ME2653 Exam 4
Which of the following statements for Electrical Discharge Machining is incorrect? A very specialized process for machining developed for machining parts for NASA rocket engine parts. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. Most frequently used of NTM processes. A matt finished is produced by the EDM process
A very specialized process for machining developed for machining parts for NASA rocket engine parts
Which of the following statements is false for rolled threads? A. The threads produced by thread rolling have a lower strength than cut threads. B. Rolled threads have a major diameter larger than the diameter of the base stock. C. Rolled threads have a hard, wear resistant, smooth surface.
A.
Which of the following does NOT apply to non-traditional machining? Removing material from a base using chemicals. Removing material from a base using a tool vibrated at ultrasonic frequencies. Removing material using ultra-high pressure water. Adding material to a base using high voltage electrical discharges. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. By an additive process where small, precise amounts of materials are built-up into a shape.
Adding material to a base using high voltage electrical discharges
Which of the following is not an abrasive material used in commerical cleaning applications? A. dry ice B. aluminum chips C. walnut shells D. plastic media
B.
Which of the following statements is false regarding thread grinding? A. Threads in hardened steels can be produced B. Only coarse threads can be produced. C. Using a centerless grinding process, 1/2" long set screws can be produced at 1 piece/sec. D. Very accurate, fine pitched threads can be produced
B.
Which of the following materials is not commonly used as a lap? A. Copper B. Cast iron C. Aluminum D. Cloth
C.
Which of the following statements is false for clamping forces? A. The clamping forces should force the workpiece against the fixed points of location and work support. B. The cutting forces should act toward the fixed part of a fixture. C. The clamping forces should be spread over a small area.
C.
Which of the following statements is false regarding the thread rolling process? A. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second. B. Thread rolling can be used to form threads on tubular products. C. Thread rolling is a hot forming process.
C.
Which of the following is not an advantage of plasma arc cutting? Very fast cutting Smooth cuts free of contaminants are produced Can be used for cutting metal based composite materials small heat-affected zone
Can be used for cutting metal based composite materials
Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and X-Y-Z linear movement of the tooling B. A process involving a rotating work piece and rotating tooling C. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements. D. A process involving a rotating tool and X-Y-Z linear movement of the work piece.
D
True or False: Electrochemical Machining is a deplating process using high DC voltage, high current for the process.
False
True or False: For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.
False
True or False: High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.
False
True or False: The operator should not have to reach past the tool to load/unload parts for machining.
True
True or False: The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.
True
True or False: With centerless grinding, no distortion of the part occurs dues to grinding forces. Therefore, it is possible to obtain very accurate finished part dimensions.
True
True or False: Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.
True
For the up milling process, complete the statements with the answers supplied The mill cutter rotates ___ the direction of feed.
against
Type of milling cutter: 45 degree, V shaped groove in the surface of a flat bar
angle cutter
The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole?
crosshatch
Which of the following is not an application for laser beam machining? Welding Drilling micro-sized holes Cutting thick materials Cutting thin materials
cutting thick materials
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.
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
You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice?
electrostatic chuck
Which cutter is best: producing a pocket in a workpiece
end mill
Which cutter is best: finishing the top surface of a work piece
face mill
Tapered end mills are used for ____.
finish cutting on molds to produce a desired angle
Type of milling cutter: Milling wood to produce wood trim
form cutter
Which cutter is best: 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 ___. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics
hard, glass, ceramics, carbides
A fixture is a special workholding device that ___ the workpiece during machining or assembly operations and establishes ___ dimensions.
holds, size
Superfinishing is a variation of what process to finish flat surfaces.
honing
Which surface grinder type: The most common type of surface grinding machine.
horizontal spindle, reciprocating table
Which surface grinder type: Surface grinder not typically used due to limited type of work which it will accommodate.
horizontal spindle, rotary table
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.
maximum
For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ as the end of the chip formation as the tool exits the work piece
maximum
For the down milling process, complete the statements with the answers supplied The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.
minimum
For the up milling process, complete the statements with the answers supplied The chip thickness is a ___ at the beginning of the chip formation.
minimum
Loading and unloading of a fixture will often abuse the fixture ____ .
more than the machining operation
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
Type of milling cutter: 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
In centerless grinding, the regulating wheel controls _____ in the grinding process.
rotating speed and axial feed of the work piece
What device is used to produce external threads with lathes, screw machines, and threading machines?
self-opening die head
Magnetic chucks are commonly used on what type of machinery?
surface grinders
To thread a blind hole the threes types of taps used, in order are ___, ___, and ___.
taper, plug, bottom
For American pattern files, the coarseness of the file cut is given by:
the tooth pattern and the length of the file
The process for machining threads which requires a CNC machining center capable of circular interpolation is ___.
thread milling
The principle of 3-2-1 uses location points to define ___.
three (3) perpendicular planes
For the up milling process, complete the statements with the answers supplied The direction of the cutting forces are ____.
toward the part
The milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches.
150
True or False: The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.
False
True or False: The honing process used stones with a grit size of 1200 or more particles per inch.
False
Which of the following applies to plasma arc cutting? Plasma arc cutting involves superheated gas for cutting only steel plates. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals. Plasma arc cutting involves super-high pressure gas propelled at mach 30 for cutting conductive metals.
Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
Which of the following is a correct statement for rapid prototyping? Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes. Rapid prototyping is used only for medical applications. Rapid prototyping is a very expensive process and has very limited applications. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.
Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.
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
True or False: The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.
True
True or False: The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.
True
True or False: The filing process is used to remove small amounts of material from a part.
True
Slab milling is typically performed using what type of knee-and-column milling machine?
horizontal milling machine
Which of the following describes the ultrasonic machining process? A harden steel tool is vibrated at low frequencies (<1000) with an small amplitude (~ 0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. A harden steel tool is vibrated at high frequencies (>20,000 Hz) with an small amplitude (~0.003") with an abrasive slurry pumped between the materail being machined and the tool as a process to remove material. A harden steel tool is vibrated at low frequencies (<1000 Hz) and large amplitudes (>0.10') with an abrasive slurry pumped between the material being machined and the tool as a process to remove material. A harden steel tool is vibrated at high frequencies (>20,000 Hz) and large amplitudes (>0.10") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.
A harden steel tool is vibrated at high frequencies (>20,000 Hz) with a small amplitude (~0.003") with an abrasive slurry pumped between the material being machined and the tool as a process to remove material.
Which of the following is not a type of broach construction? A. shell B. solid C. insert tooth D. segment
C.
Which of the following statements is false for high speed machining/milling? A. Low cutting forces are produced B. Acceleration rate is greater than 2 m/sec2. C. One or more axes are always accelerating in a 3-D cut. D. Cutting speed for steel is less than 1500 m/min E. A high material removal rate is obtained
C.
Which cutter is best: producing a groove with a 1/8" diameter concave bottom
ball end mill
In the abrasive machining process, ___ edges are cutting simultaneously resulting in a(n) ___ surface finish.
many, excellent
The milling machine was invented in approximately 1816 by ___.
Simeon North
True or False: Crush dressing is a process which is used to continuously or intermittently dress and/or true the grinding wheel while the grinding process occurs.
True
True or False: Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)
True
True or False: For the honing process the amount of material removed is less than 0.005" from the surface.
True
True or False: In centerless grinding, the work piece must be round and not include flats or keyways.
True
True or False: More flat surfaces are produced by the milling process than any other machining process.
True
True or False: The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.
True
True or False: In centerless grinding deep cuts are not possible due to the work support.
False
The amount of material removed in lapping is usually less than _____
0.001"
What percentage of EDM is used to produce tool and die sets?
80-90%
Which of the the following is not a common tooth form for saw blades? A. square B. regular C. skip D. claw
A.
True or False: Centerless grinding is a process that is performed quickly.
True
What is the most common material used for abrasives?
aluminum oxide
Which is the most frequently used mounting system for abrasives?
bonded
Producing a flat-bottom groove in the surface of a part
end mill
What is used to produce internal threads?
taps
For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.
vertically down
Common base elements for fixtures are a ___ for milling and a ___ for lathe operations.
vise, chuck
For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.
with
The maximum operator force in loading/unloading a part should be less than ___ to ___ lbf.
30, 40
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 materials is not used a a carrier to charge the lap with abrasive particles? A. water B. oil C. grease D. air
D.
What device is used to manually produce external threads?
Die
True or False: A fixture/jig should be design using the least number of standard elements as possible.
False
True or False: Broaching is a process that can be used only in mass-production.
False
True or False: Centerless grinding is a process that must be performed manually by the machinist.
False
True or False: Centerless grinding requires lots of operator skill to operate the machine.
False
True or False: Centerless grinding requires that small grinding wheels be used in the grinding process.
False
True or False: Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.
False
True or False: Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.
False
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 or Helical
Which of the following statements correctly describes the purpose of the mask in chemical machining? The mask is applied to the area of the part that is is desired to not remove material from the part. The mask is applied to the area of the part that it is desired to removal material from the part. The mask enhances the chemical machining process. None of the above.
The mask is applied to the area of the part that it is desired to not remove material from the part.
True or False: A fixture/jig should be designed to tolerate variations in the workpiece.
True
A dividing 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
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
Clamping forces must be greater than what four (4) forces?
centrifugal, gravity, cutting, inertial
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material.
charged
The teeth of an end mill cutter are located on the ___.
circumference and the face of the cutter
Which of the following is a function of the dielectric in the electrical discharge machining process? Flushing agent Lubricant Protective coating for the finished part Heating agent
flushing agent
The ability to load a part into a fixture only one way is called?
fool proofing
Type of milling cutter: 1/4" radius, convex shape along the edge of a part
form cutter
Broaching was originally developed for the production of ____.
internal keyways
The slot cut in the material by a saw blade is called ____.
kerf
The soft material used in the lapping process is called _______.
lap
A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.
location
Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways.
longitudinal (X-axis)
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 area of the cutter?
peripheral edge
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
Type of milling cutter: deep, straight walled, narrow slots
slitting saw cutter
Type of milling cutter: Deep slots in a work piece
staggered-tooth cutter
The range of rise per tooth for internal broaching is ___ to ___ inches/tooth.
0.001, 0.0025
The range of rise per tooth for external broaching is ___ to ___ inches/tooth
0.003, 0.006
What is the typical MRR for electrochemical machining? 0.01 in^3/min/1000 amps 0.1 in^3/min/1000 amps 1 in^3/min/1000 amps 100 in^3/min/1000 amps
0.1 in^3/min/1000 amps
Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. mounted D. free
C.
True or False: The lapping process must be performed only by hand without machinery.
False
True or 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.
False
True or False: Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.
False
True or False: With centerless grinding tubes will automatically have concentric inside and outside diameters.
False
True or False: Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.
False
True or False: Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.
True
True or False: Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.
True
"Power filing" is frequently performed with ___.
rotary burrs
The structure of a grinding wheel refers to ___.
the spacing of the abrasive grit in the wheel
The pattern used to offset the saw blade teeth from the centerline of the blade is called ___.
set
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways
transverse (Y-axis)
The honing process is not used for which of the following:
truing of holes
A requirement for broaching is that ___ teeth be in contact with the workpiece.
two
For the up milling process, complete the statements with the answers supplied In slab milling operations, the direction of the cutting force is _____.
up
The most common type of broaching machine construction is ____.
vertical
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways.
vertical (Z-axis)
What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment?
woodruff keyseat milling cutter
The most common type of sawing machine for cutting metal is____.
bandsaw
Which cutter is best: Deep slots with straight side walls
end mill
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?
sewing machine
Which of the following is not a common material used for the teeth of a band saw blade? A. high speed steel B. CBN C. diamond D. tungsten carbide
B.
True or False: The chemical machining process is used in mass-production of parts.
True
In _____ products, threads are frequently produced by casting.
plastic
The grade of a grinding wheel refers to ____.
the strength of the bonds between the abrasive grits
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?
vertical milling machine
Which surface grinder type: Surface grinder where the wheel diameter must exceed the width of the part being ground
vertical spindle, reciprocating table
Which surface grinder type: Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.
vertical spindle, rotary table
Which surface grinder type: Surface grinding machine used in production operations.
vertical spindle, rotary table
