NC Machine Tools and Welding Techniques Quiz
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Questions and Answers

What factor does not influence the position of the neutral point in the arc of contact when rolling a strip between two rolls?

  • Material of the rolls (correct)
  • Diameter of the rolls
  • Amount of reduction
  • Coefficient of friction

Which NC machine tool system has integrated automatic tool changing and component indexing device?

  • CNC system
  • DNC system
  • Machining centre (correct)
  • NC system

In the codes matching NC machine tool systems to their features, which option corresponds to the CNC system?

  • The controller consists of soft-wired computer and hard-wired logic.
  • The instructions on tape are prepared in binary decimal form.
  • A number of machine tools are controlled by a computer. (correct)
  • Graphic display of tool path is also possible.

Which casting method is generally known for a higher production rate?

<p>Die-casting (A)</p> Signup and view all the answers

Why are lathe spindles often made hollow?

<p>To facilitate the passage of coolant (B)</p> Signup and view all the answers

Which of the following is a benefit of submerged arc welding over conventional open air manual arc welding?

<p>Reduced spatter and slag (D)</p> Signup and view all the answers

What describes a key characteristic of the DNC system in NC machine tool systems?

<p>Operates with direct memory transmission (B)</p> Signup and view all the answers

What happens to the strength and ductility of a solid metal when its temperature increases?

<p>Strength decreases but ductility increases (B)</p> Signup and view all the answers

How does the strength of a brazed joint change with the gap between the joining surfaces?

<p>Increases up to a certain gap, then decreases (C)</p> Signup and view all the answers

Which machining method is suitable for finishing a zig zag cavity in a block of high strength alloy?

<p>Electric discharge machinery (D)</p> Signup and view all the answers

What is the time required for machining a 600 mm x 30 mm flat surface on a shaper with specified parameters?

<p>12 minutes (B)</p> Signup and view all the answers

What is the main characteristic of spheroidizing?

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

Which type of moulding is analogous to die casting of metals?

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

Which steel type is primarily used for manufacturing screws?

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

In which moulding type must the mould cavity be heated to cure the plastic?

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

Which product is associated with high carbon steel?

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

What mechanism is involved in injected moulding?

<p>Heating and forcing plastic into a mold (D)</p> Signup and view all the answers

Which steel type is most likely used for blanking dies?

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

What is the mechanism involved in jet moulding?

<p>Analogous to die casting of metals (B)</p> Signup and view all the answers

Which combination of steel types and products is correctly matched?

<p>Mild steel - Screws (A)</p> Signup and view all the answers

Which alloying element is most effective for improving the strength of steel at elevated temperatures?

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

What feature is typically associated with a turning tool?

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

What probable cause is most likely associated with poor surface finish in milling?

<p>Lack of rigidity (A)</p> Signup and view all the answers

Which characteristic of relief angle affects the direction of chip flow?

<p>Angle of clearance (D)</p> Signup and view all the answers

What is a common reason for chatter in milling operations?

<p>Too high feed (C)</p> Signup and view all the answers

Which feature is primarily associated with a reamer?

<p>Internal cutting edge (D)</p> Signup and view all the answers

What effect does a proper relief angle have on cutting tools?

<p>Enhances access for coolant (C)</p> Signup and view all the answers

Which probable cause is linked to cutter burrs in milling?

<p>Radial relief too great (C)</p> Signup and view all the answers

What is a key effect of an inadequate relief angle on cutting tools?

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

What is the most likely probable cause of loss of accuracy in milling operations?

<p>High cutting load (C)</p> Signup and view all the answers

Which code corresponds to the classification of excessive gases in the welding atmosphere?

<p>2, 1, 5, 3 (B)</p> Signup and view all the answers

Which of the following factors will not increase the size of the heat affected zone (HAZ)?

<p>Reduced base metal thickness (D)</p> Signup and view all the answers

Which combination of factors is correct regarding the magnitude of residual stresses in welding?

<p>Design of weldment, Support and clamping of components, Welding process used (A)</p> Signup and view all the answers

What is the correct cutting speed range for a milling cutter when cutting brass?

<p>45 to 60 m/min (D)</p> Signup and view all the answers

What role does the helical flute in a twist drill serve?

<p>Guides the drill into the workpiece (C)</p> Signup and view all the answers

Which statement regarding the increased size of the HAZ is false?

<p>It decreases with higher thermal conductivity. (C)</p> Signup and view all the answers

Which of the following does not impact the magnitude of residual stresses in welding?

<p>Type of base metal (C)</p> Signup and view all the answers

Which of the following describes the primary function of the clearance angle in a twist drill?

<p>Provides space for chips to escape (D)</p> Signup and view all the answers

Identify the incorrect factor affecting the size of the heat affected zone (HAZ).

<p>Increased thermal conductivity (C)</p> Signup and view all the answers

Which statements about the helical flute of a twist drill are correct?

<p>Allows for chip removal and Clearance angle (A)</p> Signup and view all the answers

What is a primary characteristic of superplastic materials during deformation?

<p>Very fine grain size around 1 μm (A)</p> Signup and view all the answers

What is a significant drawback of superplastic forming (SPF)?

<p>Very low strain rates leading to longer forming times (B)</p> Signup and view all the answers

Which of the following materials is commonly used in superplastic forming processes?

<p>Zn–22Al (B)</p> Signup and view all the answers

What application is primarily achieved through the peen forming process?

<p>Producing smooth and complex curvatures on thin metal sheets (A)</p> Signup and view all the answers

Which factor is critical for superplastic materials to perform effectively during forming?

<p>The material should not be super-plastic at service temperature (A)</p> Signup and view all the answers

Which combination of index plate and number of revolutions is correct for milling a spur gear of 28 teeth?

<p>Plate 2: 1 revolution and 9 holes in 21 hole circles. (C)</p> Signup and view all the answers

What is the correct match for Plan approach angle from List – I?

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

Which manufacturing method is correctly matched with Cemented Carbide from List – I?

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

Which angle forms the correct association with Tool flank from List – II?

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

Which alloy is most commonly used for transformer laminations?

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

Which of the following statements about the Rake angle is correct?

<p>It determines the effective angle of cutting edge penetration. (A)</p> Signup and view all the answers

Which of the following statements about cold working compared to hot working is true?

<p>Colder temperatures lead to improved surface finish. (D)</p> Signup and view all the answers

What is the correct code combination for matching Clearance angle to its respective feature?

<p>3: Tool face and flank (C)</p> Signup and view all the answers

Which of the following is considered a limitation of powder metallurgy?

<p>Size and shape limitations (D)</p> Signup and view all the answers

Which cutting tool material is associated with the manufacturing method of Casting?

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

Which one of the feature combinations pertains to the Wedge angle?

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

What is the primary cause of inclusions in welding?

<p>Oxidation during welding (B)</p> Signup and view all the answers

Which combination correctly matches the type of alloy to its application?

<p>High Carbon steel - Springs (B)</p> Signup and view all the answers

Which statement is false regarding the correlation of index plates for cutting gears?

<p>Only one index plate is required for all milling operations. (D)</p> Signup and view all the answers

Which of the following combinations correctly lists the applications of high speed steel and monel metal?

<p>High speed steel - Cutting tools; Monel metal - Marine Bearings (D)</p> Signup and view all the answers

What is a common cause of porosity in welding?

<p>Improper shielding gas types (C)</p> Signup and view all the answers

What is the correct rate of metal removal for a medium carbon steel workpiece turned at 50 m/min with a 0.8 mm/rev feed and 1.5 mm depth of cut?

<p>60,000 mm³/min (D)</p> Signup and view all the answers

In the matching of machining processes to their operating media, which combination is correct?

<p>A - 5, B - 4, C - 2, D - 1 (B)</p> Signup and view all the answers

Which equipment is incorrectly matched to its associated process?

<p>Dielectric Baker - Die Casting (B)</p> Signup and view all the answers

What is the incorrect combination for the matching of List I equipment to List II processes?

<p>P - 4, Q - 2, R - 1, S - 5 (A)</p> Signup and view all the answers

What is the depth of cut used in turning a medium carbon steel workpiece?

<p>1.5 mm (D)</p> Signup and view all the answers

Which machining process uses abrasive slurry as its operating medium?

<p>Abrasive Jet machining (C)</p> Signup and view all the answers

Which code pairing accurately matches the machining process to its operating media?

<p>A - 5, B - 4, C - 1, D - 3 (D)</p> Signup and view all the answers

What is the discrepancy in the processes matched with the equipment on the list?

<p>R - 4 lists the wrong media for Electro-chemical machining (B)</p> Signup and view all the answers

Which feed rate in mm/rev was specified for the turning operation?

<p>0.8 mm/rev (D)</p> Signup and view all the answers

Which of the following represents a key factor in calculating the rate of metal removal?

<p>Feed rate and depth of cut (B)</p> Signup and view all the answers

What is the approximate current passing through the electrodes during the welding process?

<p>4060 A (D)</p> Signup and view all the answers

How long does it take to fill the mould cavity with a downsprue 20 cm long and a cross-sectional area of 1 cm²?

<p>5.05 s (C)</p> Signup and view all the answers

What is the calculated volume of the welding nugget formed given its diameter and thickness?

<p>30 mm³ (A)</p> Signup and view all the answers

What is the latent heat of fusion of steel used in the welding calculation?

<p>1400 kJ/kg (A)</p> Signup and view all the answers

What does the effective resistance in the welding operation signify?

<p>The electrical resistance during the welding process (A)</p> Signup and view all the answers

What determines whether a sheet metal blank can be formed without failure?

<p>Material ductility and formability (B)</p> Signup and view all the answers

What is the primary mode of deformation in sheet metal forming operations?

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

When calculating the heat needed for welding, what is the mass of the welding nugget in grams?

<p>0.24 gm (A)</p> Signup and view all the answers

Which equation is used to represent the relationship between heat transferred, current, and resistance in welding?

<p>Q = I²Rt (B)</p> Signup and view all the answers

What is the primary role of the punch and die in sheet metal forming operations?

<p>To shape the blank into the desired form (B)</p> Signup and view all the answers

Flashcards

Neutral Point in Rolling

The location of the neutral point in rolling does not depend on the material of the rolls.

CNC System

A CNC system uses a computer to control multiple machine tools. It eliminates the need for tape readers as the part program is directly sent from the computer's memory.

DNC System

A DNC system connects multiple machines to a central computer, enabling efficient data transfer and control.

Machining Center

A machining center has an integrated tool changing unit and a component indexing device, allowing for complex automated machining operations.

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Die Casting vs. Investment Casting

Die casting produces parts at a high rate by injecting molten metal into a mold. Investment casting involves creating a wax pattern that is then coated and melted out, leaving a mold for casting. Both processes produce complex shapes.

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Submerged Arc Welding

Advantages of submerged arc welding include better weld quality, higher deposition rates, and less environmental impact compared to conventional open air welding.

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Hollow Lathe Spindles

Lathe spindles are hollow to allow for the passage of long workpieces and tools.

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Compression Molding

A type of molding where the plastic is softened by heating and then forced into a mold cavity.

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Injection Molding

A molding process where molten plastic is injected into a mold cavity.

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Jet Molding

A type of molding where a jet of molten plastic is forced into a mold cavity.

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Extrusion Molding

This molding process uses a die to shape the plastic material.

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Mild Steel

A type of steel used for general-purpose construction.

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Tool Steel

High-carbon steel is used in tools because of its ability to hold a sharp edge.

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Medium Carbon Steel

This medium carbon steel is used in items that require a balance of strength and ductility.

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High Carbon Steel

This steel is strong and durable, making it ideal for applications like cranes.

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Tool Steel

This steel is used to make tools that require a sharp edge.

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HAZ Size and Starting Temperature

The size of the Heat Affected Zone (HAZ) increases when the starting temperature of the material is higher.

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HAZ Size and Welding Speed

The size of the Heat Affected Zone (HAZ) is smaller when the welding speed is faster.

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HAZ Size and Thermal Conductivity

Materials that conduct heat well (like copper) have smaller HAZs compared to poor heat conductors (like steel).

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HAZ Size and Base Metal Thickness

The thicker the base metal, the larger the HAZ.

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Residual Stresses and Weldment Design

Residual stresses in welding can be influenced by the design of the welded parts.

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Residual Stresses and Support/Clamping

How components are supported and clamped during welding affects residual stresses.

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Residual Stresses and Welding Process

The specific welding process used will impact the level of residual stresses.

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Residual Stresses and Metal Deposition

The amount of metal melted or deposited during welding contributes to the magnitude of residual stresses.

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Milling Brass Cutting Speed

The cutting speed for milling brass is typically in the range of 45 to 60 meters per minute.

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Twist Drill Flute Function

The helical flute in a twist drill serves to provide space for the chip to escape during drilling.

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Which alloying element enhances steel strength at high temperatures?

Tungsten is an alloying element used to improve the strength of steel at elevated temperatures. It enhances the steel's resistance to softening and creep, allowing it to perform well under high stress conditions.

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What is the feature of a turning tool?

A turning tool has an axial relief, which is a taper on the back of the tool to prevent the tool from rubbing on the workpiece during cutting.

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What makes a reamer unique?

A reamer has flutes, which are helical grooves that help remove chips during drilling and create a precise, cylindrical hole.

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What is a crucial feature of a milling cutter?

Milling cutters have a side relief, which allows for easier chip removal and prevents the cutter from rubbing against the workpiece during machining.

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What causes chatter during milling?

Chatter in milling can occur due to lack of rigidity in the machine, fixtures, bar, or workpiece. This can cause vibrations and poor surface finish.

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What can lead to a bad surface finish in milling?

Poor surface finish during milling can be caused by a high cutting load or an insufficient amount of lubricant.

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What can cause loss of accuracy in milling?

Loss of accuracy in milling can be caused by using a high feed rate or the cutting load being too high.

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What causes cutter burrs in milling?

Cutter burrs in milling can occur if the radial relief angle on the cutting tool is too large. This can cause the cutter to wear out faster.

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What is the importance of the relief angle in a cutting tool?

The relief angle of a cutting tool affects the direction of chip flow, reduces excessive friction between the tool and workpiece, and influences tool life. A larger relief angle allows for easier chip removal and reduces friction.

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How does the relief angle on a cutting tool affect the cooling process?

A larger relief angle on a cutting tool allows for better access of coolant to the tool-workpiece interface, which can enhance the cooling and lubrication during the cutting process and prolong tool life.

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Metal Strength and Ductility with Temperature

When a solid metal heats up, its strength decreases because the atoms vibrate more, making it easier to deform. However, its ductility increases, meaning it becomes more able to bend without breaking.

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Strength of a Brazed Joint and Gap Size

A brazed joint is stronger when the gap between the joined surfaces is small. However, there's a limit. After a certain gap, the strength starts to decrease because the filler metal cannot properly bridge the gap.

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EDM for Complex Cavities

Electric Discharge Machining (EDM) is best for creating complex cavities in tough materials like high-strength alloys. It removes material by electrical sparks, making it ideal for intricate shapes.

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Continuous Path Operations in NC Machining

Continuous path operations in NC machining involve the tool moving along a continuous path. Examples include arc welding, laser cutting, and milling. These processes create continuous lines or shapes.

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Shaper Machining Time Calculation

The time taken to machine a flat surface on a shaper is determined by the length of the surface, cutting speed, feed rate, and the ratio of return time to cutting time.

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Silicon Steel

Silicon steel is an alloy of iron and silicon, known for its high magnetic permeability, making it suitable for applications like transformers, where efficient magnetization is crucial.

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High Speed Steel

High speed steel is a type of tool steel with a high amount of tungsten, molybdenum, and vanadium, enabling them to withstand high temperatures during cutting operations.

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Monel Metal

Monel metal is a nickel-copper alloy known for its resistance to corrosion, making it ideal for applications like marine bearings, where it can withstand harsh environments.

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Cold Working

Cold working refers to shaping metal at room temperature, which requires higher forces due to the metal's resistance to deformation, resulting in a better surface finish and reduced ductility.

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Limitations of Powder Metallurgy

Powder metallurgy involves producing parts from metal powders, which can limit the size and shape of parts due to pressing limitations. Additionally, porosity can be an issue.

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Cracking of Weld Metal

Cracking of weld metal is a common welding problem that occurs due to excessive stresses, which can be caused by factors like high joint rigidity or improper cooling.

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Milling

The process of removing material from a workpiece using a rotating cutter to create a desired shape.

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Peripheral milling

A type of milling where the cutter rotates around a fixed axis, while the workpiece is moved past it.

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Face milling

A type of milling where the cutter rotates at an angle to the workpiece, creating a complex surface.

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Slot milling

A type of milling where the cutter is used to create a groove or slot in the workpiece.

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End milling

A type of milling where the cutter is used to create a cylindrical shape.

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Gear milling

A type of milling where the cutter is used to cut a gear tooth profile.

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Rake angle

The angle between the face of a tool and the workpiece.

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Clearance angle

The angle between the tool flank and the workpiece.

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Plan approach angle

The angle between the tool face and the axis of rotation.

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Superplasticity

Superplasticity is a phenomenon where materials exhibit extreme ductility, allowing them to deform significantly without cracking or breaking. This occurs in fine-grained materials at elevated temperatures, typically above 0.4 times the material's melting point. The material is able to flow like a very viscous fluid with minimal strain hardening.

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Superplastic Forming (SPF)

Superplastic forming (SPF) is a manufacturing process that utilizes the superplastic behavior of materials to create complex shapes with fine details and close tolerances. It offers advantages like reduced tooling costs, lower flow stresses, and minimal residual stresses.

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Peen Forming

Peen forming is a sheet metal working process that uses shot preening to create curvatures on thin metal sheets by impacting the surface with small projectiles. It's often used in aerospace applications to form smooth and complex curvatures on aircraft wing skins.

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Limiting Strain Rate in Superplasticity

Superplastic materials exhibit a limiting strain rate beyond which they are no longer superplastic. This means that the rate at which they deform needs to be slow enough to maintain the superplastic behavior.

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Examples of Superplastic Materials and Forming Techniques

Common superplastic materials include Zn-22Al (zinc-aluminum alloy) and Ti-6Al-4V (titanium alloy). These materials can be formed using various methods like forging, coining, extrusion, and sheet forming techniques like thermo-forming, vacuum forming, and blow molding.

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Powder Metallurgy

The process of making objects from metal powders by compressing and sintering them. It's a cost-effective way to create complex shapes with precise dimensions.

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Metal Removal Rate

The rate at which metal is removed from a workpiece during machining. It's calculated by multiplying the cutting speed, feed rate, and depth of cut.

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Turning

A manufacturing process that uses a rotating cutting tool to remove material from a workpiece, creating a specific shape or dimension.

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Annealing

The process of heating a material above its critical temperature and then cooling it slowly. It's used to soften metals and improve their ductility.

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Die Casting

A type of mold used in metal casting, where the molten metal is poured into a reusable mold cavity.

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Depth of Cut

The distance between the tool and the workpiece during machining. It affects the surface finish and the accuracy of the cut.

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Welding Nugget Volume

The volume of material removed during welding, which is calculated using the diameter and thickness of the weld nugget.

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Heat Required for Welding

The amount of heat required to melt the weld nugget, calculated by multiplying the nugget's mass by the latent heat of fusion of the metal.

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Joule's Heating Law

The relationship between heat, current, resistance, and time in a welding circuit.

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Velocity at the Bottom of the Sprue

The speed at which molten metal flows through the sprue, calculated using the acceleration due to gravity and the sprue's height.

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Sheet Metal Formability

The ability of a sheet metal to be formed into a desired shape without failure.

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Sheet Metal Deformation Modes

The two primary modes of deformation during sheet metal forming, stretching and bending.

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Punch & Die

The tools used in sheet metal forming to shape the blank, typically consisting of a punch that presses on the material and a die that provides the shape.

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Time to Fill Mold Cavity

The amount of time it takes to fill the mold cavity, determined by the volume of the cavity, the sprue's cross-sectional area, and the velocity of the molten metal.

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Description

Test your knowledge on NC machine tools, welding techniques, and machining methods with this quiz. Explore topics such as tool changing systems, casting methods, and the properties of metals at various temperatures. Perfect for students in mechanical engineering or manufacturing engineering.

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