Machining and Metalworking Quiz
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Questions and Answers

What type of sparks will be produced when a piece of cast iron is held against an emery wheel?

  • Red sparks
  • Bright shiny sparks
  • No sparks
  • Dull yellow sparks (correct)

Which of the following terms is NOT commonly used to classify fits in mechanical engineering?

  • Tunking
  • Snug
  • Medium force fit
  • Bound (correct)

What is the likely cause if a drill produces an oversized hole?

  • Cutting speed is too high
  • Lips of drill are of unequal length (correct)
  • Feed is too high
  • Insufficient coolant is used

What is the primary function of studs used as a coolant in a general machine shop?

<p>An emulsion of oil and water (B)</p> Signup and view all the answers

Which material listed is generally considered the hardest?

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

What term describes the movement of a belt on the surface of a pulley within the contact arc?

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

Which of the following is often used for soldering bright tin?

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

What is the function of crowning the outer surface of a pulley?

<p>To keep the belt centered during motion (C)</p> Signup and view all the answers

What is the primary function of the dovetailed surface in relation to the plunger knob?

<p>To ensure perfect alignment and guidance of the knob. (C)</p> Signup and view all the answers

When cutting softer materials on a lathe, what adjustment should be made to the tool bit's top rake?

<p>Less top rake should be applied. (A)</p> Signup and view all the answers

What is the name of the instrument that a welding operator holds during gas welding, from which gases are emitted to perform the welding operation?

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

After sharpening a tool bit by grinding, what is the recommended next step to refine the cutting edge?

<p>Stone it with an oilstone. (D)</p> Signup and view all the answers

What type of material is best suited for making a scriber, a tool used for marking metal?

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

What is the name of a hole revolving cutter, or grinding wheel, that you would mount on an arbor?

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

In material processing, what type of mill uses two toothed metal disks rotating in opposite directions to pulverize materials?

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

What color sparks will be produced when a piece of mild steel is held against an emery wheel?

<p>Light straw colored sparks (C)</p> Signup and view all the answers

What is the typical angle range for setting up a grinding wheel?

<p>8 – 10° (A)</p> Signup and view all the answers

Which tool is specifically designed to inspect external pipe threads for accuracy?

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

In manufacturing, what characterizes abreast milling?

<p>Parts are placed in a row parallel to the cutter axis and milled simultaneously. (A)</p> Signup and view all the answers

Which tool is used to verify the dimensional accuracy of internal pipe threads?

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

What is the specialized cutting tool used for manufacturing gears called?

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

Why should a tool bit be frequently dipped in water when using a dry grinding wheel?

<p>To prevent annealing the cutting edge of the bit. (D)</p> Signup and view all the answers

What is meant by CNC in the context of a machine shop?

<p>Computer Numerical Control (C)</p> Signup and view all the answers

Which type of file features one or two edges without teeth, known as 'safe' edges?

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

Which of the following best describes 'down time' in a manufacturing context?

<p>The time lost due to equipment breakdowns, waiting for tools, or minor accidents. (A)</p> Signup and view all the answers

In the context of fire safety, which method involves removing combustible materials from the vicinity of a fire?

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

Why is specifying tolerance essential in manufacturing and engineering designs?

<p>It collectively saves labor charges, prevents material wastage and saves time during the manufacturing process. (D)</p> Signup and view all the answers

When measuring the length of a file, what is the standard reference?

<p>Point to Heel (D)</p> Signup and view all the answers

For what specific purpose is a 'pillar' file designed?

<p>Any of the above (D)</p> Signup and view all the answers

What is the likely consequence of applying excessive pressure to a flexible hacksaw blade during cutting?

<p>The blade will buckle or deviate from the intended cut line. (C)</p> Signup and view all the answers

What is the core principle of soldering?

<p>Joining two metals using a third, molten metal as an adhesive. (A)</p> Signup and view all the answers

What is the primary function of flux in the soldering process?

<p>To remove and prevent oxidation of the metals being joined. (A)</p> Signup and view all the answers

Which instrument is BEST suited for measuring the surface roughness of a hardened steel component?

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

Which type of coupling is MOST appropriate for connecting two shafts with intersecting axes?

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

For a high-speed application with a light load, which type of bearing is GENERALLY preferred due to its minimal contact area?

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

Which device is specifically designed to hold grinding wheels of unusual shapes or to secure a workpiece during grinding operations?

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

Which manufacturing process refers to creating the helical grooves on a twist drill or tap?

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

During sheet metal work, what process involves enlarging and smoothing a punched hole using tapered drifts?

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

What is the term for the condition where a grinding wheel's cutting particles become dull, leading to a reduced cutting rate?

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

What type of gear mechanism consists of multiple gears arranged on a plate, controlled by a lever to achieve different speed ratios?

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

What instrument would be best suited for accurately centering a workpiece in a lathe chuck?

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

Which type of chuck is characterized by reversible jaws that can be adjusted independently?

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

What gear finishing method involves running a gear against another with an abrasive surface?

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

What is the name of the cold working process where a limited amount of material is displaced, resulting in higher strength and a compressive surface stress layer?

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

Iron wire rope is largely used for low-strength applications, such as what?

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

Which of the following choices is not a cutting fluid?

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

What is the best method to adjust the working height of a bench vise?

<p>All of the above (D)</p> Signup and view all the answers

Files are generally classified according to which characteristics?

<p>All of the above (D)</p> Signup and view all the answers

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Flashcards

Dousing in Oil

Applying oil to a surface or object during a process like machining.

Bright Shiny Sparks

Sparks produced when a piece of cast iron is ground against an emery wheel.

Over Size Hole

A hole that is larger than intended, often due to high cutting speed or improper feed.

Coolant in Machine Shop

A mixture used to cool and lubricate during machining processes.

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Creep in Pulleys

The movement of a belt on the face of pulleys as it rotates.

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Fixture in Machining

A device that holds workpieces in place during machining.

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Common Terms for Fits

Terms used to classify the tightness and fit of machine parts.

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Hardest Material

Diamond is the hardest known natural material used in various applications.

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Plunger Knob

A device mounted on the top of a column, aligned by a dovetailed surface.

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Cutting Tool Rake

The angle of the cutting edge; softer materials require a specific rake angle.

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Welding Mechanism

The tool held by a welding operator during gas welding operations.

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Grinding Tool Edge

After grinding, the cutting edge may be finished with specific methods.

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Attrition Mill

A machine for pulverizing materials using two rotating toothed disks.

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Sparks from Grinding

The color and nature of sparks produced when grinding steel depends on the process.

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Teeth Ratio in Gear

The relationship between gear teeth affecting the RPM of connected gears.

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Types of Steel for Scriber

A scriber can be made from various types of steel, usually carbon steel.

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Rounding Degree

The process of modifying a measurement to a specified level of precision. Rounding can include 3 - 6°, 8 - 10°, 12 - 15°, or 18 - 22°.

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External Pipe Thread Tool

A tool used to check external pipe threads, called a ring gage.

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Abreast Milling

A milling method where parts are arranged in a row parallel to the cutting tool for simultaneous milling.

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Internal Pipe Thread Tool

The tool used to check internal pipe threads is called a plug gage.

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Gear Cutting Tool

The tool designed specifically for cutting gears is called a gear hob.

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Bearing Functions

Bearings are designed to support and guide shafts, NOT to transmit power, which is incorrect for their function.

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Dry Grinding Wheel Care

When using a dry grinding wheel, dip the end of the bit in water frequently to prevent annealing of the cutting edge.

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CNC in Machine Shop

CNC stands for Computer Numerical Control, a method for controlling machine tools through computer programming.

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Down time

Time lost due to breakdowns and waiting for tools.

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Tolerance in manufacturing

Allowance in dimensions to prevent waste and save time.

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A 'pillar' file

Used for filling slots, keyways, or against shoulders.

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Soldering

Joining metals using heat and a soft molten metal.

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Purpose of flux in soldering

Prevents oxidation and helps solder flow.

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Computer Numerical Control

Automated control of machines via computers.

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Flexible hacksaw blade drawbacks

Tends to buckle or snap under excessive pressure.

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Surface roughness measurement

Assessing surface texture in micro inches.

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Micrometer

A precision instrument used to measure small distances or thicknesses.

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Flexible coupling

A device used to connect shafts whose axes are misaligned.

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Ball bearing

A type of bearing that uses spheres to maintain separation between the bearing races.

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Arbor

The spindle of a grinding machine where the grinding wheel is mounted.

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Fluting

A process of grinding grooves on a twist drill or tap to aid in cutting.

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Drifting

A process of enlarging and smoothing punched holes with tapered drifts.

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Gear train

A set of gears arranged to transmit torque and motion between shafts.

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Glazing

The dulling of cutting particles on a grinding wheel, reducing cutting efficiency.

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Compound Gage

A tool used in a lathe chuck for measurements.

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Independent Chuck

A type of chuck with reversible jaws that can be adjusted separately.

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Height Adjustment of Bench Vice

The height is adjusted using a wooden packing piece under the vice base.

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Honing

A method where a gear is run with another gear that has abrasive surface material.

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Teeth Dulling in Hacksaw Blades

Hacksaw teeth can dull due to too much speed and pressure.

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Surface Rolling

Cold work that results in higher strength and compressive stress on the surface.

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Rivet Production

Rivets are made largely through a cold pressing method.

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Files Classification

Files are classified by grade, cut, shape, size, and length.

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Study Notes

IBONG TIRIRIT (MDSP 5)

  • Hacksaw Blade Placement: Place the blade in the frame with the teeth pointing forward.
  • Cutting Long Thin Metal: To cut long, thin pieces of metal, set the blade in the frame with the teeth facing you.
  • Hacksaw Blade Teeth per Inch: A blade with 18 teeth per inch is best for solid stock; a blade with 32 teeth per inch is suitable for small tubing or sheet metal under 18 gauge.
  • Coolant Use in Power Hacksaws: Coolant is used to absorb friction heat, preventing overheating and temper loss.
  • Filing Lead/Babbitt: Use a mill file for filing lead or babbitt.
  • Lathe carriage/compound rest: It moves on the lathe bed with cutting tool according to the rotation of lead screw or by hand traversing wheel
  • Cutting Tool Feed: A compound rest gives longitudinal and cross-feed to cutting tools.
  • Center fitted in the headstock: A 'dead center' is fitted in the tail stock spindle
  • Shearing Action: Top rake gives shearing action.
  • File Ordering Information: Size, shape, and type of teeth are crucial information when ordering a file.
  • File Use: Do not use a dirty file without a handle. A mill file is used when finishing sharp corners, slots, and grooves.
  • Micrometer Markings: Micrometer barrel markings are typically 0.025" apart.
  • Shaping Machine Mechanism: The ram stroke length on a quick return mechanism of a shaping machine is proportional to the crank length.
  • Spindle of Machine Tool: Type and number of bearings used for machine tool spindles depend on spindle type and load.
  • Cutting Tool Support: The 'dead center' is fitted in the tail stock spindle when used in drilling.
  • Cutting Angle: The top rake angle for cutting brass is 15°.
  • Turning Tools: A wrench is used for turning nuts or bolts.
  • Lever Shift Rail: The plunger knob is used for the lever shift for vertical rail travel.
  • Welding Accessories: A torch is the name of the mechanism a welding operator uses during gas welding.
  • Scriber Material: A scriber is typically made of tool steel.
  • Metal Removal: The amount of material removed by grinding depends on factors like the grade of the grinding wheel, operating speed, feed rate, etc.
  • Grit Size: The size of abrasive grains produced by a crushing process is called grit.
  • Alloy Steel Composition: Alloy steel is a combination of iron, carbon, and other alloying elements.
  • Surface Unevennesses: Flaws and irregularities resulting from various manufacturing methods are called surface roughness.
  • Hardest Material: Diamond is considered the hardest material.
  • Surface Preparation for Soldering: Clean surfaces are necessary before soldering.

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Description

A quiz covering fundamental topics in machining and metalworking. Topics include spark types, fitting classifications, drilling issues, coolant studs, material hardness, belt movement, soldering materials, pulley crowning, dovetail surfaces, lathe adjustments, welding instruments, and tool sharpening.

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