NIMS: Milling

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 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 optimum thread percentage that most tap drill charts are based on is: A) 75% B) 65% C) 55% D) 85%

A

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) I .250 inches

B

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) O. 100 inches C) 0.400 inches D) 0.050 inches

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

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 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 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 maimum pressure D) The T-bolt is the same distance from the work and the step block and is set at a three degree angle tilted up

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

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

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

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 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 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

Which of the following statements will NOT prevent tap breakage? A) The tap drill size creates a 75% thread B) The tap and material 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

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 visualization of the part to be machined

D

Which of the following is the best e)emple 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

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 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

Which of the following vertical milling machine components is labeled as 1? A) Knee B) Column C) Table D) Knee lock E) Head

E

Calculate the feed in inches per minute for 01 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

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

a

Surface finish can be checked with a: a) Comparison Chart b) ToolMakers Microscope c) Eye Loupe d) Depth Micrometer

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" + or - 1/64". Which of the following statements is true if a 0.584" 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 included angle on the point of a general purpose drill is: a) 118 degrees b) 39.5 degrees c) 59 degrees d) 135 degrees

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

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 machine is running. d) Variable speed drive must be adjusted with differential gearing while the machine is stopped and a belt pulley drive requires no differential gearing

b

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

b

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

b

The correct RPM for a 0.750 diameter high speed steel end mill machining 01 tool steel at 50 sfm is: a) 533 RPM b) 266.7 RPM c) 133.3 RPM d) 150 RPM

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

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 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

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

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

Production 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

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

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

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

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

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

d

The depth of a 3/8" diameter counterbore can be best 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

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 are advantages of drilling on a milling machine instead of a 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