CH 21-22 (Theory of metal machining/Machine tools and operations)

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?

(a) aluminum

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) boring (c) drilling (f) turning

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) broach

End milling is most similar to which one of the following: (a) face milling, (b) peripheral milling, (c) plain milling, or (d) slab milling?

(a) face milling

Knurling is performed on a lathe, but it is not a metal cutting operation: (a) true or (b) false?

(a) true

The twist drill is the most common type of drill bit: (a) true or (b) false?

(a) true

In a turning operation, the change in diameter of the work part is equal to which one of the following: (a) 1 depth of cut, (b) 2 depth of cut, (c) 1 feed, or (d) 2 feed?

(b) 2 depth of cut

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 singlepoint tool?

(b) a tool with multiple teeth moves linearly past a stationary workpart

The three basic types of sawing, according to type of blade motion involved, are (a) abrasive cutoff, (b) bandsawing, (c) circular sawing, (d) contouring, (e) friction sawing, (f) hacksawing, and (g) slotting?

(b) bandsawing (c) circular sawing (f) hacksawing

Which of the following are examples of generating the work part 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) contour turning (d) profile milling

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 in shear plane angle?

(b) decrease in power requirements (e) increase in shear plane angle

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning: (a) depth of cut d, (b) feed f, or (c) speed v?

(b) feed f

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) knee-and-column

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) lathe

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) milling

Which of the following cutting conditions has the strongest effect on cutting temperature: (a) feed or (b) speed?

(b) speed

The chip thickness ratio is which one of the following: (a) tc/to, (b) to/tc, (c) f/d, or (d) to/w, where tc ¼ chip thickness after the cut, to ¼ chip thickness before the cut, f ¼ feed, d ¼ depth, and w ¼ width of cut?

(b) to/tc

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 in, (b) 0.025 in, (c) 0.12 mm, or (d) 0.50 mm?

(c) 0.12 mm

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 built-up edge, (c) discontinuous, or (d) serrated?

(c) discontinuous

A roughing operation generally involves which one of the following combinations of cutting conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v,f, and d

(c) low v, high f

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?

(c) round hole

Which one of the following turning machines permits very long bar stock to be used: (a) chucking machine, (b) engine lathe, (c) screw machine, (d) speed lathe, or (e) turret lathe?

(c) screw machine

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 workpart moves linearly past a single-point tool?

A tap is a cutting tool used to create which one of the following geometries: (a) external threads, (b) flat planar surfaces, (c) holes used in beer kegs, (d) internal threads, or (e) square holes?

(d) internal threads

Which of the following are characteristics of the orthogonal cutting model (three best answers): (a) a circular cutting edge is used, (b) a multiplecutting-edge tool is used, (c) a single-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?

(d) only two dimensions play an active role in the analysis (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?

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) pressworking, and (i) spinning?

(e) grinding (f) machining

A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, or (e) turning?

(e) turning