ME 2653 Test 5-7-15

the range of rise per tooth for internal broaching is ___ to ___ inches/tooth

.001 .0025

the range of rise per tooth for external broaching is ___ to ___ inches/tooth

.003 .006

up milling: the mill cutter rotates ___ the direction of feed

against

tapered end mills are used for

finish cutting on molds to produce a desired angle

the saddle provides ___ movement on the knee ways

transverse (y-axis)

centerless grinding is a process that is performed quickly t/f

true

crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs t/f

true

more flat surfaces are produced by the milling process than any other machining process t/f

true

the filing process is used to remove small amounts of material from a part t/f

true

the truing of a grinding wheel is a process performed to restore the desired shape to the wheel t/f

true

a requirement of broaching is that ___ teeth be in contact with the workpiece

two

up milling: in slab milling operations, the direction of the cutting force is ___

up

the most common type of broaching machine construction is ___

vertical

the knee provides ___ movement on the column ways

vertical (z-axis)

end milling, drilling, and boring is typically performed using what type of knee-and-column milling machine

vertical milling machine

down milling: in slab milling operations, the direction of the cutting force is ___

vertically down

down milling: the mill cutter rotates ___ the direction of the feed

with

what type of milling is used to mill a semi-circular keyway in a shaft used in power transmission equipment?

woodruff keyseat milling cutter

the milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches

150

the surface finish obtained from the broaching process has a surface finish measurement of ___ to ___ microinches

32 125

vertical broaching machines are usually limited to strokes of ___ inches due to height and load considerations

72

which of the following is not a common material used for the teeth of a band saw blade?

CBN

the milling machine was invented in approximately 1816 by ___

Simeon North

which of the following best describes the tool and workpiece movement for the milling process

a process involving a rotating tool and x-y-z linear movement of the workpiece

a diving head is an accessory used with a milling machine primarily to provide what operation?

accurate rotation of the work piece through any desired arc of rotation

which of the following is not an abrasive material used in commercial cleaning applications?

aluminum chips

what is the most common material used for abrasives?

aluminum oxide

horizontal milling: 45 degree, v-shaped groove in the surface of a flat bar

angle cutter

vertical milling: producing a groove with a 1/8" diameter concave bottom

ball end mill

the most common type of sawing machine for cutting metal is ___

bandsaw

in mass production operations, a milling machine with the capability of making heavy cuts, having 1, 2, or 3 spindles, and no vertical table movement is often used. This describes what type of milling machine?

bed milling machine

which is the most frequently used mounting system for abrasives?

bonded

the teeth of an end mill cutter are located on the ___

circumference and the face of the cutter

what type of grinding machining would be used for the grinding of camshafts and crankshafts?

cylindrical external

attrition refers to the material property regarding the wearing action of the abrasive, resulting in ___ edges and ___ of the abrasive grit

dull flattening

vertical milling: deep slots with straight side walls

end mill

vertical milling: producing a flat-bottom groove in the surface of a part

end mill

vertical milling: producing a pocket in a work piece

end mill

vertical milling: finishing the top surface of a work piece

face mill

broaching is a process that can be used only in mass-production t/f

false

dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened t/f

false

for grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles t/f

false

high ductile materials (i.e. aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth t/f

false

the milling process is characterized by low MRR, good to excellent finished surface (low surface roughness), and is used in mass production, tool and die work, and prototype work t/f

false

horizontal milling: 1/4" radius, convex shape along the edge of the part

form cutter

horizontal milling: milling wood to produce wood trim

form cutter

vertical milling: bearing pocket in gearbox housing

form cutter

friability refers to the ability of the abrasive material to ___

fracture, producing new, sharp edges

by using extremely ___ materials for abrasives, it is possible to machine hardened steel, ___, ___, and ___

hard ceramics carbides glass

slab milling is typically performed using what type of knee-and-column milling machine

horizontal milling machine

which of the following is not a type of broach construction?

insert tooth

broaching was originally developed for the production of ___

internal keyways

the slot cut in the material by a saw blade is called ___

kerf

the table has ___ movement on the saddle ways

longitudinal (x-axis)

in the abrasive machining process, ___ edges are cutting simulatenously resulting in a(n) ___ surface finish

many excellent

down milling: the chip thickness is a ___ at the beginning of the chip formation

maximum

up milling: the chip thickness is a ___ as the end of the chip formation as the tool exits the work piece

maximum

down milling: the chip thickness is a ___ at the end of the chip formation as the tool exits the work piece

minimum

up milling: the chip thickness is a ___ at the beginning of the chip formation

minimum

which of the following is not a type of mounting method that is used with the abrasive machining process?

mounted

the milling process uses ___ and involves ___ cutting

multi-tooth cutter interrupted

helical teeth on a cutter allow ___ to contact the work surface at a time. This results in ___ chatter and shock and a ___ surface

multiple teeth less smoother (lower surface roughness value)

milling cutters with carbide and ceramic cutting edges have a ___ rake angle and can be operated at ___ times faster than a HSS cutter

negative 3 to 5

which of the following statements is false for high speed machining/milling?

one or more axes are always accelerating in a 3-D cut

in the slab milling process, the finished surface is ___ to the axis of rotation of the cutter and is normally performed on a ___ spindle milling machine

parallel horizontal

in face milling, most of the cutting occurs at what areas of the cutter?

peripheral edge

horizontal milling: finishing the top surface of a flat bar

plain cutter

the abrasive machining process is a mixture of three processes; ___ moves material, ___ causes friction and ___ forms chips

plowing rubbing cutting

a CNC milling machine ___

provides for machining of more complex parts than a manual milling machine

the blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade

radius

"power filing" is frequently performed with ___

rotary burrs

the pattern used to offset the saw blade teeth from the centerline of the blade is called ___

set

the first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?

sewing machines

the broaching process can be described as: a ___ process using a ___ tooth cutter to remove material with roughing and finishing operations performed in ___ of the cutter

single-stroke multi a single pass

horizontal milling: deep, straight walled, narrow slots

slitting saw cutter

which of the following is not a common tooth form for saw blades?

square

horizontal milling: deep slots in a work piece

staggered-tooth cutter

what is the milling of two parallel surfaces with side cutters called?

straddle milling

plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter

straight helical

what is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables?

t-slot milling cutter

the structure of a grinding wheel refers to ___

the spacing of the abrasive grit in the wheel

the grade of a grinding wheel refers to ___

the strength of the bonds between the abrasive grits

for american pattern files, the coarseness of the file cut is given by:

the tooth pattern and the length of the file

up milling: the direction of the cutting forces are ___

toward the part