Question 1

In abrasive water jet cutting, the abrasive particles are added to the water stream:

Accepted Answer

A) after it exits the nozzle 
B) before it enters the pumping unit 
C) just before it enters the nozzle 
D) while it is in the nozzle 
A) after it exits the nozzle 
B) before it enters the pumping unit 
C) just before it enters the nozzle 
D) while it is in the nozzle A

Question 2

In water jet cutting and abrasive water jet cutting, the separation between the nozzle opening and the work surface is called which one of the following:

Accepted Answer

A) gap 
B) gap size 
C) orifice 
D) overcut 
E) standoff distance 
A) gap 
B) gap size 
C) orifice 
D) overcut 
E) standoff distance E

Question 3

In ultrasonic machining, material removal rate decreases with increasing frequency and amplitude of vibration:

Accepted Answer

A) True 
 B)False  False

Question 4

Which one of the following fuels used in flame cutting produces the highest flame temperatures:

Accepted Answer

A) acetylene 
B) methylacetylene-propadiene 
C) propane 
D) propylene 
A) acetylene 
B) methylacetylene-propadiene 
C) propane 
D) propylene

Question 5

Chemical milling is used in which of the following applications (two best answers):

Accepted Answer

A) drilling holes with high depth-to-diameter ratio 
B) making intricate patterns in thin sheet metal 
C) removing material to make shallow pockets in metal 
D) removing metal from aircraft wing panels 
E) cutting of plastic sheets 
A) drilling holes with high depth-to-diameter ratio 
B) making intricate patterns in thin sheet metal 
C) removing material to make shallow pockets in metal 
D) removing metal from aircraft wing panels 
E) cutting of plastic sheets

Question 6

Which of the following processes would be appropriate for cutting a narrow slot, less than 0.40 mm (0.016 in) wide, in a 3/8-in-thick sheet of fiber-reinforced plastic that is 9.5 mm (3/8 in) thick (two best answers):

Accepted Answer

A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM 
A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM

Question 7

Ultrasonic machining can be used to machine both metallic and nonmetallic materials:

Accepted Answer

A) True 
 B)False

Question 8

Which of the following processes could be used to cut a large piece of 12.7-mm (0.50-in) plate steel into two sections (two best answers):

Accepted Answer

A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM 
A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM

Question 9

Which one of the following is closest to the temperatures used in plasma arc cutting:

Accepted Answer

A) 2750 $\degree$C (5000 $\degree$F) 
B) 5500 $\degree$C (10000 $\degree$F) 
C) 8300 $\degree$C (15000 $\degree$F) 
D) 11000 $\degree$C (20000 $\degree$F) 
E) 16500 $\degree$C (30000 $\degree$F) 
A) 2750 $\degree$C (5000 $\degree$F) 
B) 5500 $\degree$C (10000 $\degree$F) 
C) 8300 $\degree$C (15000 $\degree$F) 
D) 11000 $\degree$C (20000 $\degree$F) 
E) 16500 $\degree$C (30000 $\degree$F)

Question 10

The metal removal rate in electric discharge machining depends on which of the following variables and properties (two correct answers):

Accepted Answer

A) discharge current 
B) hardness of the work metal 
C) melting temperature of the work metal 
D) tensile strength of the work metal 
A) discharge current 
B) hardness of the work metal 
C) melting temperature of the work metal 
D) tensile strength of the work metal

Question 11

Abrasive water jet cutting and abrasive jet machining are two different names for the same process:

Accepted Answer

A) True 
 B)False

Question 12

Which one of the following processes would be appropriate to drill a hole with a square cross section, 6 mm (0.25 in) on a side and 25 mm (1 in) deep in a steel workpiece:

Accepted Answer

A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM 
A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM

Question 13

Disadvantages of electrochemical machining include which of the following (two best answers):

Accepted Answer

A) disposing of the electrolyte sludge created in the process 
B) high cost of electrical power 
C) high tool wear 
D) low metal removal rates for hard metals 
E) surface damage to work 
A) disposing of the electrolyte sludge created in the process 
B) high cost of electrical power 
C) high tool wear 
D) low metal removal rates for hard metals 
E) surface damage to work

Question 14

Which one of the following processes would be appropriate for cutting a hole of 0.075 mm (0.003 in) diameter through a plate of aluminum that is 1.6 mm (1/16 in) thick:

Accepted Answer

A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM 
A) abrasive jet machining 
B) chemical milling 
C) EDM 
D) laser beam machining 
E) oxyfuel cutting
F)water jet cutting
G)wire EDM

Question 15

The liquid used to create the discharge path between the tool and the work in electric discharge machining is called which one of the following:

Accepted Answer

A) dielectric fluid 
B) electrolyte 
A) dielectric fluid 
B) electrolyte

Question 16

The etch factor in chemical machining is equal to which one of the following:

Accepted Answer

A) CIt 
B) d/u 
C) u/d; where C = specific removal rate d = depth of cut I = current t = time and u = undercut 
A) CIt 
B) d/u 
C) u/d; where C = specific removal rate d = depth of cut I = current t = time and u = undercut

Question 17

Applications of electron beam machining are limited to metallic work materials because the work must be electrically conductive:

Accepted Answer

A) True 
 B)False

Question 18

Of the following processes, which one is noted for the highest material removal rates:

Accepted Answer

A) electric discharge machining 
B) electrochemical machining 
C) laser beam machining 
D) oxyfuel cutting 
E) plasma arc cutting
F)ultrasonic machining
G)water jet cutting 
A) electric discharge machining 
B) electrochemical machining 
C) laser beam machining 
D) oxyfuel cutting 
E) plasma arc cutting
F)ultrasonic machining
G)water jet cutting

Question 19

Which of the following processes use mechanical energy as the principal energy source (three correct answers):

Accepted Answer

A) electrochemical grinding 
B) laser beam machining 
C) conventional milling 
D) ultrasonic machining 
E) water jet cutting
F)wire EDM 
A) electrochemical grinding 
B) laser beam machining 
C) conventional milling 
D) ultrasonic machining 
E) water jet cutting
F)wire EDM

Exam 22: Nontraditional Machining and Thermal Cutting

In abrasive water jet cutting, the abrasive particles are added to the water stream:

In water jet cutting and abrasive water jet cutting, the separation between the nozzle opening and the work surface is called which one of the following:

In ultrasonic machining, material removal rate decreases with increasing frequency and amplitude of vibration:

Which one of the following fuels used in flame cutting produces the highest flame temperatures:

Chemical milling is used in which of the following applications (two best answers):

Which of the following processes would be appropriate for cutting a narrow slot, less than 0.40 mm (0.016 in) wide, in a 3/8-in-thick sheet of fiber-reinforced plastic that is 9.5 mm (3/8 in) thick (two best answers):

Ultrasonic machining can be used to machine both metallic and nonmetallic materials:

Which of the following processes could be used to cut a large piece of 12.7-mm (0.50-in) plate steel into two sections (two best answers):

Which one of the following is closest to the temperatures used in plasma arc cutting:

The metal removal rate in electric discharge machining depends on which of the following variables and properties (two correct answers):

Abrasive water jet cutting and abrasive jet machining are two different names for the same process:

Which one of the following processes would be appropriate to drill a hole with a square cross section, 6 mm (0.25 in) on a side and 25 mm (1 in) deep in a steel workpiece:

Disadvantages of electrochemical machining include which of the following (two best answers):

Which one of the following processes would be appropriate for cutting a hole of 0.075 mm (0.003 in) diameter through a plate of aluminum that is 1.6 mm (1/16 in) thick:

The liquid used to create the discharge path between the tool and the work in electric discharge machining is called which one of the following:

The etch factor in chemical machining is equal to which one of the following:

Applications of electron beam machining are limited to metallic work materials because the work must be electrically conductive:

Of the following processes, which one is noted for the highest material removal rates:

Which of the following processes use mechanical energy as the principal energy source (three correct answers):

Introduction and Overview of Manufacturing

The Nature of Materials

Mechanical Properties of Materials

Physical Properties of Materials

Engineering Materials

Dimensions, Surfaces, and Their Measurement

Fundamentals of Metal Casting

Metal Casting Processes

Glassworking

Shaping Processes for Plastics

Processing of Polymer Matrix Composites and Rubber

Powder Metallurgy

Processing of Ceramics and Cermets

Fundamentals of Metal Forming

Bulk Deformation Processes in Metal Workiing

Sheet Metalworking

Theory of Metal Machining

Machining Operations and Machine Tools

Cutting Tool Technology

Economic and Product Design Considerations

Grinding and Other Abrasive Processes

Heat Treatment of Metals

Surface Processing Operations

Fundamentals of Welding

Welding Processes

Brazing, Soldering, and Adhesive Bonding

Mechanical Assembly

Rapid Prototyping and Additive Manufacturing

Processing of Integrated Circuits

Electronics Assembly and Packaging

Microfabrication Technologies

Nanofabrication Technologies

Automation Technologies for Manufacturing Systems

Integrated Manufacturing Systems

Process Planning and Production Control

Quality Control and Inspection

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