 5-C e) Brown & Sharpe

C

When should the Way oil and coolant be checked? Multiple Choice (select the best answer) A Never B Once a week C Every work shift D Every Hour

C

Which of the following best describes the procedure for drilling a hole? a) Layout, center drill, prick punch, countersink, drill b) Drill, center drill, layout, countersink, prick punch c) Layout, prick punch, center drill, drill, countersink d) Countersink, center drill, drill, layout, prick punch

C

Which of the following instruments is used for precision layout? a) Scale and scriber b) Combination set and scriber c) Dial indicator height gage and scriber attachment d) Machinist square, scale and scriber

C

Which of the following is the most common drilling practice? a) Counterboring b) Reaming c) Drilling holes d) Lapping e) Countersinking

C

Which of the following statements is not considered a safe practice when operating a vertical milling machine? a) Using a brush to clear away chips b) Stopping the machine before taking any measurements c) Climb milling on a mill without backlash control d) Never reaching over a revolving cutter e) Using the speeds and feeds appropriate for the machine rigidity

C

Which of the following statements will not prevent tap breakage? a) The tap drill size creates a 75% thread b) The tap and material are have lubrication c) The tap drill creates a 95% thread and the hole is drilled to the full thread depth found on the print d) The hole is drilled deeper for chip accumulation

C

Which of the following vertical milling machine components is labeled as 12? a) Column b) Table c) Saddle d) Table

C

Handling solvents, lubricants and cleaning fluids properly maintains a safe work area. A document used as a reference for handling these materials is a: a) Failure Mode Effects Analysis (FMEA) b) Control plan c) Maintenance schedule d) Material Safety Data Sheet (MSDS) information

D

How many 3-1/2" long bars can be cut from a bar measuring a total of 18-3/4" long? A 10 B 7 C 8 D 5

D

The Four Quadrants of the Work Coordinate System are established by the? A Tool Radius B 3rd Quadrant C Tool Length D X and Y intersect

D

What is the correct tap drill for a 3/4-14 NPT (pipe thread)? a) 7/16 inch diameter drill b) 23/32 inch diameter drill c) 1 1/2 inch diameter drill d) 59/64 inch diameter drill

D

What is the first aid procedure for control bleeding for a minor cut? a) Apply a tourniquet b) Apply pressure to a pressure point on the body c) Apply a cotton pad to the wound d) Apply pressure to the wound and seek further first aid

D

Which of the following is not a function of layout lines? a) Identifies which side machining is to take place b) Aligns cutting tools c) Prevents machining errors and allows for finishing stock d) Measures parts within 0.0001 inches e) Aids in the visualization of the part to be machined

D

Which of the following is the best example for milling a 0.375-inch slot on a vertical milling machine? a) Use a 0.375-inch diameter end mill and take the cut in one pass b) Use a 0.250-inch diameter end mill and take two passes each overlapping one another c) Use a 0.125-inch diameter end mill and take three passes each overlapping one another d) Use a 0.250-inch diameter end mill for a roughing cut and a 0.375-inch diameter mill for a finishing cut

D

Which of the following measuring instruments can measure both the depth and diameter of a counterbore? a) Inside micrometer b) Outside micrometer c) Depth micrometer d) Dial caliper

D

Which of the following vertical milling machine components is labeled as 5? a) Table traverse handle b) Quill c) Head d) Table e) Ram

D

Which of the following types of end mills is capable of plunge cutting a hole? a) Three fluted gashed end mill b) Two fluted end mill c) Four fluted gashed end mill d) Four fluted center cutting end mill e) Both b and d are capable of starting a hole

E

A closed loop system checks to make sure that the axis distance sent is correct before it makes another move. A True B False

A

A direction of motion is called an axis. A True B False

A

Calculate the feed in inches per minute for O1 tool steel with a cutting speed of 55 SFM. The HSS end mill has a diameter of 0.875 inches with four flutes. The chip load per tooth is 0.008 inches. a) 8.05 IPM b) 601.6 IPM c) 17.86 IPM d) 296.51 IPM

A

When adding Soluble Oil to a machine, it is necessary to check the concentration level. If the mixture is think from water evaporating, add water appropriately. A True B False

A

Which of the following vertical milling machine components is labeled as 7? a) Crossfeed handle b) Table traverse handle c) Vertical traverse handle d) Table traverse lock

A

X, Y, and Z represent primary linear axes. A True B False

A

what is the code M03? A Spindle ON clockwise B Spindle ON counterclockwise C Spindle OFF D Coolant OFF

A

To calculate proper Feed Rates the following information must be known: A Work Piece Material B Type of Application (i.e., Roughing or Finishing) C Cutting Tool Diameter D Type of Coolant E Number of Cutting Teeth or Flutes

A B C E

A shaft has a two-inch diameter. The milling cutter has a diameter of 0.250 inches. The machinist has touched off at the side (not the top) of the shaft and has raised the milling cutter to clear the part. How far must the table be moved to center the milling cutter over the shaft? a) 2.125 inches b) 1.125 inches c) 2.250 inches d) 1.250 inches

B

The process of checking and adjusting a measuring instrument to an acceptable standard is called: a) Reliability b) Calibration c) Repeatability d) Discrimination

B

What does ±.005 represents? A Datum B Tolerance C Dimension D None of the above

B

Which metal removal variable has the greatest affect on tool life? a) Depth of cut b) Cutting speed (SFM) c) Feed rate d) Lubrication

B

Which of the following criteria determines the choice of a measuring instrument when checking a dimension? a) The machine tool used to produce the feature b) The tolerance of the dimension being inspected c) Availability of calibration standards d) The measuring skills of the operator

B

Which of the following is considered a safe practice for a milling cutter or face mill when approaching the workpiece? a) Enter the workpiece at a high rate of speed b) A face mill taking a cut of at least 1/2 to 2/3 of the diameter c) Climb milling on a vertical mill that has no backlash control d) Plunge cutting with a four fluted gashed end mill

B

Identify the center finding device used to line up a center or prick punched hole? a) Center drill b) Machining center c) Cone pointed edge finder d) Wiggler

C

To prevent large burrs and a tendency for the drill to grab, a machinist should ________ the spindle pressure when breaking through the material. a) Increase b) Vary c) Decrease d) Maintain

C

What direction do you turn the Jog Handle to move the spindle from left to right in relationship to the machine table? A +Y B -Y C +X D -X

C

What effect will a very small primary clearance angle have on the cutting action of a milling cutter? a)The cutter will cut efficiently and provide better wear characteristics b)The cutter will dig into the workpiece on the first pass regardless of the depth of cut c)The back of the land will rub on the work and cause poor cutting action d)The cutter will chatter leaving a poor surface finish

C

What is a boxed dimension? A Tolerance Limit Value B Datum Tolerance C Basic D None of the above

C

What is the code G91? A Rapid position B Absolute positioning C Incremental positioning D Work Offset positioning

C

A CNC milling machine uses a feed rate given in inches per revolution (IPR). What is the feed in inches per revolution for a four fluted end mill with a recommended chip load per tooth of 0.014 inches? a) 0.014 IPR b) 0.028 IPR c) 0.042 IPR d) 0.056 IPR

D

Feed rates for milling operations are expressed as _________________. a) Inches per revolution b) Feet per minute c) Meters per millimeter d) Inches per minute

D

The Revolutions Per Minute (RPM) that the cutting tool rotates, is what? A Rapid B Feed Rate C Axis Speed D Spindle Speed

D

The depth of a 3/8-inch diameter counterbore can best be measured with a: a) Dial caliper b) Dial test indicator c) Gage pins d) Depth micrometer

D

The width of a milled slot, hole diameter or counterbore depth can best be measured with a/an: a) Outside micrometer b) Dial test indicator c) Inside micrometer d) Dial caliper

D

What is the most important safety rule? A Wear safety Glasses B Wear proper attire C Keep work area clean D Follow all safety rules

D

To tram the head of a vertical mill properly, the spindle (or Z-axis) must be perpendicular to the: a) X-axis only b) Y-axis only c) X-axis and Z-axis d) Z-axis and Y-axis e) X-axis and Y-axis

E

Which of the following are advantages of drilling on a milling machine instead of drill press? a) The milling machine is capable of greater accuracy b) The milling machine has greater rigidity c) The milling machine is less expensive than purchasing a drill press d) All of the above e) Only a and b

E

Which of the following vertical milling machine components is labeled as 1? a) Knee b) Column c) Table d) Knee lock e) Head

E

If a tool change is required, the program should only be restarted after a safe tool change is completed. A True B False

True