Elements of Metal Processing Quiz

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Questions and Answers

What is the relationship between design stress and factor of safety?

  • Design stress = ultimate stress times factor of safety.
  • Design stress = ultimate stress divided by factor of safety. (correct)
  • Design stress = factor of safety divided by design stress.
  • Design stress = Design stress divided by ultimate stress.

What type of gauge is used to measure clearances in a group of thin steel strips?

  • Feeler gage (correct)
  • Depth gage
  • Lay-out gage
  • Clearance gage

Which device is specifically designed to measure tension on bolts?

  • Torque wrench (correct)
  • Indexer
  • Torsionmeter
  • Tensiometer

Which material can wear away substances softer than itself?

<p>Abrasive (A)</p> Signup and view all the answers

What is the primary material used in high-speed machining processes?

<p>High speed steel (C)</p> Signup and view all the answers

Which alloy consists of copper and zinc?

<p>Brass (A)</p> Signup and view all the answers

What process involves cooling a heated workpiece rapidly by immersion in water or oil?

<p>Quenching (A)</p> Signup and view all the answers

Which machine tool is used to machine flat surfaces?

<p>Planer (A)</p> Signup and view all the answers

What process involves heating above the transformation range to soften metal and increase machinability?

<p>Annealing (C)</p> Signup and view all the answers

Which process is characterized by heating above the transformation temperature and then quenching?

<p>Hardening (D)</p> Signup and view all the answers

What process involves reheating metal below the transformation range to achieve desirable properties?

<p>Stress Relieving (C)</p> Signup and view all the answers

What is the purpose of heating metal to a temperature of about 1,100°F to 1,300°F in stress relieving?

<p>Reducing internal residual stresses (B)</p> Signup and view all the answers

Which machining process involves producing holes in metal using a specific cutting tool?

<p>Drilling machine (D)</p> Signup and view all the answers

Which machine tool is used for forming parts by removing material with a revolving cutter that has many teeth?

<p>Milling machine (C)</p> Signup and view all the answers

What type of machine tool is used to sharpen or shape tools using an abrasive wheel?

<p>Tool grinder (B)</p> Signup and view all the answers

Which machine tool is specifically used for producing flat surfaces on oversized or heavy pieces?

<p>Planer (B)</p> Signup and view all the answers

Which machine tool is specifically designed to enlarge a hole using an adjustable cutting tool with a single cutting edge?

<p>Boring machine (A)</p> Signup and view all the answers

What type of machine is used to finish surfaces, including holes, using a cutter called a broach?

<p>Broaching machine (B)</p> Signup and view all the answers

Which alloy is created by combining copper and tin?

<p>Bronze (C)</p> Signup and view all the answers

What is the term for the process that involves shaping metal by heating it and then applying a force using dies?

<p>Forging (C)</p> Signup and view all the answers

Which machine tool utilizes a rotating cutter with multiple teeth to remove metal?

<p>Milling machine (C)</p> Signup and view all the answers

What type of machine tool acts on a rotating workpiece using a cutting tool that moves parallel to its axis?

<p>Lathe machine (B)</p> Signup and view all the answers

Which of these accurately describes the process of grinding?

<p>Finishing with a rotating abrasive wheel (A)</p> Signup and view all the answers

Which tool is primarily used for measuring diameters with precision?

<p>Caliper (C)</p> Signup and view all the answers

What is used to test and inspect the size trueness of finished work?

<p>Dial gauge (A)</p> Signup and view all the answers

Which term describes the ability of metal to be deformed without rupture?

<p>Ductility (C)</p> Signup and view all the answers

What is the operation of enlarging a hole by means of a cutting tool with a single cutting edge called?

<p>Boring (A)</p> Signup and view all the answers

Which operation creates a cone-shaped enlargement for a recess for a flat head screw?

<p>Countersinking (A)</p> Signup and view all the answers

What defines an imaginary circle that passes through the contact points of meshing gears?

<p>Pitch circle (B)</p> Signup and view all the answers

What is the term for the portion of a gear tooth that extends above the pitch circle?

<p>Addendum (D)</p> Signup and view all the answers

Which type of bolt is designed to prevent turning while being tightened in wood?

<p>Carriage bolt (B)</p> Signup and view all the answers

What measures the number of teeth per inch of pitch diameter in gears?

<p>Diametral pitch (A)</p> Signup and view all the answers

What process involves heating steel to a temperature within or above the critical range and cooling it rapidly?

<p>Hardening (A)</p> Signup and view all the answers

Which welding operation uses a non-ferrous filler metal that melts at a temperature below that of the metal being joined?

<p>Brazing (A)</p> Signup and view all the answers

What term describes the unitization of two pieces of metal through the application of a molten different metal?

<p>Brazing (D)</p> Signup and view all the answers

In which fusion process is the metal heated into a state of fusion to create a solid joint?

<p>Electric arc welding (D)</p> Signup and view all the answers

What type of welding joins metal through high current at low voltage, creating a forge weld with pressure from electrodes?

<p>Resistance welding (C)</p> Signup and view all the answers

Which tool is specifically designed to measure diameters accurately?

<p>Micrometer (A)</p> Signup and view all the answers

What is the term for a group of thin steel strips used for measuring clearances?

<p>Feeler gage (C)</p> Signup and view all the answers

What does the term 'tolerance' specifically refer to in the context of engineering dimensions?

<p>Tolerance (A)</p> Signup and view all the answers

Which type of gage is primarily used for measuring and checking clearances?

<p>Feeler gage (D)</p> Signup and view all the answers

Which machine tool has a ram that reciprocates vertically?

<p>Slotter (D)</p> Signup and view all the answers

Which machine tool is primarily used for machining flat or plane surfaces with a single-point cutting tool?

<p>Shaper (C)</p> Signup and view all the answers

What type of bolts feature threads on both ends but no head?

<p>Stud bolts (A)</p> Signup and view all the answers

Which type of chuck has jaws that can be adjusted separately and are reversible?

<p>Independent chuck (C)</p> Signup and view all the answers

What tool helps provide centers for machining by being pressed into a finished hole?

<p>Mandrel (A)</p> Signup and view all the answers

Which type of chuck is not recommended for use when extreme accuracy is required?

<p>Magnetic chuck (C)</p> Signup and view all the answers

Steel balls used for ball bearings are primarily produced by which method?

<p>Rolling (C)</p> Signup and view all the answers

Flashcards

Planer

A machine tool used to produce flat surfaces on large or heavy pieces.

Broaching Machine

A machine tool that finishes surfaces, like holes, using a cutter called a broach.

Bronze

An alloy made from copper and tin.

Brass

An alloy of copper and zinc.

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Forging

The process of forming metal parts by applying pressure after heating to a plastic range.

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Milling Machine

A machine tool that removes metal using a revolving cutter with multiple teeth.

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Lathe Machine

A tool that rotates workpieces while a cutting tool shapes them along the axis of rotation.

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Caliper

A tool used to measure diameters with precision.

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Dial Gauge

Device used to align machine tools and measure size trueness.

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Ductility

The ability of metal to be deformed without breaking.

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Laying Out

Marking center points and lines on metal surfaces for guidance.

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Reaming

Enlarging a hole using a cutting tool with multiple edges.

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Countersinking

Enlarging a hole to create a recessed area for screw heads.

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Pitch Circle

Imaginary circle where gear teeth contact each other.

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Carriage Bolt

A bolt designed with a round head for using in wood to metal connections.

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Diametral Pitch

The number of teeth per inch of pitch diameter in gears.

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Annealing

Heating metal above the transformation range and cooling slowly to soften it.

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Hardening

Heating metal above transformation temperature and quenching to increase hardness.

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Normalizing

Heating metal above transformation, then cooling in still air to create uniform structure.

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Tempering

Reheating hardened metal to reduce brittleness and improve toughness.

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Tool Grinder

A machine tool used to sharpen or shape tools using an abrasive wheel.

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Boring Machine

A machine tool that enlarges a hole using a single adjustable cutting tool.

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Feeler Gage

A tool used to measure and check clearances.

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Slotter

A machine tool similar to a shaper with a vertically reciprocating ram.

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Shaper

A machine used to machine flat surfaces with a single-point cutting tool.

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Stud Bolts

Bolts without heads that have threads on both ends.

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Independent Chuck

A chuck that has reversible jaws that can be adjusted separately.

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Mandrel

A tool that provides centers for turning pieces in machining.

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Knurling

The process of creating checkered depressions on surfaces by rolling.

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Headstock

Part of a lathe that includes the spindle and speed mechanisms.

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Design Stress

The stress level for safe operation, related to ultimate stress and safety factor.

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Torque Wrench

A hand tool that measures tightness or tension on bolts.

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Abrasive

A material that can wear away softer substances.

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High Speed Steel

Material used in tools for high-speed processes.

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Brazing

A welding process with a non-ferrous filler that melts below the joined metal's temperature.

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Quenching

The rapid cooling of heated material, usually in water or oil.

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Soldering

Uniting two metal pieces using a different metal in molten state.

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Welding

Fusion process where metal flows together to form a solid joint.

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Resistance Welding

Joining metal with high current at low voltage, using pressure for a forge weld.

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Tension on Bolts

Tool used to measure how much tension is applied to bolts.

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Tolerance

Permissible variation in size; difference between size limits.

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Pitch Diameter

Diameter of a circle coinciding with the top of internal gear teeth.

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Study Notes

Past ME Board Questions (Elements)

  • Question 1: Heating metal above the transformation range (1300°F to 1350°F) and slowly cooling it to soften the metal for machining is known as annealing.
  • Question 2: Heating above the transformation temperature and quenching in oil increases metal hardness, this process is called hardening.
  • Question 3: Reheating below the transformation range, followed by controlled cooling, precisely adjusts metal properties. This is tempering.
  • Question 4: Heating to a subcritical temperature (1100°F to 1300°F) and holding at that temperature reduces internal stresses. This is annealing.
  • Question 5: Heating above the transformation range, then cooling in still air below that range, produces a uniform metal structure, which is normalizing.
  • Question 6: A drilling machine creates holes in metal using a drill bit.
  • Question 7: A metalworking machine used to remove metal from a workpiece using a tool is a broaching machine.
  • Question 8: A tool grinder, using an abrasive wheel, sharpens or shapes tools.
  • Question 9: A boring machine is a machine tool used to enlarge a hole using an adjustable cutting tool with only one cutting edge.
  • Question 10: A shaper is a machine tool used to cut metal parts of various lengths using a reciprocating blade.
  • Question 11: A milling machine is a machine tool used to create various shapes on metal parts.
  • Question 12: A planer is a machine tool for creating flat surfaces for large, heavy, or unwieldy work pieces.
  • Question 13: A broaching machine is a machine tool used to finish internal or external surfaces, like holes or keyways, using a broach tool.
  • Question 14: Brass is an alloy of copper and zinc.
  • Question 15: Bronze is an alloy of copper and tin.
  • Question 16: Forging is a metalworking process that uses pressure to shape hot metal using a hammer or press.
  • Question 17: Forging is a metal-forming process that uses intense pressure (such as a press or hammer) using the hot plastic metal to get the desired shape.
  • Question 18: SAE 1020 is a manganese steel with 0.2% carbon.
  • Question 19: A milling machine uses a multi-toothed revolving cutter to remove metal.
  • Question 20: A lathe is a machine tool in which the workpiece, mounted on a revolving axis, is acted on by a cutting tool moving parallel to the axis.
  • Question 21: A planer is a machine tool used to machine flat surfaces on large or heavy work pieces.
  • Question 22: Grinding shapes a piece of metal using an abrasive wheel.
  • Question 23: A caliper is a tool for measuring diameters.
  • Question 24: Dial gauges and dial indicators measure sizes, alignment, and trueness of mechanical parts and machine surfaces.
  • Question 25: The ability of a material to be severely deformed without breaking.
  • Question 26: Marking points, circles, arcs and straight lines on surfaces, a shop term.
  • Question 27: Reaming is an operation of sizing and finishing a hole.
  • Question 28: Countersinking creates a cone-shaped enlargement of a hole.
  • Question 29: Boring enlarge a hole by means of an adjustable cutting tool with only a single cutting edge.
  • Question 30: A pitch circle is a line that intersects the gear teeth, a circle through the points of contact between meshed gear teeth. ... (Note: The question list and answer key provided cover many more questions, so to keep the study notes concise, they have been aggregated into these groupings.)

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