Question 1

Which one of the following cutting conditions has the strongest effect on cutting temperature:

Accepted Answer

A) cutting speed 
B) depth of cut 
C) feed 
A) cutting speed 
B) depth of cut 
C) feed A

Question 2

A single-point cutting tool is used for which one of the following operations:

Accepted Answer

A) drilling 
B) milling 
C) turning 
A) drilling 
B) milling 
C) turning C

Question 3

With which one of the following geometric forms is the turning operation most closely associated:

Accepted Answer

A) external cylinder 
B) flat plane 
C) round hole 
D) screw threads 
E) sphere 
A) external cylinder 
B) flat plane 
C) round hole 
D) screw threads 
E) sphere A

Question 4

Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material:

Accepted Answer

A) continuous 
B) continuous with built-up edge 
C) discontinuous 
D) serrated 
A) continuous 
B) continuous with built-up edge 
C) discontinuous 
D) serrated

Question 5

A lathe is used to perform which one of the following manufacturing operations:

Accepted Answer

A) broaching 
B) drilling 
C) lapping 
D) milling 
E) turning 
A) broaching 
B) drilling 
C) lapping 
D) milling 
E) turning

Question 6

Which of the following manufacturing processes are classified as material removal processes (two correct answers):

Accepted Answer

A) casting 
B) drawing 
C) extrusion 
D) forging 
E) grinding
F)machining
G)molding
H)pressworking
I)spinning 
A) casting 
B) drawing 
C) extrusion 
D) forging 
E) grinding
F)machining
G)molding
H)pressworking
I)spinning

Question 7

The chip thickness ratio in orthogonal cutting is which one of the following:

Accepted Answer

A) tc/to 
B) to/tc 
C) to/w, where tc = chip thickness after the cut, to = chip thickness before the cut, and w = width of cut 
A) tc/to 
B) to/tc 
C) to/w, where tc = chip thickness after the cut, to = chip thickness before the cut, and w = width of cut

Question 8

Which of the following are characteristics of the orthogonal cutting model (three best answers):

Accepted Answer

A) a circular cutting edge is used 
B) a multiple-cutting-edge tool is used 
C) a single-point tool is used 
D) only two dimensions play an active role in the analysis 
E) the cutting edge is parallel to the direction of cutting speed,
F)the cutting edge is perpendicular to the direction of cutting speed,
G)the two elements of tool geometry are rake angle and relief angle 
A) a circular cutting edge is used 
B) a multiple-cutting-edge tool is used 
C) a single-point tool is used 
D) only two dimensions play an active role in the analysis 
E) the cutting edge is parallel to the direction of cutting speed,
F)the cutting edge is perpendicular to the direction of cutting speed,
G)the two elements of tool geometry are rake angle and relief angle

Question 9

A roughing operation generally involves which one of the following combinations of cutting conditions:

Accepted Answer

A) high v, f, and d; 
B) high v, low f and d; 
C) low v, high f and d; 
D) low v, f, and d, where v = cutting speed, f = feed, and d = depth of cut 
A) high v, f, and d; 
B) high v, low f and d; 
C) low v, high f and d; 
D) low v, f, and d, where v = cutting speed, f = feed, and d = depth of cut

Question 10

The mechanism of chip formation in machining is best described by which one of the following:

Accepted Answer

A) compression 
B) fracture failure 
C) shear deformation 
D) tensile failure 
A) compression 
B) fracture failure 
C) shear deformation 
D) tensile failure

Question 11

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning:

Accepted Answer

A) depth of cut d 
B) feed f 
C) speed v 
A) depth of cut d 
B) feed f 
C) speed v

Question 12

Machining is noted for which of the following characteristics relative to other manufacturing processes (two best answers):

Accepted Answer

A) creates three-dimensional geometries 
B) good dimensional accuracy 
C) net shape process 
D) poor surface finish 
E) wasteful of energy
F)wasteful of material 
A) creates three-dimensional geometries 
B) good dimensional accuracy 
C) net shape process 
D) poor surface finish 
E) wasteful of energy
F)wasteful of material

Question 13

According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers):

Accepted Answer

A) decrease in friction angle 
B) decrease in power requirements 
C) decrease in shear plane angle 
D) increase in cutting temperature 
E) increase in shear plane angle 
A) decrease in friction angle 
B) decrease in power requirements 
C) decrease in shear plane angle 
D) increase in cutting temperature 
E) increase in shear plane angle

Question 14

Which one of the following metals would usually have the lowest specific energy in a machining operation:

Accepted Answer

A) aluminum 
B) brass 
C) cast iron 
D) steel 
A) aluminum 
B) brass 
C) cast iron 
D) steel

Question 15

Which of the following are the three most common machining operations:

Accepted Answer

A) broaching 
B) drilling 
C) lapping 
D) milling 
E) planing
F)shaping
G)turning 
A) broaching 
B) drilling 
C) lapping 
D) milling 
E) planing
F)shaping
G)turning

Question 16

Specific energy in metal machining is a measure of the amount of energy required to remove a unit volume of material:

Accepted Answer

A) True 
 B)False

Question 17

The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry:

Accepted Answer

A) True 
 B)False

Exam 17: Theory of Metal Machining

Which one of the following cutting conditions has the strongest effect on cutting temperature:

A single-point cutting tool is used for which one of the following operations:

With which one of the following geometric forms is the turning operation most closely associated:

Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material:

A lathe is used to perform which one of the following manufacturing operations:

Which of the following manufacturing processes are classified as material removal processes (two correct answers):

The chip thickness ratio in orthogonal cutting is which one of the following:

Which of the following are characteristics of the orthogonal cutting model (three best answers):

A roughing operation generally involves which one of the following combinations of cutting conditions:

The mechanism of chip formation in machining is best described by which one of the following:

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning:

Machining is noted for which of the following characteristics relative to other manufacturing processes (two best answers):

According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers):

Which one of the following metals would usually have the lowest specific energy in a machining operation:

Which of the following are the three most common machining operations:

Specific energy in metal machining is a measure of the amount of energy required to remove a unit volume of material:

The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry:

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

Machining Operations and Machine Tools

Cutting Tool Technology

Economic and Product Design Considerations

Grinding and Other Abrasive Processes

Nontraditional Machining and Thermal Cutting

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

Filters

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut t_o corresponds to which one of the following cutting conditions in turning: