mech 2653 test 4
rotary burrs
"Power filing" is frequently performed with ____ A. a filing machine B. band filing C. rotary burrs D. disk filing
Aluminum and aluminum alloys are:
"fabrication friendly".
Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock for the process.
(1) multiple teeth (2) less
The accuracy that can be expected from the milling process is:
.0005 inches
The range of rise per tooth for internal broaching is (x) to (y) inches/tooth.
.001 .006
The range of rise per tooth for *internal* broaching is [x] to [y] inches/tooth.
.001 to .0025
The amount of material removed in lapping is usually less than _____ A. None of these B. 1 millionth of an inch C. 0.0005" D. 0.001"
.001"
The range of rise per tooth for external broaching is (x) to (y) inches/tooth.
.003 .006
The range of rise per tooth for *external* broaching is [x] to [y] inches/tooth
.003 to .006
What is the typical MRR for electrochemical machining? A. in^3/ min/ 1000 amps B. .1 in^3/min/1000 amps C. 100 in^3/min/1000 amps
.1 in^3/min/1000 amps
The accuracy that can be expected from the milling process is:
0.0005 inches
The range of rise per tooth for internal broaching is ______ inches/tooth
0.001 to 0.0025
The amount of material removed in lapping is usually less than _____
0.001"
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?
0.1 in^3/min/1000 amps
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
1) 45 degree, V shaped groove in the surface of a flat bar
1) angle cutter
1) Deep slots with straight side walls
1) end mill
The broaching processes is used in the manufacturing of
1. Pipe wrench jaw teeth 2. internal keyways 3. dovetail for a turbine blade 4. internal splines
Non-Traditional Machining produces parts by which of the following (mark all that apply)?
1. Removing material from a base using chemicals 2. Removing material from a base using a tool vibrated at ultrasonic frequencies 3. Removing material using ultra-high pressure water 4. Removing materials by metaling materials using laser beams, electronic beams, and plasma arc. 5. By an additive process where small, precise amounts of materaisl are built-up into a shape
Modular fixturing is frequently used ...
1. for prototyping and small jobs 2. because standard parts can be used to construct the fixture 3. to lower costs
The abrasive machining process is used for which of the following?
1. improving the surface finish of a part 2. accurately machining a part to a finished size with an excellent surface finish 3. cleaning the particle 4. Part seperation
CNC milling machines are used in machining operations becase
1. the part geometry can be more complex and 3D compound curves are possible 2. the part can be machined more accurately 3. the part can be machined faster
The milling process will produce a surface finish with a surface roughness measurement of 60 to ___ microinches.
150
The milling process will produce a surface finish with a surface roughness measurement of 60 to ____ microinches.
150
2) finishing the top surface of a work piece
2) face mill
2) finishing the top surface of a flat bar
2) plain cutter
In the design of fixtures/jigs the principle of 3-2-1 uses location points to define:
3 perpendicular planes
In the design of fixtures/jigs the principle of 3-2-1 uses locaton points to define
3 perpendicular planes
3) producing a groove with a 1/8" diameter concave bottom
3) ball end mill
3) deep, straight walled, narrow slots
3) slitting saw cutter
The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.
30 40
The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.
30 to 40
The maximum operator force in loading/unloading a part should be less than ___ to ___ lbf.
30, 40
A good design consideration is to limit operator force in operating clamping mechanisms to ___ lbs
30-40
The surface finish obtained from the broaching process has a surface finish measurement of (x) to (y) microinches
32 125
The surface finish obtained from the broaching process has a surface finish measurement of [x] to [y] micro inches.
32 to 125
The surface finish obtained from the broaching process has a surface finish measurement of ___ to ___ microinches.
32, 125
4) Bearing pocket in gearbox housing
4) end mill
4) 1/4" radius, convex shape along the edge of the part
4) form cutter
5) Producing a flat-bottom groove in the surface of a part
5) end mill
5) milling wood to produce wood trim
5) form cutter
6) Deep slots in a work piece
6) Staggered- tooth cutter
Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations.
72
Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations. A. 100 B. 72 C. 48 D. 60
72
What percentage of EDM is used to produce tool and die sets? A.10-20% B. 80-90% C. 70-80% D. 50-60%
80-90
What percentage of EDM is used to produce tool and die sets?
80-90%
Provides for machining of more complex parts than a manual milling machine
A CNC milling machine ___. A. Requires highly trained operators to operate. B. Is used only in mass production operations. C. Can machine parts slower and more accurately than a manual milling machine D. Provides for machining of more complex parts than a manual milling machine
The honing process is a finishing process typically used to produce
A cross-hatch pattern on an internal cylindrical surface
accurate rotation of the work piece through any desired arc of rotation
A dividing head is an accessory used with a milling machine primarily to provide what operation? A. rotation of a part 90 degrees so that additional machining can be performed on it B. rotation of a part 180 degrees C. accurate rotation of the work piece through any desired arc of rotation D. rotation of a group of parts so that the next piece in the group can be machined
holds (x) size (y)
A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.
False
A fixture/jig should be design using the least number of standard elements as possible. True or False
True
A fixture/jig should be designed to tolerate variations in the workpiece. True or False
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 describes the ultrasonic machining process?
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 material being machined and the tool as a process to remove material.
Which of the following describes the ultrasonic machining process? A. 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. B. 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. C. 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. D. 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 material being machined and the tool as a process to remove material.
The milling process is characterized by
A high MRR, a good surface finish, and is used in mass production
location
A jig is a special workholding device that determines ____ dimensions that are produced by machining or assembly operations.
The milling process typically involves
A non-rotating part and a rotating cutter
Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and rotating tooling B. A process involving a rotating tool and X-Y-Z linear movement of the work piece. C. A process involving a rotating work piece and X-Y-Z linear movement of the tooling D. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements.
A process involving a rotating tool and X Y Z linear movement of the work piece
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 work piece
Which of the following statements applies to creep feed grinding?
A process with very slow t able feeds and deep depth-of-cut compared to conventional surface grinding
two
A requirement for broaching is that _____ teeth be in contact with the workpiece. A. two B. one C. three D. five
The broaching process can be described as
A single- stroke process using a multi-toothed cutter to remove small amounts of material with roughing and finishing operations performed in the single pass of the cutter
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 for electical discharge machining is incorrect? A. A matt finished is produced by the EDM process B. A very specialzied process for machining developed for machining parts for NASA rocket engine parts. C. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. D. Most frequently used of NTM processes.
A very specialized process for machining developed for machining parts for NASA rocket engine parts.
Which of the following statements for Electical Discharge Machining is incorrect?
A very specialzied 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 the following is not a common tooth form for saw blades? A. square B. regular C. skip D. claw
A.
What NTM process is used to cut composites?
Abrasive waterjet
True
Abrasive waterjet machining involves an abrasive grit carried with ultra high pressure water jet to cut metals and non-metals. True or False?
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 statements applies to creep feed grinding?
All of the these
Because of its FCC structure, it has the highest ductility of the lightweight metals.
Aluminum
Color anodizing is a surface finishing treatment that is somewhat unique to this metal.
Aluminum
Which of the following materials is not commonly used as a lap?
Aluminum
For American pattern files, the coarseness of a file is determined by:
An ASME standard that gives teeth per inch
dull (x) flattening (y)
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit. A. dislodging B. sharp C. dull D. flattening
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.
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.
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
Because this metal is considered to be toxic, processing often requires special precautions.
Beryllium
This metal is lighter than aluminum, but stiffer than steel.
Beryllium
This metal is sometimes used for nuclear applications because it is relatively transparent to the movement of neutrons.
Beryllium
False
Broaching is a process that can be used only in mass-production. True or False
internal keyways
Broaching was orginally developed for the production of ____. A. splines B. internal keyways C. flat surfaces D. external keyways
hard (m) glass(n) ceramics (o) carbides (p)
By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics
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.
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 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 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 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 a common material used for the teeth of a band saw blade?
CBN
Which of the following is not a common material used for the teeth of a band saw blade? A. tungsten carbide B. diamond C. high speed steel D. CBN
CBN
Which of the following is not an advantage of plasma arc cutting?
Can be used for cutting metal based composite materials
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
True
Centerless grinding is a process that is performed quickly. True or False
False
Centerless grinding is a process that must be performed manually by the machinist. True or False
False
Centerless grinding requires lots of operator skill to operate the machine. True or False
False
Centerless grinding requires that small grinding wheels be used in the grinding process. True or False
True
Centerless grinding requires the use of special, dedicated equipment to perform the grinding process. True or False
The NTM process used to manufacture printed circuit boards is ____.
Chemical Machining
The teeth of an end mill cutter are located on the ___.
Circumference and the face of the cutter
centrifugal gravity inertial cutting
Clamping forces must be greater than what four (4) forces? A. aerodynamic B. centrifugal C. frictional D. gravity E. inertial F. cutting
vise chuck
Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.
Two different types of monomers or reactants are required for this type of polymerization that involves the production of a small by-product molecule.
Condensation polymerization
False
Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder. True or False
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. True or False
Which of the following is not an application for laser beam machining?
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
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
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.
Inducing extensive branching of the chains would _______ the strength of a polymer.
Decrease
N=(12V)/(pi*D) f_m(table feed rate) = f_tNn(number of teeth) MRR = Wtf_m(table feed rate)
Determine the MRR in in^3/min, given the following data: Face milling 1020 steel, 55" long, 7" wide (W) 8" diameter, ? teeth, 9 tungsten carbide inserts Depth of cut (t) = 0.29" Feed/tooth (f_t) = 0.011 in/tooth Cutting speed (V) = 754 ft/min (ignore length of approach [L_a] and length of over-travel [L_o])
What device is used to manually produce external theads?
Die
What device is used to manually produce external threads?
Die
False
Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened. True or False
Which of the following is NOT a correct statement regarding magnesium?
Ductility and corrosion resistance are both good.
An adhesive example of this type of polymer would be flexible silicone bathtub caulk
Elastomeric
Extremely large elastic deformations are possible with this type of polymer.
Elastomeric
False
Electrochemical machining is deplating process using high DC voltage, high current for the process. True or False?
True
Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites). True or False?
vertical milling machine
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. both vertical and horizontal milling machines C. vertical milling machine
Identify the type of cutter that would be used to machine a 12" wide, 48" long aluminum bar stock to produce a flat, smooth, and an excellent finish on the 12" wide surface of t he bare using a *vertical* knee-and- column milling machine
Face mill
Identify the type of cutter that would be used to machine a 12" wide, 48" long aluminum bar stock to produce a flat, smooth, and excellent finish on the 12" wide surface of the bar using as vertical knee-and-column milling machine.
Face mill
A fixture/jig should be design using the least number of standard elements as possible.
False
A fixture/jig should be design using the least number of standard elements as possible. True or False
False
A fixture/jig should be design using the least number of standard elements possible.
False
A high-strength aerospace aluminum alloy has strength equivalent to a quenched-and-tempered medium carbon steel. True/False
False
Adhesive bonding is an attractive means of joining materials that will be used at elevated temperature. True/False
False
Broaching is a process that can be used only in mass-production. True or False
False
Centerless grinding is a process that must be performed manually by the machinist.
False
Centerless grinding is a process that must be performed manually by the machinist. True or False
False
Centerless grinding requires lots of operator skill to operate the machine.
False
Centerless grinding requires lots of operator skill to operate the machine. True or False
False
Centerless grinding requires that small grinding wheels be used in the grinding process.
False
Centerless grinding requires that small grinding wheels be used in the grinding process. True or False
False
Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder.
False
Creep feed grinding is a process preformed on a conventional horizontal spindle, reciprocating table surface grinder. True or False
False
Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened.
False
Dressing a grinding wheel refers to the process where the abrasive grit edges are dulled and flattened. True or False
False
Electrochemical Machining is a deplating process using high DC voltage, high current for the process.
False
Electrochemical machining is deplating process using high DC voltage, high current for the process. True or False?
False
For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles. True or False
False
Good electrical and thermal conductivity is a characteristic or description of most polymeric materials. True/False
False
Good electrical and thermal conductivity is a property that is characteristic or descriptive of most ceramic materials. True/False
False
Good mechanical properties at elevated temperature is a characteristic or description of most polymeric materials. True/False
False
Good wear resistance is a characteristic or description of most polymeric materials. True/False
False
High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth.
False
High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth. True or False?
False
In centerless grinding deep cuts are not possible due to the work support.
False
In centerless grinding deep cuts are not possible due to the work support. True or False
False
Low thermal expansion is a characteristic or description of most polymeric materials. True/False
False
Magnesium can be significantly strengthened by cold work. True/False
False
PVC piping is an approved material for compressed air lines.
False
The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes.
False
The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes. True or False
False
The honing process used stones with a grit size of 1200 or more particles per inch.
False
The honing process used stones with a grit size of 1200 or more particles per inch. True or False
False
The lapping process must be performed only by hand without machinery
False
The lapping process must be performed only by hand without machinery.
False
The lapping process must be performed only by hand without machinery. True or False
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
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. True of False
False
The surface finish produced by electrical discharge machining has a cross-hatch pattern with a roughness value of 32 to 120 microinches.
False
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
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: In centerless grinding deep cuts are not possible due to the work support.
False
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
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
Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent. True or False?
False
With centerless grinding tubes will automatically have concentric inside and outside diameters.
False
With centerless grinding tubes will automatically have concentric inside and outside diameters. True or False
False
With centerless grinding, tubes will automatically have concentric inside and outside diameters.
False
Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool.
False
Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool. True or False
False
Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent.
False (Water jets are used to cut non-metal materials. To cut metals, an abrasive is added to the water stream)
Tapered end mills are used for ____
Finish cutting on molds to produce a desired angle
Which of the following is a function of the dielectric in the electrical discharge machining process?
Flushing agent
the tooth pattern and the length of the file
For American pattern files, the coarseness of the file cut is given by: A. xx teeth/ inch B. the tooth pattern and the length of the file C. tooth pattern of the file D. the length of the file
False
For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles. True or False
vertically down
For the DOWN milling process, complete the statements with the answers supplied: In slab milling operations, the direction of the cutting force is _______.
maximum
For the DOWN milling process, complete the statements with the answers supplied: The chip thickness is a _______ at the beginning of the chip formation.
with
For the DOWN milling process, complete the statements with the answers supplied: The mill cutter rotates _______ the direction of feed.
Up
For the UP milling process, complete the statements with the answers supplied: In the slab milling operations, the direction of the cutting force is ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
maximum
For the UP 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. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
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. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
minimum
For the UP 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.
toward the part
For the UP milling process, complete the statements with the answers supplied: The direction of the cutting forces are ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
against
For the UP milling process, complete the statements with the answers supplied: The mill cutter rotates ____ the direction of feed. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
True
For the honing process the amount of material removed is less than 0.005" from the surface. True or False
____ is the property referring to the ability of the abrasive material to fracture producing new, sharp edges
Friability
fracture, producing new, sharp edges
Friability refers to the ability of the abrasive material to ____. A. form chips B. withstand high temperatures C. withstand exposure to water and cutting oils D. fracture, producing new, sharp edges
Which of the following is not an asset of aluminum?
Good elevated temperature strength
Which of the following statements applies to centerless grinding
Heavy cuts and accurate size control are possible because the workpiece is supported at the grinding location
which of the following statements applies to centerless grinding
Heavy cuts and accurate size control is possible because the workpiece is supported at the grinding location
Two teeth less smoother (lower surface roughness value)
Helical teeth on a cutter allow ____ to contact the work surface at a time. This results in ____ chatter and shock and a ____ surface. A. one tooth B. multiple teeth C. more D. less E. rougher (higher surface roughness value) F. smoother (lower surface roughness value)
Bandsaw blades are frequently made with teeth of what material
High Speed Steel
False
High ductile materials (i.e, aluminum) should be milled with the up milling process to prevent rapid dulling of the cutter teeth. True or False?
Slab milling is typically performed using what type of knee-and-column milling machine?
Horizontal milling machine
Match the following surface grinder types with the description / property / application. (answers may be used more than once). The most common type of surface grinding machine. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Horizontal spindle, reciprocating table
Surface grinder not typically used due to limited type of work which it will accommodate.
Horizontal spindle, reciprocating table
The most common type of surface grinder is a
Horizontal spindle, reciprocating table
The most common type of surface grinding machine is ___.
Horizontal spindle, reciprocating table
The most common type of surface grinding machine.
Horizontal spindle, reciprocating table
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
form cutter
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
face mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
ball end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 1/4" radius, convex shape along the edge of a part A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
angle cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 45 degree, V shaped groove in the surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
staggered-tooth cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Deep slots in a work piece A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Milling wood to produce wood trim A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
slitting saw cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) deep, straight walled, narrow slots A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
plain cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) finishing the top surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
plastic
In ___ products, threads are frequently produced by casting.
False
In centerless grinding deep cuts are not possible due to the work support. True or False
rotating speed and axial feed of the work piece
In centerless grinding, the regulating wheel controls _____ in the grinding process. A. rotating speed of the grinding wheel B. axial feed of the workpiece C. rotating speed of the workpiece D. rotating speed and axial feed of the work piece
True
In centerless grinding, the work piece must be round and not include flats or keyways. True or False
Peripheral edge
In face milling, most of the cutting occurs at what area of the cutter? A. Equal amount of cutting both at the center and peripheral edge B. Peripheral edge C. center
bed milling machine
In mass-production opeations, 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? A. knee-and-column milling machine B. universal milling machine C. bed milling machine D. gantry milling machine
many (x) excellent (y)
In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish. A. Rough B. excellent (y) C. many (x) D. few E. two F.three
Parallel (x) horizontal (y)
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. A. perpendicular B. Parallel C. horizontal D. vertical
Increasing the length of the average chain would _______ the strength of a polymer.
Increase
Inducing "crystallization" during cooling would _______ the strength of a polymer.
Increase
Replacing hydrogen side atoms with chlorine would _______ the strength of a polymer.
Increase
The milling machine was invented in approximately 1816 by Simeon North to machine
Interchangeable parts for rifles for the US Gov.
The cutting process during the milling operation is a(n)___ process
Interrupted
Which of the following does not apply to the thread milling process?
It is a process performed on a manually-operated milling machine
The slot cut in the material by a saw blade is called ____.
Kerf
charged
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material. A. charged B. mounted C. lapped D. pasted
more than the machining operation
Loading and unloading of a fixture will often abuse the fixture ____ . A. less than the machining operation B. more than the machining operation C. equal to the machining operation
The table has ___ movement on the saddle ways.
Longitudinal (X- axis)
Which of the following would not be a desirable property of a wrought alloy?
Low melting point
Attractive properties for casting alloys include:
Low melting point, Good fluidity, High as-solidified strength
It has the lowest density of all of the engineering metals (i.e. is the lightest engr. metal).
Magnesium
People specifying the use of this metal are driven by a desire for light weight, and are willing to accept the numerous negative properties and characteristics.
Magnesium
The designation system for this metal consists of two letters followed two or three numbers, such as AZ61 or AM100.
Magnesium
This metal can be very difficult to fabricate. It is brittle at room temperature; machining chips can burn: and molten metal must be kept under protective atmospheres.
Magnesium
surface grinders
Magnetic chucks are commonly used on what type of machinery? A. Lathes B. Surface grinders C. Micro-drill presses D. Milling machines
vertical (z axis)
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
transverse (y axis)
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
longitudinal (x axis)
Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
Head
Match the part numbers on the schematic diagram with the names. Part 1
Table
Match the part numbers on the schematic diagram with the names. Part 2
Workpiece
Match the part numbers on the schematic diagram with the names. Part 3
Saddle
Match the part numbers on the schematic diagram with the names. Part 4
Knee
Match the part numbers on the schematic diagram with the names. Part 5
Base
Match the part numbers on the schematic diagram with the names. Part 6
Column Ways
Match the part numbers on the schematic diagram with the names. Part 7
Spindle
Match the part numbers on the schematic diagram with the names. Part 8
Column
Match the part numbers on the schematic diagram with the names. Part 9
More flat surfaces are produced by the _______ process than any other milling process.
Milling
negative 3-5
Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter. A. positive B. negative C. 10-15 D. 3-5
True
More flat surfaces are produced by the milling process than any other machining process. True or False
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 By an additive process where small, precise amounts of materials are built up into a shape
Non-traditional machining produces parts by which of the following (mark all that apply)? A. removing material from a base using chemicals B. Removing material from a base using a tool vibrated at ultrasonic frequencies. C. Removing material using ultra high pressure water. D. By an additive process where small, precise amounts of materials are built up into a shape E. Adding material to a base using high voltage electrical discharges.
Which of the following statements is false for high speed machining/milling
One or more axes are always accelerating in a 3-D cut
Which of the following statements is *false* for high speed machining/milling?
One or more axes are always accelerating in a 3-D cut.
Which of the following statements is false regarding thread grinding?
Only course threads can be produced
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. A. perpendicular B. Parallel C. horizontal D. vertical
Parallel (x) horizontal (y)
In face milling, most of the cutting process occurs at the ___ portion of the cutter
Peripheral
In face milling, most of the cutting occurs at what area of the cutter? A. Equal amount of cutting both at the center and peripheral edge B. Peripheral edge
Peripheral edge
straight helical
Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter. A. straight B. pointed C. spiral D. helical
Which of the following applies to plasma arc cutting?
Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
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 applies to plasma arc cutting? A. Plasma arc cutting involves superheated gas for cutting only steel plates B. Plasma cutting involves super high pressure gas propelled at mach 30 for cutting conductive metals. C. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F 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 not a limitation of magnesium and magnesium alloys?
Poor machinability
Which of the following is not a limitation of aluminum?
Poor thermal conductivity
A CNC milling machine ___. A. Requires highly trained operators to operate. B. Is used only in mass production operations. C. Can machine parts slower and more accurately than a manual milling machine D. Provides for machining of more complex parts than a manual milling machine
Provides for machining of more complex parts than a manual milling machine
In the equation fm = ftNn, N refers to :
RPM of the spindle
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.
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.
Which of the following is a correct statement for rapid prototyping? A. Rapid prototyping is an additive manufacturing process that can be produce parts fro various materials using various processes. B. Rapid prototyping is very expensive process and has very limited applications C. 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.
In centerless grinding, the ___ controls the rotation and longitudinal motion of the workpiece
Regulating wheel
Non-traditional machining produces parts by which of the following (mark all that apply)? A. removing material from a base using chemicals B. Removing material from a base using a tool vibrated at ultrasonic frequencies. C. Removing material using ultra high pressure water. D. By an additive process where small, precise amounts of materials are built up into a shape E. Adding material to a base using high voltage electrical discharges.
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 By an additive process where small, precise amounts of materials are built up into a shape
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
The milling machine was invented in approximately 1816 by ___.
Simeon North
The milling machine was invented in approximately 1816 by ____. A. Thomas Edison B. Simeon North C. James Watt D. Eli Whitney
Simeon North
horizontal milling machine
Slab milling is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. vertical milling machine C. both horizontal and vertical milling machines
Identify the type of cutter that would be used to mill deep narrow slots in a part using a *horizontal* knee-and-column milling machine
Slitting saw cutter
What is the milling of two parallel surfaces with side cutters called ?
Straddle Milling
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
honing
Superfinishing is a variation of what process to finish flat surfaces. A. lapping B. None of these C. surface grinding D. honing
Magnetic chucks are commonly used on what type of machinery?
Surface grinders
What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ? A. L-Slot milling cutter B. T-slot milling cutter C. Staggered-tooth mill cutter D. Plain milling cutter
T slot milling cutter
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
finish cutting on molds to produce a desired angle
Tapered end mills are used for ____ A. rough cutting in the machining of molds B. both rough and finished cutting in the machining of molds C. Finish cutting on molds to produce a desired angle D. machining a chamfer on finished parts
fool proofing
The ability to load a part into a fixture only one way is called? A. proofing B. fool proofing C. robotic design D. auto loading
plowing (x) rubbing (y) cutting (z)
The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips. A. Cutting (z) B. digging C. plowing (x) D. rubbing (y) E. scrapping F. planning
True
The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process. True or False?
.001"
The amount of material removed in lapping is usually less than _____ A. None of these B. 1 millionth of an inch C. 0.0005" D. 0.001"
radius
The blade width of the saw blade determines the minimum ____ that can be cut with a bandsaw blade A. depth of cut B. radius C. rate of cutting D. thickness
single-stroke (x) multi (y) a single pass (z)
The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter. A. single-stroke B. multi-stroke C. single D. multi E. a single pass F. multiple passes
True
The chemical machining process is used in mass-production of parts True or False?
Which of the following statements is false for clamping forces?
The clamping forces should be spread over a small area
True
The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials. True or False
True
The creep feed grinding process is used to grind deep slots with straight parallel sides into parts. True or False
False
The depth of cut in creep feed grinding is 1,000 to 10,000 times less than conventional grinding processes. True or False
True
The filing process is used to remove small amounts of material from a part. True or False
sewing machines
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device? A. revolvers B. sewing machines C. bicycle bearings D. steam engines
The strength of the bonds between the abrasive grits
The grade of a grinding wheel refers to ____. A. the ratio of bonding material volume to abrasive material volume B. the strength of the bonds between the abrasive grits C. the spacing of the abrasive particles in the wheel D. the ratio of bonding material weight to abrasive material weight
crosshatch
The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole? A. no defined pattern B. circular C. crosshatch
Truing of holes
The honing process is not used for which of the following: A. truing of holes B. removing taper, waviness, and tool marks from the boring process C. sizing and finishing of bored holes D. removing tooling marks
False
The honing process used stones with a grit size of 1200 or more particles per inch. True or False
False
The lapping process must be performed only by hand without machinery. True or False
Which of the following statements correctly describes the purpose of the mask in chemical machining? A. The mask is applied to the area of the part that is desired to not remove material from the part B. The mask is applied to the area of the part that it is desired to removal material from the part. C. The mask enhances the chemical machining process. D. None of the above.
The mask is applied to the area of the part that is desired to not remove material from the part
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
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.
30 40
The maximum operator force in loading/unloading a part should be less than [x] to [y] lbf.
Simeon North
The milling machine was invented in approximately 1816 by ____. A. Thomas Edison B. Simeon North C. James Watt D. Eli Whitney
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. True of False
multi tooth cutting tool interrupted
The milling process uses [x] and involves [y] cutting. a) single-point tool b) multi-tooth cutter c) continuous d) interrupted
150
The milling process will produce a surface finish with a surface roughness measurement of 60 to ____ microinches.
vertical
The most common type of broaching machine construction is ____. A. vertical B. Horizontal
bandsaw
The most common type of sawing machine for cutting metal is : A. cold saw B. power hacksaw C. bandsaw D. milling machine
True
The operator should not have to reach past the tool to load/unload parts for machining. True or False
set
The pattern used to offset the saw blade teeth from the centerline of the blade is called ____. A. pitch B. rake C. set
three perpendicular planes
The principle of 3-2-1 uses location points to define ___. A. three (3) intersecting planes B. 6 points C. 3 axis, 2 rotations, 1 point D. three (3) perpendicular planes
Thread milling
The process for machining threads which requires a CNC machining center capable of circular interpolation is ____.
.003 .006
The range of rise per tooth for external broaching is (x) to (y) inches/tooth.
.001 .0025
The range of rise per tooth for internal broaching is (x) to (y) inches/tooth. A. 0.0015 B. 0.001 C. 0.0005 D. 0.003 E. 0.0025 F. 0.005
kerf
The slot cut int eh material by a saw blade is called ____. A. slot B. groove C. kerf D. gullet
lap
The soft material used in the lapping process is called _______. A. felt B. rouge C. lap D. None of these
The grade of a grinding wheel refers to ____. A. the ratio of bonding material volume to abrasive material volume B. the strength of the bonds between the abrasive grits C. the spacing of the abrasive particles in the wheel D. the ratio of bonding material weight to abrasive material weight
The strength of the bonds between the abrasive grits
the spacing of the abrasive grit in the wheel
The structure of a grinding wheel refers to ____. A. the strength of the bonds between the abrasive grit in the wheel B. The ratio of the bonding material volume to the abrasive material volume C. The ration of the bonding material weight to the abrasive material weight D. the spacing of the abrasive grit in the wheel
32 (x) 125 (y)
The surface finish obtained from the broaching process has a surface finish measurement of (x) to (y) microinches
circumference and the face of the cutter
The teeth of an end mill cutter are located on the ___. A. circumference and the face of the cutter B. circumference of the cutter C. face of the cutter
Which of the following statements is false for rolled threads?
The threads produced by thread rolling have a lower strenghth than cut threads
True
The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel. True or False
An adhesive example of this type of polymer would be hot-melt glue.
Thermoplastic
Extremely large plastic deformations are possible with this type of polymer.
Thermoplastic
In this type of polymer, heating softens, cooling hardens, and the cycle can be repeated.
Thermoplastic
These polymers are the most easily recycled variety
Thermoplastic
An adhesive example of this type of polymer would be two-part epoxy.
Thermosetting
The highest rigidity is found in this type of polymer.
Thermosetting
The highest strength polymers would most likely be of this type.
Thermosetting
The process for machining threads which requires a CNC machining center capable of circular interpolation is ____.
Thread milling
Which of the following statements is false regarding the thread rolling process?
Thread rolling is a hot forming process
Which of the following statements is false regarding the thread rolling process? A. Thread rolling is a hot forming process B. Thread rolling can be used to form threads on tubular products C. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second.
Thread rolling is a hot forming process
Because it is allotropic (BCC at elevated temp and HCP at room temp), this material can be heat treated by both age hardening and phase transformation processes
Titanium
It is often used in place of steel for weight saving, or in place of aluminum when use involves elevated temperatures.
Titanium
It is the only high temperature, lightweight metal, retaining useful strength up to 900F (500C).
Titanium
Since it is strong, light weight and corrosion resistant to body fluids, orthopedic implants and bone-repair screws and plates often use this material.
Titanium
This metal offers the strength of a heat-treated medium-carbon steel at a little more than half the weight.
Titanium
taper plug bottom
To thread a blind hold the three types of taps used, in order are ___, ___, and ___. A. plug B. spiral C. fluteless D. taper E. bottom
A fixture/jig should be designed to tolerate variations in the workpiece.
True
A fixture/jig should be designed to tolerate variations in the workpiece. True or False
True
Abrasive waterjet machining involves an abrasive grit carried with ultra high pressure water jet to cut metals and non-metals. True or False?
True
Abrasive waterjet machining involves an abrasive grit carried with ultra-high pressure water jet to cut metals and non-metals.
True
Adhesive bonding is an attractive means of joining dissimilar materials. True/False
True
Adhesive joints often compensate for their lower strength by increasing the area of the bond. True/False
True
Brittleness is a property that is characteristic or descriptive of most ceramic materials. True/False
True
Can have integral color is a characteristic or description of most polymeric materials. True/False
True
Casting alloys can be heat-treated after casting for added strength.
True
Centerless grinding is a process that is performed quickly.
True
Centerless grinding is a process that is performed quickly. True or False
True
Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.
True
Centerless grinding requires the use of special, dedicated equipment to perform the grinding process. True or False
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.
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. True or False
True
Ease of fabrication is a characteristic or description of most polymeric materials. True/False
True
Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites)
True
Electrochemical machining is used for machining hard, brittle materials (silicon nitride, quartz, ceramic composites). True or False?
True
For the honing process the amount of material removed is less than 0.005" from the surface.
True
For the honing process the amount of material removed is less than 0.005" from the surface. True or False
True
Good chemical and thermal stability is a property that is characteristic or descriptive of most ceramic materials.
True
Good corrosion resistance is a characteristic or description of most polymeric materials. True/False
True
Good elevated temperature creep resistance is a property that is characteristic or descriptive of most ceramic materials. True/False
True
High compressive strength is a property that is characteristic or descriptive of most ceramic materials. True/False
True
High elastic modulus is a property that is characteristic or descriptive of most ceramic materials. True/False
True
High hardness is a property that is characteristic or descriptive of most ceramic materials. True/False
True
High melting temperature is a property that is characteristic or descriptive of most ceramic materials. True/False
True
In centerless grinding, the work piece must be round and not include flats or keyways.
True
In centerless grinding, the work piece must be round and not include flats or keyways. True or False
True
Light weight is a characteristic or description of most polymeric materials. True/False
True
Low thermal expansion is a property that is characteristic or descriptive of most ceramic materials true/false
True
Magnesium can be cast to final shape provided special mold materials are used and the molten metal and hot solid is isolated from oxygen by some form of protective atmosphere. True/False
True
More flat surfaces are produced by the milling process than any other machining process
True
More flat surfaces are produced by the milling process than any other machining process. True or False
True
The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process.
True
The advantage of spiral flutes on a tap is that the chips are pulled out of the hole during the threading process. True or False?
True
The chemical machining process is used in mass-production of parts True or False?
True
The chemical machining process is used in mass-production of parts.
True
The corrosion resistance of titanium is due to an adherent oxide, much like aluminum True/False
True
The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials.
True
The creep feed grinding process is used to grind complex profiles in difficult-to-grind materials. True or False
True
The creep feed grinding process is used to grind deep slots with straight parallel sides into parts.
True
The creep feed grinding process is used to grind deep slots with straight parallel sides into parts. True or False
True
The filing process is used to remove small amounts of material from a part.
True
The filing process is used to remove small amounts of material from a part. True or False
True
The operator should not have to reach past the tool to load/unload parts for machining.
True
The operator should not have to reach past the tool to load/unload parts for machining. True or False
True
The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel.
True
The truing of a grinding wheel is a process preformed to restore the desired shape to the wheel. True or False
True
True or False: A fixture/jig should be designed to tolerate variations in the workpiece.
True
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 is a process that is performed quickly.
True
True or False: Centerless grinding requires the use of special, dedicated equipment to perform the grinding process.
True
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: The chemical machining process is used in mass-production of parts.
True
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
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
Waterjet machining is used to cut nonmetals.
True
When magnesium is the material of choice, it is almost always for weight reduction. true/False
True
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
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 or False
True
Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly
True
Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly.
True
Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly. True or False
True
The honing process is not used for which of the following:
Truing of holes
The honing process is not used for which of the following: A. truing of holes B. removing taper, waviness, and tool marks from the boring process C. sizing and finishing of bored holes D. removing tooling marks
Truing of holes
3) In slab milling operations, the direction of the cutting force is _____.
Up
For the up milling process, complete the statements with the answers supplied: In the slab milling operations, the direction of the cutting force is ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
Up
72
Vertical broaching machines are usually limited to strokes of ____ inches due to height and load considerations. A. 100 B. 72 C. 48 D. 60
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine?
Vertical milling machine
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder where the wheel diameter must exceed the width of the part being ground.A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Vertical spindle reciprocating table
Surface grinder where the wheel diameter must exceed the width of the part being ground
Vertical spindle, reciprocating table
A surface grinder that can be equipped with multiple heads, ad automatic loading, and unloading is a
Vertical spindle, rotary table
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Vertical spindle, rotary table
Surface grinder that can be equipped with multiple heads and automatic loading and unloading of the parts.
Vertical spindle, rotary table
Surface grinding machine used in production operations.
Vertical spindle, rotary table
False
Waterjet machining is used to cut metal parts using ultra-high pressure water as the cutting agent. True or False?
die
What device is used to manually produce external threads? A .file B. taps C. Die D. grinding wheel
self opening die head
What device is used to produce external threads with lathes, screw machines, and threading machines? A. self closing die head B. self opening die head C. die attachment D. threader
straddle milling
What is the milling of two parallel surfaces with side cutters called? A. saddle milling B. twin milling C. parallel milling D. straddle milling
aluminum oxide
What is the most common material used for abrasives? A. plastic media B. silicon carbide C. diamond D. aluminum oxide E. dry ice F. CBN
T slot milling cutter
What is the type of mill cutter used to machine the slots for bolt heads in base plates, bed plates, and work tables ? A. L-Slot milling cutter B. T-slot milling cutter C. Staggered-tooth mill cutter D. Plain milling cutter
.1 in^3/min/1000 amps
What is the typical MRR for electrochemical machining? A. in^3/ min/ 1000 amps B. .1 in^3/min/1000 amps C. 100 in^3/min/1000 amps
taps
What is used to produce internal threads?
80-90
What percentage of EDM is used to produce tool and die sets? A.10-20% B. 80-90% C. 70-80% D. 50-60%
cylindrical external
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4. A. cylindrical external B. surface grinder C. None of these D. cylindrical internal
woodruff keyseat milling cutter
What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment? A. end mill cutter B. T-slot milling cutter C. woodruff keyseat milling cutter D. Slitting saw cutter
bonded
Which is the most frequently used mounting system for abrasives? A. free B. bonded C. mounted D. coated
Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
Which of the following applies to plasma arc cutting? A. Plasma arc cutting involves superheated gas for cutting only steel plates B. Plasma cutting involves super high pressure gas propelled at mach 30 for cutting conductive metals. C. Plasma arc cutting involves superheated gas at 30,000 to 60,000 F for cutting conductive metals.
A process involving a rotating tool and X Y Z linear movement of the work piece
Which of the following best describes the tool and workpiece movement for the milling process? A. A process involving a rotating work piece and rotating tooling B. A process involving a rotating tool and X-Y-Z linear movement of the work piece. C. A process involving a rotating work piece and X-Y-Z linear movement of the tooling D. A process involving a total fixed work piece and a rotating tooling that moves X-Y-Z with linear movements.
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 material being machined and the tool as a process to remove material.
Which of the following describes the ultrasonic machining process? A. 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. B. 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. C. 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. D. 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.
mounted
Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. free D. mounted
Rapid prototyping is an additive manufacturing process that can produce parts from various materials using various processes.
Which of the following is a correct statement for rapid prototyping? A. Rapid prototyping is an additive manufacturing process that can be produce parts fro various materials using various processes. B. Rapid prototyping is very expensive process and has very limited applications C. Rapid prototyping is a new additive manufacturing process that has been developed in the last 5 years.
flushing agent
Which of the following is a function of the dielectric in the electical discharge machining process? A. Flushing agent B. heating agent C. lubricant D. protective coating for the finished part
CBN
Which of the following is not a common material used for the teeth of a band saw blade? A. tungsten carbide B. diamond C. high speed steel D. CBN
square
Which of the following is not a common tooth for saw blades? A. square B. regular C. skip
insert tooth
Which of the following is not a type of broach construction? A. segment B. shell C. insert tooth D. solid
aluminum chips
Which of the following is not an abrasive material used in commercial cleaning applications? A. walnut shells B. dry ice C. aluminum chips D. plastic media
can be used for cutting metal based composite materials
Which of the following is not an advantage of plasma arc cutting? A. small heat-affected zone B. Can be used for cutting metal based composite materials C. very fast cutting D. smooth cuts free of contaminants are produced
cutting thick materials
Which of the following is not an application for laser beam machining? A. welding B. cutting thin materials C. Drilling micro-sized holes D. cutting thick materials
Horizontal spindle, reciprocating table
Which of the following is the most common type of surface grinding machine? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
aluminum
Which of the following materials is not commonly used as a lap? A. Aluminum B. Copper C. Cloth D. Cast iron
air
Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. grease B. oil C. water D. air
The mask is applied to the area of the part that is desired to not remove material from the part
Which of the following statements correctly describes the purpose of the mask in chemical machining? A. The mask is applied to the area of the part that is desired to not remove material from the part B. The mask is applied to the area of the part that it is desired to removal material from the part. C. The mask enhances the chemical machining process. D. None of the above.
A very specialized process for machining developed for machining parts for NASA rocket engine parts.
Which of the following statements for electical discharge machining is incorrect? A. A matt finished is produced by the EDM process B. A very specialzied process for machining developed for machining parts for NASA rocket engine parts. C. Metal is removed from the part by melting tiny particles using electrical sparks between the tool and work piece. D. Most frequently used of NTM processes.
one or more axes are always accelerating in a 3D cut
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. Cutting speed for steel is less than 1500 m/min D. One or more axes are always accelerating in a 3-D cut. E. A high material removal rate is obtained
the threads produced by thread rolling have a lower strength than cut threads
Which of the following statements is FALSE for rolled threads? A. Rolled threads have a hard, wear resistance, smooth surface. B. the threads produced by thread rolling have a lower strength than cut threads. C. Rolled threads have a major diameter larger than the diameter of the base stock.
Thread rolling is a hot forming process
Which of the following statements is FALSE regarding the thread rolling process? A. Thread rolling is a hot forming process B. Thread rolling can be used to form threads on tubular products C. Thread rolling is used to produce bolts in large quantities at a rate of 1 per second.
only coarse threads can be produced
Which of the following statements is FALSE regarding thread grinding? A. only coarse threads can be produced B. threads in hardened steels 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
the clamping forces should be spread over a small area
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.
Vertical spindle, reciprocating table
Which of the following surface grinder requires the wheel diameter to exceed the width of the part being abrasively machined? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
horizontal spindle, rotary table
Which of the following surface grinder types is typically NOT used due to limited type of work which it will accommodate? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
vertical spindle, rotary table
Which of the following surface grinding machines is frequently used in production operations? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
Vertical spindle, rotary table
Which surface grinder can be equipped with multiple grinding heads and automatic loading and unloading of the parts? A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
False
With centerless grinding tubes will automatically have concentric inside and outside diameters. True or False
True
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 or False
True
Without proper chip disposal from a jig/fixture, chips can cause the workpiece to not seat properly. True or False
False
Without proper chip disposal from a jig/fixture, tool life will be increased due to increased heating of the tool. True or False
electrostatic chuck
You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice? A. electrostatic chuck B. vise C. toggle clamps D. magnetic chuck
The surface finish of a mold or plastic injection molding can be damaged by
a finger print
Cermets gain their enhanced toughness through:
a metal matrix.
The aluminum designation system identifies metal chemistry. An aluminum alloy with a four-digit designation would be considered to be:
a wrought alloy.
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
A dividing head is an accessory used with a milling machine primarily to provide what operation? A. rotation of a part 90 degrees so that additional machining can be performed on it B. rotation of a part 180 degrees C. accurate rotation of the work piece through any desired arc of rotation D. rotation of a group of parts so that the next piece in the group can be machined
accurate rotation of the work piece through any desired arc of rotation
1) The mill cutter rotates ___ the direction of feed.
against
For the up milling process, complete the statements with the answers supplied The mill cutter rotates ___ the direction of feed.
against
For the up milling process, complete the statements with the answers supplied: The mill cutter rotates ____ the direction of feed. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
against
In up milling, the cutter rotates ___ the direction of the feed
against
In up milling, the cutter rotates _____ the direction of the feed.
against
The most effective strengthening method for aluminum alloys is:
age hardening
Which of the following materials is not used a a carrier to charge the lap with abrasive particles?
air
Which of the following materials is not used a a carrier to charge the lap with abrasive particles? A. grease B. oil C. water D. air
air
CNC milling machines are used in machining operations because:
all of the above
Which of the following materials is not commonly used as a lap? A. Aluminum B. Copper C. Cloth D. Cast iron
aluminum
Which of the following is not an abrasive material used in commercial cleaning application?
aluminum chips
Which of the following is not an abrasive material used in commercial cleaning applications?
aluminum chips
Which of the following is not an abrasive material used in commercial cleaning applications? A. walnut shells B. dry ice C. aluminum chips D. plastic media
aluminum chips
What is the most common material used for abrasives?
aluminum oxide
What is the most common material used for abrasives? A. plastic media B. silicon carbide C. diamond D. aluminum oxide E. dry ice F. CBN
aluminum oxide
In the color anodizing process, the material being colored is:
aluminum oxide.
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 45 degree, V shaped groove in the surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
angle cutter
Type of milling cutter: 45 degree, V shaped groove in the surface of a flat bar
angle cutter
The chips formed during the broaching process
are trapped in the gullet until the cutting edge exits the workpiece
The chips formed during the broaching process:
are trapped in the gullet until the cutting edge exits the workpiece
The crystal structures of ceramic materials are often quite complex because:
atoms of different sizes are in the same structure,covalent structures often have a limited number of nearest neighbors,charge neutrality must be maintained throughout ionic structures
The "degree of polymerization" refers to the:
average number of mers per molecule
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a groove with a 1/8" diameter concave bottom A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
ball end mill
Which cutter is best: producing a groove with a 1/8" diameter concave bottom
ball end mill
What is the type of mill cuter used to produce a grove with a 1/8" diameter concave bottom in a vertical milling machine?
ball nose end mill
The most common sawing machine is
band saw
The most common type of sawing machine for cutting metal is : A. cold saw B. power hacksaw C. bandsaw D. milling machine
bandsaw
The most common type of sawing machine for cutting metal is____.
bandsaw
In mass-production opeations, 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? A. knee-and-column milling machine B. universal milling machine C. bed milling machine D. gantry milling machine
bed milling machine
In mass-production operations, a milling machine capable of making heavy cuts, having 1,2, or 3 spindles, and without vertical tale motion is often used. This is a
bed milling machine
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
Titanium has a density that is:
between steel and aluminum.
Which is the most frequently used mounting system for abrasives?
bonded
Which is the most frequently used mounting system for abrasives? A. free B. bonded C. mounted D. coated
bonded
While it is unlikely that we will be able to change the ___ of ceramic materials, it may be possible to impart significant amounts of ___.
brittleness, toughness
Which of the following is not an advantage of plasma arc cutting? A. small heat-affected zone B. Can be used for cutting metal based composite materials C. very fast cutting D. smooth cuts free of contaminants are produced
can be used for cutting metal based composite materials
The threads on plastic flood containers are formed by:
casting
Clamping forces must be greater than what four (4) forces? A. aerodynamic B. centrifugal C. frictional D. gravity E. inertial F. cutting
centrifugal gravity intertial intertial cutting
Clamping forces must be greater than what four (4) forces?
centrifugal, gravity, cutting, inertial
The cemented carbide on a carbide-tipped drill is actually carbide particles bonded by cobalt metal. This is an example of a:
cermet
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material.
charged
Lapping is a surface finishing process where fine abrasive particles are _____ into a soft material. A. charged B. mounted C. lapped D. pasted
charged
The teeth of an end mill cutter are located on the ___.
circumference and the face of the cutter
The teeth of an end mill cutter are located on the ___. A. circumference and the face of the cutter B. circumference of the cutter C. face of the cutter
circumference and the face of the cutter
The teeth of an end mill cutter are located on the___.
circumference and the face of the cutter
The suffix (the letter or letter and number that appear after the hyphen) in the aluminum designation system designates the material:
condition (past processing history).
The bonding mechanism between the atoms along the spine of linear polymers is:
covalent
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
The honing process involves rotation and oscillatory motion to form what type of final surface finish lay pattern on the walls of the hole? A. no defined pattern B. circular C. crosshatch
crosshatch
The equilibrium structure in ceramic materials (lowest energy) would be:
crystalline
The abrasive machining process is a mixture of processes, which of the processes produces the *chips* are formed by the grit?
cutting
The abrasive machining process is a mixture of processes. Which of the processes produces the chips formed by the grit?
cutting
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
Which of the following is not an application for laser beam machining? A. welding B. cutting thin materials C. Drilling micro-sized holes D. cutting thick materials
cutting thick materials
Clamping forces must be greater than what four (4) forces?
cutting, gravity, inertial, and centrifugal
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4.
cylindrical external
What type of grinding machining would be used for the grinding of camshafts and crankshafts? Hint: See table 27-4. A. cylindrical external B. surface grinder C. None of these D. cylindrical internal
cylindrical external
Increasing the amount of initiator or activator in an addition polymerization reaction will ___ the length of the chains and ___ the strength of the resulting polymer.
decrease, decrease
The fracture resistance of a ceramic can be best improved by:
decreasing the flaw size.
What device is used to manually produce external threads? A .file B. taps C. Die D. grinding wheel
die
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit.
dull flattening
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in [x] edges and [y] of the abrasive grit. A. dislodging B. sharp C. dull D. flattening
dull (x) flattening (y)
Attrition refers to the material property regarding the wearing action of the abrasive, resulting in ___ edges and ___ of the abrasive grit.
dull, flattening
Beryllium is unique among the engineering metals because of its extremely high:
elastic modulus
You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice?
electrostatic chuch
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
You need to hold several small non-magnetic, thin stainless steel parts for machining. Which if the following would be a good choice? A. electrostatic chuck B. vise C. toggle clamps D. magnetic chuck
electrostatic chuck
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Deep slots with straight side walls A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) Producing a flat-bottom groove in the surface of a part A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) producing a pocket in a workpiece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
end mill
Producing a flat-bottom groove in the surface of a part
end mill
Which cutter is best: Deep slots with straight side walls
end mill
Which cutter is best: producing a pocket in a workpiece
end mill
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) finishing the top surface of a work piece A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
face mill
Which cutter is best: finishing the top surface of a work piece
face mill
Broaching is a process that can be used only in mass-production.
false
For grinding wheels, glazing is the process to clean the grinding wheel and sharpen the abrasive particles.
false
In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish.
few excellent
Tapered end mills are used for ____ A. rough cutting in the machining of molds B. both rough and finished cutting in the machining of molds C. Finish cutting on molds to produce a desired angle D. machining a chamfer on finished parts
finish cutting on molds to produce a desired angle
Tapered end mills are used for ____.
finish cutting on molds to produce a desired angle
Which of the following is a function of the dielectric in the electical discharge machining process? A. Flushing agent B. heating agent C. lubricant D. protective coating for the finished part
flushing agent
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
The ability to load a part into a fixture only one way is called? A. proofing B. fool proofing C. robotic design D. auto loading
fool proofing
Identify the best type of cutter that would be used for each of the following milling operations in a vertical milling machine. (some answers maybe used more than once) bearing pocket in gearbox housing A. form cutter B. twist drill C. T-slot cutter D. ball end mill E. end mill F. face mill G. fly cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) 1/4" radius, convex shape along the edge of a part A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Deep slots in a work piece A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) Milling wood to produce wood trim A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
form cutter
Type of milling cutter: 1/4" radius, convex shape along the edge of a part
form cutter
Type of milling cutter: Milling wood to produce wood trim
form cutter
Which cutter is best: bearing pocket in gearbox housing
form cutter
While crystalline ceramic materials contain dislocations, they do not exhibit plastic deformation because:
fracture occurs at a lower stress than dislocation movement
Friability refers to the ability of the abrasive material to ____.
fracture, producing new, sharp edges
Friability refers to the ability of the abrasive material to ____. A. form chips B. withstand high temperatures C. withstand exposure to water and cutting oils D. fracture, producing new, sharp edges
fracture, producing new, sharp edges
By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics
hard glass, ceramics, carbides
By using extremely [m] materials for abrasives, it is possible to machine hardened steel, [n], [o], and [p]. Choices: hard, soft, glass, ceramics, carbides, diamonds, wood, and plastics
hard (m) glass(n) ceramics (o) carbides (p)
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
Synthetic abrasive materials are commonly used in manufacturing instead of natural abrasive materials because synthetic materials
have more uniform physical properties
The highest strength aluminum alloys are:
heat-treatable.
Bandsaw blades are frequently made with teeth of what material
high speed steel
A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.
holds size
A fixture is a specical workholding device that [x] the workpiece during machining or assembly operations and establishes [y] dimensions.
holds (x) size (y)
A fixture is a special workholding device that ___ during machining or assembly operations
holds the workpiece and determines size demensions
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
Superfinishing is a variation of what process to finish flat surfaces. A. lapping B. None of these C. surface grinding D. honing
honing
Slab milling is typically performed using what type of knee-and-column milling machine?
horizontal milling machine
Slab milling is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. vertical milling machine C. both horizontal and vertical milling machines
horizontal milling machine
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
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinder not typically used due to limited type of work which it will accommodate. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
horizontal spindle, rotate table
Which of the following is not a type of broach construction?
insert tooth
Which of the following is not a type of broach construction? A. segment B. shell C. insert tooth D. solid
insert tooth
Broaching was orginally developed for the production of ____.
internal keyways
Broaching was orginally developed for the production of ____. A. splines B. internal keyways C. flat surfaces D. external keyways
internal keyways
Broaching was originally developed for the production of ____.
internal keyways
Ceramic materials have ___ atomic bonding.
ionic or covalent
The slot cut in the material by a saw blade is called ____.
kerf
The slot cut int eh material by a saw blade is called ____. A. slot B. groove C. kerf D. gullet
kerf
The soft material used in the lapping process is called _______.
lap
The soft material used in the lapping process is called _______. A. felt B. rouge C. lap D. None of these
lap
For elevated temperature creep resistance, a crystalline ceramic should have ___ crystals.
large
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)
Match the axis movement with the knee-and-column milling component. The table has ___ movement on the saddle ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
longitudinal (x axis)
In the abrasive machining process, [x] edges are cutting simultaneously resulting in a(n) [y] surface finish. A. Rough B. excellent (y) C. many (x) D. few E. two F.three
many (x) excellent (y)
In the abrasive machining process, ___ edges are cutting simultaneously resulting in a(n) ___ surface finish.
many, excellent
3) The chip thickness is a ___ at the beginning of the chip formation.
maximum
5) 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 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 up 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. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
maximum
4) The chip thickness is a ___ at the beginning of the chip formation.
minimum
4) The chip thickness is a ___ at the end of the chip formation as the tool exits the work piece.
minimum
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
For the up milling process, complete the statements with the answers supplied: The chip thickness is a _____ at the beginning of the chip formation. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
minimum
Loading and unloading of a fixture will often abuse the fixture ____ .
more than the machining operation
Loading and unloading of a fixture will often abuse the fixture ____ . A. less than the machining operation B. more than the machining operation C. equal to the machining operation
more than the machining operation
Which of the following is NOT a type of mounting method that is used with the abrasive machining process?
mounted
Which of the following is NOT a type of mounting method that is used with the abrasive machining process? A. bonded B. coated C. free D. mounted
mounted
The milling process uses [x] and involves [y] cutting. a) single-point tool b) multi-tooth cutter c) continuous d) interrupted
multi tooth cutter interrupted
The milling process typically uses
multi-point tools
The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter. A. single-stroke B.multi-stroke C.single D.multi (y) E.a single pass F.multiple passes
multi-stroke (x) multi (y)
The milling process uses __ and involves __ cutting
multi-tooth cutter interrupted
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. A. one tooth B. multiple teeth C. more D. less E. rougher (higher surface roughness value) F. smoother (lower surface roughness value)
multiple teeth less smoother (lower surface roughness value)
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)
A plain arbor helical-toothed cutter is preferred over straight-toothed cutters because
multiple teeth contact the work during the milling operation
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)
Mill cutters manufacturing from carbide and ceramic have a ____ rake angle
negative
Milling cutters with carbide and ceramic cutting edges have a ____ rake angle and can be operated at ____ times faster than a HSS cutter. A. positive B. negative C. 10-15 D. 3-5
negative 3-5
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
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
The best corrosion resistance is found in alloys that are
non-heat-treatable
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. Cutting speed for steel is less than 1500 m/min D. One or more axes are always accelerating in a 3-D cut. E. A high material removal rate is obtained
one or more axes are always accelerating in a 3D cut
Which of the following statements is false regarding thread grinding? A. only coarse threads can be produced B. threads in hardened steels 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
only coarse threads can be produced
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 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
Which of the following is not an abrasive material used in commercial cleaning applications?
peanuts
In face milling, most of the cutting occurs at what area of the cutter?
peripheral edge
Ceramic materials excel when:
physical properties dominate the selection process.
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) finishing the top surface of a flat bar A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
plain cutter
Type of milling cutter: finishing the top surface of a flat bar
plain cutter
In ___ products, threads are frequently produced by casting.
plastic
In _____ products, threads are frequently produced by casting.
plastic
The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips.
plowing rubbing cutting
The abrasive machining process is a mixture of three processes; [x] moves material, [y] causes friction and [z] forms chips. A. Cutting B. digging C. plowing (x) D. rubbing (y) E. scrapping F. planning
plowing (x) rubbing (y)
The abrasive machining process is a mixture of three processes; ___ moves material, ___ causes friction and ___ forms chips.
plowing, rubbing, cutting
Crystalline ceramic products are usually fabricated by
pressing and firing solid particles
A CNC milling machine ___.
provides for machining of more complex parts than a manual milling machine
Tempered glass has enhanced fracture resistance because it incorporates:
quenching to produce compressive residual stresses on the surface
The blade width determines the minimum ___ that can be cut with a bandsaw for contour cutting
radius
The blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade
radius
The blade width of the saw blade determines the minimum ___ that can be cut with a bandsaw blade.
radius
The blade width of the saw blade determines the minimum ____ that can be cut with a bandsaw blade A. depth of cut B. radius C. rate of cutting D. thickness
radius
Conventional abrasive machine involves
rapid movement of abrasive grit at a shallow depth of cut
Ceramic materials that are used for applications like the containment of molten metals are:
refractories
In centerless grinding, the ____ controls the rotation and longitudinal motion of the workpiece
regulating wheel
"Power filing" is frequently performed with ___.
rotary burrs
"Power filing" is frequently performed with ____ A. a filing machine B. band filing C. rotary burrs D. disk filing
rotary burrs
Powered filing is most frequently performed with
rotary burrs
In centerless grinding, the regulating wheel controls _____ in the grinding process.
rotating speed and axial feed of the work piece
In centerless grinding, the regulating wheel controls _____ in the grinding process. A. rotating speed of the grinding wheel B. axial feed of the workpiece C. rotating speed of the workpiece D. rotating speed and axial feed of the work piece
rotating speed and axial feed of the work piece
The abrasive machining process is a mixture of processes. Which of the processes produces friciton?
rubbing
What device is used to produce external threads with lathes, screw machines, and threading machines? A. self closing die head B. self opening die head C. die attachment D. threader
self opening die head
What device is used to produce external threads with lathes, screw machines, and threading machines?
self-opening die head
The pattern used to offset the saw blade teeth from the center-line of the blade is called ___.
set
The pattern used to offset the saw blade teeth from the centerline of the blade is called ___.
set
The pattern used to offset the saw blade teeth from the centerline of the blade is called ____. A. pitch B. rake C. set
set
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?
sewing machine
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device?
sewing machines
The first grinding machines were made by Brown and Sharpe in the 1860s for the grinding of parts for what device? A. revolvers B. sewing machines C. bicycle bearings D. steam engines
sewing machines
Wrought alloys are shaped how
shaped as a solid
What process is used to manufacture the jaw teeth on a pipe wrench as discussed in class?
shaping
The broaching process can be described as: A [x] process using a [y]-tooth cutter to remove material with roughing and finishing operations performed in [z] of the cutter.
single stroke multi a single pass
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
Identify the type of milling cutter that would be used for each of the following milling opeations in a horizontal milling machine. (Some answers may be used more than once.) deep, straight walled, narrow slots A. angle cutter B. form cutter C. slitting saw cutter D. staggered-tooth cutter E. plain cutter F. fly cutter G. side cutter
slitting saw cutter
Type of milling cutter: deep, straight walled, narrow slots
slitting saw cutter
The clamping forces should be:
spread over a large area to avoid distorting the part
Which of the following is not a common tooth for saw blades? A. square B. regular C. skip
square
Which of the the following is not a common tooth form for saw blades?
square
Type of milling cutter: 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. A. straight B. pointed C. spiral D. helical
straight helical
Plain cutters are used in slab milling operations and can have ___ or ___ teeth located around the circumference of the cutter.
straight helical
Magnetic chucks are commonly used on what type of machinery?
surface grinders
Magnetic chucks are commonly used on what type of machinery? A. Lathes B. Surface grinders C. Micro-drill presses D. Milling machines
surface grinders
To thread a blind hole the threes types of taps used, in order are [x], [y], and [z].
taper plug bottom
To thread a blind hole the threes types of taps used, in order are ___, ___, and ___.
taper, plug, bottom
To thread a blind hold the three types of taps used, in order are ___, ___, and ___.
tapered plug bottoming
Internal threads are produced using
taps
What is used to produce internal threads?
taps
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.
the damping forces should be spread over a small area
In the equation fm=ftNn, n refers to
the number of teeth on the cutter
The coarseness of a file is determined by
the pattern of cut and length of the file
For grinding wheels, dressing refers to ____.
the process to clean the grinding wheel and sharpen the abrasive particles
The structure of a grinding wheel refers to ___.
the spacing of the abrasive grit in the wheel
The structure of a grinding wheel refers to ____.
the spacing of the abrasive grit in the wheel
The structure of a grinding wheel refers to ____. A. the strength of the bonds between the abrasive grit in the wheel B. The ratio of the bonding material volume to the abrasive material volume C. The ration of the bonding material weight to the abrasive material weight D. the spacing of the abrasive grit in the wheel
the spacing of the abrasive grit in the wheel
The structure of a grinding wheel refers to
the spacing of the abrasive particles
The grade of a grinding wheel refers to ___.
the strength of the bonds between the abrasive grits
The grade of a grinding wheel refers to ____.
the strength of the bonds between the abrasive grits
Which of the following statements is false for rolled threads? A. Rolled threads have a hard, wear resistance, smooth surface. B. the threads produced by thread rolling have a lower strength than cut threads. C. Rolled threads have a major diameter larger than the diameter of the base stock.
the threads produced by thread rolling have a lower strength than cut threads
For American pattern files, the coarseness of the file cut is given by:
the tooth pattern and the length of the file
For American pattern files, the coarseness of the file cut is given by: A. xx teeth/ inch B. the tooth pattern and the length of the file C. tooth pattern of the file D. the length of the file
the tooth pattern and the length of the file
in up milling, the chip starts out ___ and is ____ as the tool exists the workpeice
thin/thick
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
The functionality of polymer reactants that form 3-dimensional network polymers is
three or more
The principle of 3-2-1 uses location points to define ___. A. three (3) intersecting planes B. 6 points C. 3 axis, 2 rotations, 1 point D. three (3) perpendicular planes
three perpendicular planes
The designation scheme for cast aluminum alloys involves a:
three-digit number.
2) The direction of the cutting forces are ____.
toward the part
For the up milling process, complete the statements with the answers supplied The direction of the cutting forces are ____.
toward the part
For the up milling process, complete the statements with the answers supplied: The Direction of the cutting forces are ____. A. against B. toward the cutter C. toward the part D. maximum E. minimum F. with G. down H. up
toward the part
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways
transverse (Y-axis)
The saddle provides ___ movement on the knee ways
transverse (Y-axis)
Match the axis movement with the knee-and-column milling component. The saddle provides ___ movement on the knee ways A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
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 work piece.
two
A requirement for broaching is that ___ teeth be in contact with the workpiece.
two
A requirement for broaching is that _____ teeth be in contact with the workpiece. A. two B. one C. three D. five
two
The functionality of polymer reactants that form linear or chain-type polymers is: #
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 wide variation in mechanical properties for nominally "identical" ceramic components (same material and same processing) can be attributed to:
variation in the size, shape and location of flaws
The most common type of broaching machine construction is ____.
vertical
The most common type of broaching machine construction is ____. A. vertical B. Horizontal
vertical
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways.
vertical (Z-axis)
Match the axis movement with the knee-and-column milling component. The knee provides ____ movement on the column ways. A. rotation (B-axis) B. longitudinal (X-axis) C. transverse (Y-axis) D. vertical (Z-axis)
vertical (z axis)
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
End milling, drilling, and boring is typically performed using what type of knee-and-column milling machine? A. horizontal milling machine B. both vertical and horizontal milling machines C. vertical 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
Match the following surface grinder types with the description / property / application. (answers may be used more than once). Surface grinding machine used in production operations. A. Horizontal spindle, reciprocating table B. Horizontal spindle, rotary table C. Vertical spindle, reciprocating table D. Vertical spindle, rotary table
vertical spindle, rotary 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
2) In slab milling operations, the direction of the cutting force is ____.
vertically down
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 [x] for milling and a [y] for lathe operations.
vise chuck
Common base elements for fixtures are a [x] for milling and a [y] for lathe operations.
vise chuch
Common base elements for fixtures are a ___ for milling and a ___ for lathe operations.
vise, chuck
1) The mill cutter rotates ____ the direction of feed.
with
For the down milling process, complete the statements with the answers supplied The mill cutter rotates ____ the direction of feed.
with
In down milling, the cutter rotates _____ the direction of the feed.
with
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
What type of milling cutter is used to mill a semi-circular keyway in a shaft used in power transmission equipment? A. end mill cutter B. T-slot milling cutter C. woodruff keyseat milling cutter D. Slitting saw cutter
woodruff keyseat milling cutter
