Manufacturing Test 2 (Lectures (10-17))

Forging requires that the applied stress exceed the workpiece material's yield strength a) True b) False

a) True

Hot rolled material has higher ductility than cold rolled a) True b) False

a) True

Tube Drawing can be performed without a mandrel a) True b) False

a) True

Tube drawing is used to reduce diameter of existing tube a) True b) False

a) True

You need 4 cylindrical rods of Al 6061 that are 50 +/ - 0.2 mm long and 10+/ -0.1 mm dia. Which process would you choose: a) turn b) mills c) extrude d) draw e) none of the above

a) Turn

you need to have $1,000,000 in your bank account in 330 years to retire you want to invest a lump sum today in a bank which with a 5% nominal annual interest? which compounding interval with minimize the needed investment amount? a) daily b) weekly c) monthly d) annually e) in this case they are all equivalent

a) daily

You need 4000 aluminum tubes 30 mm long and 12 mm in diameter with an internal diameter of 6 mm: what is the ideal process to produce them (assuming that all can meet the tolerances): a) extrusion + cut-off saw b) casting c) turning and drilling / boring d) drawing + cut off saw e)deep drawing

a) extrusion + cut-off saw

In sand casting, the volumetric size of the pattern is a) larger than the cast part b) smaller than the cast part c) the same size as the cast part

a) larger than the cast part

Die casting is limited to high volume applications by the high cost of machines and dies. a) true b) false

a) true

Forging requires that the applied stress exceeds the work piece material's yield strength a)true b) false

a) true

In open die forging, barreling is primarily caused by friction and can be reduced by use of lubrication or ultrasonic vibration. a) true b) False

a) true

Smaller diameter rolls in cold rolling are used to produce thinner sheet metal a) true b) false

a)True

Japanes diamond grit grades have different average sizes than US grades with the same a) true b) False

a)true

Which of the following is not part of the investment casting process a) Wax/plastic pattern production b)assembly into a "tree" c) Shell building d) Burn out e) finishing ad) None of the Above

ad) None of the Above

All cast metals contract on solidification: a) True b) False

b) False

Powder metallurgy is only used to produce discrete parts. a) True b) False

b) False

Rolling Direction for the sheet metal has no effect on the minimum bend radii: a) True b) False

b) False

Sintering temperatures for powder metallurgy are typically less that 70% of the metal melting temperature: a) True b) False

b) False

Strain Hardening is never beneficial a) True b) False

b) False

The only application of multi-stage deep drawing is the production of beverage cans : a) True b) False

b) False

Too large radii at deep drawing punch and die corners lead to tearing: a) True b) False

b) False

Which of the following is NOT used to produce powders for PM processes: a) atomization b) diminution c) reduction d) electrolytic deposition e) Mechanical alloying

b) diminution

Which of the following cannot be depreciated? a) New milling machine b) land on which a new factory is built c) second hand overhead crane d) New furnace to heat factory in winter

b) land on which a new factory is built

Which of the following is not a bending process? a) hemming b) stitching c) seaming

b) stitching

Which of the following statements about sand casting is/are false: a) green sand molds are less expensive than dry sand molds b)Dry sand molds give worse surface finish than green sand molds c) sand casting is a good choice for small lot sizes

b)Dry sand molds give worse surface finish than green sand molds

Anisotropy in the properties of the sheet metal used has no effect on the process results in deep drawing: a) True b) False

b)False

hot rolled material occurs just below the recrystillization temperature: a)true b) false

b)false

You need to make 10,000 aluminum automotive oil filter housing per month. Which processes would you choose: a) turn b) mill c) deep draw d) forge e) none of the above

c) Deep Draw

Spring back in sheet metal bending does NOT depend on; a) Sheet thickness b) Sheet metal material properties c) Die Material d) Bend radius

c) Die material

Which of the following is true about "wiping" or "flanging"; a) the blank is unconstrained b) thinning typically occurs on the inside edge of the bend c) Different bend angles can be produces with a single die set d) Different bend radii can be produced with a single dies set

c) Different bend angles can be produces with a single die set

what is an ideal process for large volume production of copper wire: a)hot rolling b) extrusion c)drawing d) deep drawing e) None of the above

c) Drawing

Which ONE of the following is FALSE about abrasive machining processes: a) they are use on hard or brittle materials b) they are used when tight tolerances are required c) They have higher removal rates than the conventional machining processes d) they are used to generate some surfaces with specific functions (eg cylinder liners)

c) They have higher removal rates than the conventional machining processes

Which of the following is NOT an operation in sheet metal processing a) flanging b)seaming c) crimping d) hemming e)seaming

c) crimping

The present worth (6% interest compounded quarterly) of the cash flow shown in figure 2 (drawn from your perspective) is; a) positive b)zero c) negative d) none of the above

c) negative

You need 4 aluminum tubes 30 mm long and 12 mm in diameter with an internal diameter of 6 mm: what is the ideal process to produce them (assuming that all can meet the tolerance) : a) extrusion + cut-off saw b) casting c) turning and drilling / boring d) drawing + cut off saw e)deep drawing

c)Turning and drilling/ boring

One year revenue is shown in the cash flow diagram in figure 1. at 6% nominal interest compounded quarterly, what is the value at the end of the year (round the nearest dollar) a)$2313 b) $2400 c) $2418 d) $2455 e)$2625

d) $2455

What is the book value of $15,000 investment with an 8-year life after 3 years of straight-line depreciation? a)$1875 b)$5625 c)$7500 d)$9375 e) None of the above

d) $9375

The effective interest rate for a loan at 6% nominal compounding weekly is: a) 6% b)6.14% c)6.17% d) 6.18% e) None of the above

d) 6.18%

Rolling Direction of sheet metal has no effect on the minimum bend radius: a)Burnishing b) fracture c) burs d) all of the above e) none of the above

d) all of the above

You need to make 10,000 zinc parts per month as Shown to the right. Which process would you choose: (a) mill (b) sand cast (c) investment cast (d) die cast e) none of the above

d) die cast

Which of the following is true about hot rolling: a) it requires lower forces than cold rolling b) it occurs above the recrystallization temperature c) vin<vout d) Tolerances are worse than cold rolling e) all of the above

e) all of the above

Three body abrasions does not involve a) lap/tool b) loose abrasive c) workpiece d) slurry e)vitreous bond

e) vitreous bond

For a capitalized cost of $50,000 at a 6% annual interest rate how much can you withdraw every year in perpetuity? a) $3000 b) $833333 c)$53000 d) None of the above

(a) $3000

Which of the following may be depreciated: (a) a newly acquired milling machine (b) box of pens (c ) A subscription to the Economist (d) acquisition of the lot adjacent to the factory for future expansion

(a) a newly acquired milling machine

Which of the following is/are considered in engineering economic analysis currently in the USA: (a) cash cost (b) book cost (c) life cycle cost (d)opportunity cost.

(a) cash cost (d) opportunity cost

You take a $1000 loan at 6% nominal interest, planning to repay at the end of 1 year. You will have to repay most if interest compounds (a) daily (b) weekly (c ) monthly (d) quarterly (e ) they are all the same

(a) daily

... plus $100,000 research, development and engineering costs. Are these a (a) fixed cost (b) variable cost?

(a) fixed cost

For an analysis of breakeven of the "new" product idea a new $200,000 electron beam welder is required: Is this a (a) fixed cost (b) variable cost

(a) fixed cost

Your company make 1000 washing machine drive shafts per week on 2 old manual lathes operated by workers earning $30/hr (no benefits, no overtime). The shafts sell for $25 each. Your boss suggests that new, higher powered CNC lathe costing $20,000 can produce all the shafts with a skilled operator earning $40/hr (no benefits, no overtime). The higher spindle speed and/or depth of cut required will lead to (a) higher tool replacement costs (b) higher power consumption (c) lower maintenance costs (d) all of the above.

(a) higher tool (b) higher power consumption

Your receive a payment of $1000 at the end of each month for 12 months. At a nominal interest rate of 6%. If interest compounds monthly, the present value of these payments is: (a) $9430 (b) $11,619 (c ) $12,000 (d) $12,336 (e ) $16,870

(b) $11,619

Chvorinov's rule relates cutting tool life to surface velocity and depth of cut a) true (b) false

(b) False

You are comparing two options for a new machine. The conclusion reached over which to choose will be different depending if you use Net Present Worth or Net Equivalent Uniform Annual: (a) true (b) false

(b) False

During casting, all metal shrink: (a) true (b) false

(b) false

Metal powders used in powder metal laser or e-beam sintering (metal additive manufacturing) are produced using different methods form those used for metal powders for powder metallurgy processes (a) true (b) false

(b) false

You are planning a trip to New Zealand to celebrate completion of an MS in manufacturing/metrology (in 2023) and need to consider financial options. One option is to invest $300 dollars every 3 months in a saving account that pays a nominal interest rate of 6% compounded quarterly. For your economics analysis, which of the following is/are correct: (a) i = 6% (b) i =1.5 % (c ) 0.5% (d) n= 5 ( e ) n = 60

(b) i=1.5%

... and $400 of bought-in components and labor for each "product". Are these a (a) fixed cost (b) variable cost

(b) variable cost

The structure of a cast elemental metal has a skin of fine grained crystals and columnar (elongated grains) (a) randomly oriented (b) with the long axis aligned with the direction of heat transfer (c ) with the long axis perpendicular to the direction of heat transfer (d)none of the above

(b) with the long axis aligned with the direction of heat transfer

You will receive a payment of $1000 six months from now, and again 12 months from now. What is the present value (nominal interest =6%, compounding quarterly) of these payments: (a) $1840.20 (b) $1912.90 (c ) $2000 (d) $6106 (e ) none of the above

(b)$1912.90

The new product will sell for $1000 ea. What is breakeven? (a) 300 units (b) 334 units (c) 500 units (d) 600 units (e) 5000 units

(c) 500 units

3 years ago, the company you work for purchased a 5 axis CNC milling machine for $500,000 to improved productivity on one of their products. That product has been discontinued. Your boss has an idea for a new product that will use the same machine. In your economic analysis of the project do you treat this machine as (a) a fixed cost (b) a variable cost (c) sunk cost (d) marginal cost (e) recurring cost

(c) sunk cost

3 years ago, the company you work for purchased a 5 axis CNC milling machine for$500,000 to improved productivity on one of their products. That product has been discontinued. Your boss has an idea for a new product that will use the same machine. The 5- axis machine has greater capability than needed for the new product. Which of the following options should be considered (a) Sell the 5-axis machine second hand and buy a new 3-axis machine (b) Outsource the machining (c) Sell the 5-axis machine, ignore the new product idea, and lay off staff (d) do nothing (e) all of the above.

(e) all of the above