1- The basic and most common milling machine is the:

A. Bed type milling

B. Knee-and column milling
C. Tracer milling
D. Planner milling

2- A vertical milling machine is more appropriate than a horizontal milling machine for:

A. Surface contouring
B. Slab milling
C. Peripheral milling
D. Plain milling

3- Which of the following tools cannot be used on a lathe machine:

A. Broach
B. Cutoff tool
C. Drill bit
D. Threading tool

4- In turning operation, change in diameter of the work piece is equal to:

A. 1 x depth of cut
B. 2 x depth of cut
C. 1 x feed
D. 2 x feed

5- A lathe machine can do which of the following operations:

A. Broaching
B. Planning
C. Milling
D. Boring

6- Machining is known for which one of the following relative to other manufacturing
process:

A. Creates 3D geometry
B. Good dimensional accuracy
C. Near net shape process
 D. Wasteful of energy

7- With which of the following geometric forms is the turning operation most closely
associated in cutting:

A. Cylindrical shape
B. Reaming
C. Countersinking
D. Pocketing

8- A finishing operation generally involves which one of the following combination of

cutting conditions (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

9- The mechanism of chip formation in machining is best described by:

A. Compression failure
B. Fracture failure
C. Shear failure
D. Tensile failure

10- Which type of the chip is expected in a turning operation conducting at low speed
on a brittle material:

A. Continuous B. continuous with build up edge C. discontinuous D. serrated

11- Gradual wear is the preferred mode for tool failure because:

A. It’s premature tool failure

B. The cutting temperature becomes very high
C. It results in a long tool life
D. The cutting force is very high

12- To drill a 150 mm diameter hole use:

A. Spade drill
B. Gun drill
C. Twist drill
D. Straight flute drill
 13- A very thin coating on a tool insert is produced by:

A. Chemical vapor deposition

B. Sintering
C. Electroplating
D. Polishing

14- Boring operation is done after:

A. Drilling
B. Shaping
C. Straight turning
D. Taper turning

15- A weld can be inspected without damaging the specimen by:

A. Shear test
B. Peel test
C. Bend test
D. Magnetic particle test

:Welding process to create a narrow and deep weld is )16

a. electroslag welding
b. electron beam welding
c. electrogas welding
d. plasma arc welding

which of the following operation done on lathe machine isnot a metal cutting )18
:operation
a. knurling
b. threading
c. taper turning
d. reaming

: … a single point cutting tool is used )19

a. Drilling
b. Milling
c. turning
d. broaching
of the following cutting conditions which one has the greatest effect on cutting )20
: .temp
a. cutting speed
 b. depth of cut
c. feed
d. none of the above
in the multiple cutting-edge tools, the cutting speed is achieved by the rotation )21
of the workpiece
A. True B. false
in the cutting operation, the cutting force and energy dissipated in the cutting )22
.process are considered
A. True B. false
in the cutting operation, the shear plane angle can be increased by increasing )23
.the coefficient of friction in the cutting zone
A. True B. false
.argon is a common gas used for shielding in arc welding )24
A. True B. false
.flux cannot be used if shielding gas is used in arc welding process )25
A. True B. false

.Both electroslag and electrogas welding can be used for joining vertical plates )26
A. True B. false
tungsten or molybdenum are the major alloying elements in high speed steel )27
.tool material
A. True B. false
increase of cobalt content in carbide tools increases their hardness and wear )28
.resistance
A. True B. false
ceramic tools are prepared by sintering and pressing Al2O2 at high pressure and )29
.temp
A. True B. false
.the twist drill is usually made of carbide )30
A. True B. false

Chapter 17 THEORY OF METAL MACHINING (Multiple Choice Quiz)

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
true (b) false )a(

Which of the following manufacturing processes are classified as material removal

:processes (two correct answers)
grinding (b) machining (c) casting (d) drawing (e) extrusion (f) forging )a(
molding (h) press working (i) spinning )g(
 :Which of the following are the three most common machining operations
broaching (b) drilling (c) lapping (d) milling (e) planning (f) shaping )a(
turning )g(

Machining is noted for which of the following characteristics relative to other

:manufacturing processes (two best answers)
creates three-dimensional geometries (b) good dimensional accuracy (c) net )a(
shape process (d) poor surface finish (e) wasteful of energy (f) wasteful of material

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

broaching (b) drilling (c) lapping (d) milling (e) turning )a(

With which one of the following geometric forms is the turning operation most closely
associated: (a) external cylinder (b) flat plane (c) round hole (d) screw threads
(e) sphere

:A single-point cutting tool is used for which one of the following operations
drilling (b) milling (c) turning )a(

A roughing operation generally involves which one of the following combinations of

:cutting conditions
high v, f, and d (b) high v, low f and d (c) low v, high f and d )a(
?low v, f, and d where v = cutting speed, f = feed, and d = depth of cut )d(

The mechanism of chip formation in machining is best described by which one of the
following: (a) compression (b) fracture failure (c) shear deformation (d) tensile
failure

Which of the following are characteristics of the orthogonal cutting model (three best
:answers)
a circular cutting edge is used (b) a multiple-cutting-edge tool is used )a(
a single-point tool is used (d) only two dimensions play an active role in the )c(
analysis
the cutting edge is parallel to the direction of cutting speed )e(
the cutting edge is perpendicular to the direction of cutting speed )f(
 the two elements of tool geometry are rake angle and relief angle )g(

:The chip thickness ratio in orthogonal cutting is which one of the following
tc/to (b) to/tc (c) to/w )a(
where tc = chip thickness after the cut, to = chip thickness before the cut, and w =
?width of cut

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
continuous (b) continuous with built-up edge (c) discontinuous (d) serrated )a(

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)
decrease in friction angle (b) decrease in power requirements )a(
decrease in shear plane angle (d) increase in cutting temperature )c(
increase in shear plane angle )e(

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
depth of cut d (b) feed f (c) speed v )a(

Specific energy in metal machining is a measure of the amount of energy required to

:remove a unit volume of material
?true (b) false )a(

Which one of the following metals would usually have the lowest specific energy in a
:machining operation
aluminum (b) brass (c) cast iron (d) steel )a(

Which one of the following cutting conditions has the strongest effect on cutting
:temperature
cutting speed (b) depth of cut (c) feed )a(
Chapter 18 MACHINING OPERATIONS AND MACHINE TOOLS (Multiple
Choice)
Machined parts can be classified as rotational or nonrotational. Which of the following
:are examples of operations that create nonrotational geometries (two best answers)
boring (b) drilling (c) milling (d) planing (e) turning )a(

Which of the following are examples of generating the work part geometry in
:machining, as opposed to forming the geometry (two best answers)
broaching (b) contour turning (c) drilling (d) profile milling (e) thread )a(
cutting

In a turning operation, the change in diameter of the work part is equal to which one
:of the following
?1 x depth of cut (b) 2 x depth of cut (c) 1 x feed (d) 2 x feed )a(

A lathe can be used to perform which of the following machining operations (three
:correct answers)
boring (b) broaching (c) drilling (d) milling (e) planing (f) turning )a(

:A facing operation is normally performed on which one of the following machine tools
drill press (b) lathe (c) milling machine (d) planer (e) shaper )a(

Boring and reaming share the common feature that they are both used to enlarge an
existing hole: (a) true (b) false

:Knurling is performed on a lathe, but it is not a metal cutting operation

true (b) false )a(

A live center is one way of holding a workpiece in the headstock of a lathe, whereas a
:dead center is used to hold the work in the tailstock
true (b) false )a(

:Which one of the following cutting tools cannot be used on a turret lathe
broach (b) cutoff tool (c) drill bit (d) single-point turning tool (e) threading )a(
tool
 :Which one of the following turning machines permits very long bar stock to be used
chucking machine (b) engine lathe (c) screw machine (d) speed lathe (e) )a(
turret lathe

Most vertical boring machines are equipped for both turning and boring and are used
:for large, heavy work parts with large diameters
true (b) false )a(

:The twist drill is the most common type of drill bit

true (b) false )a(

When the drill bit in a drilling operation exits the opposite side of the work, the
:resulting hole is called which one of the following
a blind hole (b) a through hole )a(

:A tap is a cutting tool used to create which one of the following geometries
external threads (b) flat planar surfaces (c) holes used in beer kegs (d) )a(
internal threads (e) square holes

:Reaming is used for which of the following functions (three correct answers)
accurately locate a hole position (b) create a stepped hole (c) enlarge a drilled )a(
hole
improve surface finish on a hole (e) improve tolerance on hole diameter )d(
?provide an internal thread )f(

The distinguishing feature between a drilling fixture and a drill jig is that the fixture
:provides a means of guiding the tool during the hole-making operation
true (b) false )a(

Which of the following are classified as peripheral milling rather than face milling
:(three best answers)
end milling (b) plain milling (c) pocket milling (d) slab milling (e) straddle )a(
milling
surface contouring )f(
 The difference between up milling and down milling is that in down milling the
direction of motion of the cutter teeth is opposite the feed direction when the teeth
:cut into the work
true (b) false )a(

A vertical milling machine is more appropriate than a horizontal milling machine for
:performing which of the following types of operations (three best answers)
end milling (b) face milling (c) peripheral milling (d) plain milling (e) slab )a(
milling
surface contouring )f(

:The basic milling machine is which one of the following

bed type (b) knee-and-column (c) profiling mill (d) ram mill )a(
universal milling machine )e(

Typical operations performed on a machining center include which of the following

:(two best answers)
boring (b) drilling (c) milling (d) sawing (e) turning )a(

:A planing operation is best described by which one of the following

a single-point tool moves linearly past a stationary work part )a(
a tool with multiple teeth moves linearly past a stationary work part )b(
a work part is fed linearly past a rotating cutting tool )c(
a work part moves linearly past a single-point tool )d(

:A broaching operation is best described by which one of the following

a rotating tool moves past a stationary work part )a(
a tool with multiple teeth moves linearly past a stationary work part )b(
a work part is fed past a rotating cutting tool )c(
a work part moves linearly past a stationary single-point tool )d(

The three basic types of sawing, according to type of blade motion involved, are which
:of the following
abrasive cutoff (b) bandsawing (c) circular sawing (d) contouring )a(
friction sawing (f) hacksawing (g) slotting )e(
 Which one of the following terms is used for cutting external threads using self-
:opening threading dies
tapping (b) thread chasing (c) thread forming (d) thread milling )a(

:Gear hobbing is a special form of which one of the following machining operations
grinding (b) milling (c) planing (d) shaping (e) turning )a(

Chapter 19 CUTTING TOOL TECHNOLOGY Multiple Choice Quiz

one of the three possible modes by which a cutting tool can fail during a machining
:operation, which one is most preferable
fracture failure (b) gradual wear (c) temperature failure )a(

:Which of the following are the two main types of gradual wear on a cutting tool
clearance wear (b) crater wear (c) flank wear (d) nose wear (e) notch wear )a(

The basic Taylor tool life equation defines the relationship between which two of the
:following variables
cutting speed (b) depth of cut (c) feed (d) feed rate (e) tool life )a(
work material hardness )f(

:Of the following cutting conditions, which one has the greatest effect on tool wear
cutting speed (b) depth of cut (c) feed )a(

Which of the following are the three most important properties of a tool material that
:are suggested by the three modes of tool failure
ductility (b) hot hardness (c) impact resistance (d) tensile strength (e) )a(
toughness
wear resistance )f(

As an alloying ingredient in high-speed steel, tungsten serves which of the following

:functions (two best answers)
depth hardenability during heat treatment (b) forms hard carbides to resist )a(
abrasion
improves strength and hardness (d) increases corrosion resistance (e) increases )c(
hot hardness
increases toughness )f(

As an alloying ingredient in high-speed steel, chromium serves which of the following

:functions (three best answers)
depth hardenability during heat treatment (b) forms hard carbides to resist )a(
abrasion
improves strength and hardness (d) increases corrosion resistance )c(
increases hot hardness (f) increases toughness )e(

Cast cobalt alloys typically contain which of the following as their main ingredients
:(three best answers)
aluminum (b) cobalt (c) chromium (d) iron (e) nickel (f) steel (g) )a(
tungsten

Which of the following is not a common ingredient in cemented carbide cutting tools
:(two correct answers)
Al2O3 (b) Co (c) CrC (d) TiC (e) WC )a(

An increase in cobalt content has which of the following effects on WC-Co cemented
:carbides (two best answers)
decreases hardness (b) decreases transverse rupture strength (c) increases )a(
hardness
increases toughness (e) increases wear resistance )d(

Steel-cutting grades of cemented carbide are typically characterized by which of the

:following ingredients (three correct answers)
Co (b) CrC (c) Mo (d) Ni (e) TiC (f) WC )a(

If you had to select a cemented carbide for an application involving finish turning of
:steel, which C-grade would you select (one best answer)
C1 (b) C3 (c) C5 (d) C7 )a(

Which of the following processes are used to provide very thin coatings on the surface
:of coated carbide inserts (two best answers)
chemical vapor deposition (b) electroplating (c) physical vapor deposition )a(
 pressing and sintering (e) spray painting )d(

:Which one of the following materials has the highest hardness

aluminum oxide (b) cubic boron nitride (c) high-speed steel (d) titanium )a(
carbide
tungsten carbide )e(

:Most ceramic cutting tools are fabricated from which one of the following materials
aluminum oxide (b) cubic boron nitride (c) titanium carbide (d) titanium )a(
nitride
tungsten carbide )e(

Sialon is a cutting tool material containing which of the following as its principal
:ingredients (two correct answers)
aluminum oxide (b) cubic boron nitride (c) silicon carbide (d) silicon nitrid )a(
?titanium nitride (e) tungsten carbide )e(

How many elements of tool geometry are required to completely specify a single-point
:tool (one correct answer)
two (b) five (c) seven (d) eight (e) ten )a(

Chip breakers are frequently used with single-point tools. They work by forcing the
chips to curl more tightly than they would naturally be inclined to curl, thus causing
:them to fracture
?true (b) false )a(

Which of the following drill types would be the most likely choice to drill a hole with a
:100 mm (4.0 in) diameter (one best answer)
gun drill (b) spade drill (c) straight-flute drill (d) twist drill )a(

Which of the following are the two main functions of a cutting fluid in machining (two
:best answers)
improve surface finish on the workpiece (b) reduce forces and power )a(
reduce friction at the tool-chip interface (d) remove heat from the process )c(
wash away chips )e(
CHAPTER 26
 The feature that distinguishes fusion welding from solid-state welding is that
melting of the faying surfaces occurs during fusion welding but not in solid-state
:welding
true (b) false )a(

Which of the following processes are classified as fusion welding (three correct
:answers)
electrogas welding (b) electron-beam welding (c) explosion welding )a(
forge welding (e) laser-beam welding (f) ultrasonic welding )d(

Which of the following processes are classified as solid-state welding (three correct
:answers)
cross-wire welding (b) diffusion welding (c) friction welding )a(
pressure gas welding (e) resistance seam welding (f) roll welding )d(
stud welding )g(

Electrodes used in arc welding processes are classified as consumable or

nonconsumable. Filler metal is always added when consumable electrodes are used
:and never added when nonconsumable electrodes are used
true (b) false )a(

An electric arc is a discharge of current across a gap in an electrical circuit. The arc
is sustained in arc welding processes by the transfer of molten metal across the gap
:between the electrode and the work
true (b) false )a(

:Which two of the following are common gases used for shielding in arc welding
argon (b) carbon monoxide (c) fluorine (d) flux (e) helium )a(
hydrogen (g) nitrogen )f(

Which one of the following arc welding processes has the lowest heat transfer
:factor
FCAW (b) GMAW (c) GTAW (d) SMAW )a(

:Which one of the following arc welding processes uses a nonconsumable electrode
FCAW (b) GMAW (c) GTAW (d) SMAW )a(
 MIG welding is a term sometimes applied when referring to which one of the
:following processes
FCAW (b) GMAW (c) GTAW (d) SMAW )a(

Stick" welding is a term sometimes applied when referring to which one of the"
:following processes
FCAW (b) GMAW (c) GTAW (d) SMAW )a(

Which one of the following arc welding processes uses an electrode consisting of
:continuous consumable tubing containing flux and other ingredients in its core
FCAW (b) GMAW (c) GTAW (d) SMAW )a(

Which one of the following arc-welding processes produces the highest

:temperatures
CAW (b) PAW (c) SAW (d) TIG welding )a(

Resistance-welding processes make use of the heat generated by electrical resistance

to achieve fusion of the two parts to be joined; no pressure is used in these
:processes, and no filler metal is added
true (b) false )a(

Metals that are easiest to weld in resistance welding are ones that have low
:resistivities since low resistivity assists in the flow of electrical current
true (b) false )a(

The rate of heat energy supplied in a resistance spot welding operation is

:determined by which one of the following equations
RH = ERt (b) RH = E2R (c) RH = IR (d) RH = I^2R (e) RH = I^2Rt )a(
where RH =rate of heat energy, E = voltage, I = current, R = resistance, and t =
?time

The fused zone between the two parts in a resistance spot welding operation is
:called which one of the following
 weld contact (b) weld fillet (c) weld nugget (d) weld seam (e) weld )a(
spot

Oxyacetylene welding is the most widely used oxyfuel welding process because
acetylene mixed with an equal volume of oxygen burns hotter than any other
:commercially available fuel
true (b) false )a(

:"The term "laser" stands for "light actuated system for effective reflection
true (b) false )a(

Thermite used in thermit welding is a mixture of which two of the following powder
:ingredients
aluminum (b) aluminum oxide (c) iron oxide (d) magnesium )a(
nitroglycerine (f) potassium nitrate )e(

Friction stir welding is a fusion welding process in which a rotating tool is fed along
the joint line between two workpieces, generating friction heat and mechanically
:stirring the metal to form the weld seam
true (b) false )a(

Which of the following solid-state welding processes applies heat from an external
:source (two best answers)
diffusion welding (b) forge welding (c) friction welding (d) ultrasonic )a(
welding

The term weldability takes into account not only the ease with which a welding
:operation can be performed, but also the quality of the resulting weld
true (b) false )a(

:Copper is a relatively easy metal to weld because its thermal conductivity is high
true (b) false )a(
 :Which of the following processes are classified as fusion welding
diffusion welding (b) friction welding (c) pressure gas welding )a(
resistance welding (e) roll welding )d(

Ch.17
Which of the following manufacturing processes are classified as material removal
processes (two
:)correct answers
casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) )a(
?molding, (h) pressworking, and (i) spinning

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

(a) broaching, (b)drilling, (c) lapping, (d) milling, or (e) turning

With which one of the following geometric forms is the drilling operation most
closely associated: (a) external cylinder, (b) flat plane, (c) round hole, (d) screw
?threads, or (e) sphere

If the cutting conditions in a turning operation are cutting speed = 300 ft/min, feed =
0.010 in/rev, and depth of cut = 0.100 inch, which one of the following is the
:material removal rate
(a) 0.025 in3 /min, (b) 0.3 in3 /min, (c) 3.0 in3 /min, or (d) 3.6 in3 /min?

A roughing operation generally involves which one of the following combinations of

:cutting conditions
(a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d,
where v = cutting speed, f = feed, and d = depth?

Which of the following are characteristics of the orthogonal cutting model (three
:best answers)
a circular cutting edge is used, (b) a multiple-cutting-edge tool is used, (c) a )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, and (g) the two elements of tool
?geometry are rake and relief angle
 :The chip thickness ratio is which one of the following
tc/to, (b) to/tc, (c) f/d, or (d) to/w, where tc = chip thickness after the cut, to = )a(
?chip thickness before the cut, f = feed, d = depth, and w = width of cut

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
?continuous, (b) continuous with built-up edge, (c) discontinuous, or (d) serrated )a(

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)
decrease in friction angle, (b) decrease in power requirements, (c) decrease in )a(
shear plane angle, (d) increase in cutting temperature, and (e) increase in shear
plane angle

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
depth of cut d, (b) feed f, or (c) speed v )a(

Which one of the following metals would usually have the lowest unit horsepower in
:a machining operation
?aluminum, (b) brass, (c) cast iron, or (d) steel )a(

For which one of the following values of chip thickness before the cut to would you
:expect the specific energy in machining to be the greatest
0.010 inch, (b) 0.025 inch, (c) 0.12 mm, or (d) 0.50 mm )a(

Which of the following cutting conditions has the strongest effect on cutting
:temperature
feed or (b) speed )a(

Ch.18

Which of the following are examples of generating the workpart geometry in

:machining, as opposed to forming the geometry (two best answers)
broaching, (b) contour turning, (c) drilling, (d) profile milling, and (e) thread )a(
cutting
In a turning operation, the change in diameter of the workpart is equal to which one
:of the following
?1 x depth of cut, (b) 2 x depth of cut, (c) 1 x feed, or (d) 2 x feed )a(

A lathe can be used to perform which of the following machining operations (three
:correct answers)
?boring, (b) broaching, (c) drilling, (d) milling, (e) planing, and (f) turning )a(

A facing operation is normally performed on which one of the following machine

:tools
drill press, (b) lathe, (c) milling machine, (d) planer, or (e) shaper )a(

Knurling is performed on a lathe, but it is not a metal cutting operation: (a) true or
?(b) false
Answer. (a). It is a metal forming operation

:Which one of the following cutting tools cannot be used on a turret lathe
broach, (b) cutoff tool, (c) drill bit, (d) single-point turning tool, or (e) threading )a(
?tool

:Which one of the following turning machines permits very long bar stock to be used
chucking machine, (b) engine lathe, (c) screw machine, (d) speed lathe, or (e) )a(
turret lathe

(a) true or (b) false The twist drill is the most common type of drill bit:

:A tap is a cutting tool used to create which one of the following geometries
external threads, (b) flat planar surfaces, (c) holes used in beer kegs, (d) internal )a(
threads, or (e) square holes

:Reaming is used for which of the following functions (three correct answers)
accurately locate a hole position, (b) enlarge a drilled hole, (c) improve surface )a(
finish on a hole, (d) improve tolerance on hole diameter, and (e) provide an internal
thread

:End milling is most similar to which one of the following

face milling, (b) peripheral milling, (c) plain milling, or (d) slab milling )a(
 :The basic milling machine is which one of the following
bed type, (b) knee-and-column, (c) profiling mill, (d) ram mill, or (e) universal )a(
milling machine

:A planing operation is best described by which one of the following

a single-point tool moves linearly past a stationary workpart, (b) a tool with )a(
multiple teeth moves linearly past a stationary workpart, (c) a workpart is fed
linearly past a rotating cutting tool, or (d) a workpart moves linearly past a single-
point tool

:A broaching operation is best described by which one of the following

a rotating tool moves past a stationary workpart, (b) a tool with multiple teeth )a(
moves linearly past a stationary workpart, (c) a workpart is fed past a rotating cutting
tool, or (d) a workpart moves linearly past a stationary single-point tool

The three basic types of sawing, according to type of blade motion involved, are
abrasive cutoff, (b) bandsawing, (c) circular sawing, (d) contouring, (e) friction )a(
sawing, (f) hacksawing, and (g) slotting

:Gear hobbing is a special form of which one of the following machining operations
grinding, (b) milling, (c) planing, (d) shaping, or (e) turning )a(

Ch.19

:Of the following cutting conditions, which one has the greatest effect on tool wear
cutting speed, (b) depth of cut, or (c) feed )a(

As an alloying ingredient in high-speed steel, tungsten serves which of the following

:functions (two best answers)
forms hard carbides to resist abrasion, (b) improves strength and hardness, (c) )a(
increases corrosion resistance, (d) increases hot hardness, and (e) increases
toughness

Cast cobalt alloys typically contain which of the following main ingredients (three
:best answers)
aluminum, (b) cobalt, (c) chromium, (d) iron, (e) nickel, (f) steel, and (g) tungsten )a(

Which of the following is not a common ingredient in cemented carbide cutting tools
:(two correct answers)
Al2O3, (b) Co, (c) CrC, (d) TiC, and (e) WC )a(
An increase in cobalt content has which of the following effects on WC-Co cemented
:carbides (two best answers)
decreases hardness, (b) decreases transverse rupture strength, (c) increases )a(
hardness, (d) increases toughness, and (e) increases wear resistance

Steel-cutting grades of cemented carbide are typically characterized by which of the

:following ingredients (three correct answers)
Co, (b) Fe, (c) Mo, (d) Ni, (e) TiC, and (f) WC )a(

If you had to select a cemented carbide for an application involving finish turning of
:steel, which C-grade would you select (one best answer)
C1, (b) C3, (c) C5, or (d) C7 )a(

Which of the following processes are used to provide the thin coatings on the
:surface of coated carbide inserts (two best answers)
chemical vapor deposition, (b) electroplating, (c) physical vapor deposition, (d) )a(
pressing and sintering, and (e) spray painting

:Which one of the following materials has the highest hardness

aluminum oxide, (b) cubic boron nitride, (c) high-speed steel, (d) titanium )a(
carbide, or (e) tungsten carbide

Which of the following are the two main functions of a cutting fluid in machining
:(two best answers)
improve surface finish on the workpiece, (b) reduce forces and power, (c) reduce )a(
friction at the tool-chip interface, (d) remove heat from the process, and (e) wash
away chips

Ch.26

The feature that distinguishes fusion welding from solid-state welding is that melting
(a) of the faying surfaces occurs during fusion welding but not in solid-state welding:
true or (b) false

Which of the following processes are classified as fusion welding (three correct
:answers)
electrogas welding, (b) electron-beam welding, (c) explosion welding, (d) forge )a(
welding, (e) laserbeam welding, and (f) ultrasonic welding
 Which of the following processes are classified as fusion welding (two correct
:answers)
diffusion welding, (b) friction welding, (c) pressure gas welding, (d) resistance )a(
welding, and (e) roll welding

Which of the following processes are classified as solid-state welding (three correct
:answers)
diffusion welding, (b) friction stir welding, (c) resistance spot welding, (d) roll )a(
welding, (e) thermit welding, and (f) upset welding

An electric arc is a discharge of current across a gap in an electrical circuit. The arc is
sustained in arc welding processes by the transfer of molten metal across the gap
between the electrode and the work: (a) true or (b) false
Answer. (b). The arc is sustained, not by the transfer of molten metal, but by the
presence of a thermally ionized column of gas through which the current flows

:Which one of the following arc welding processes uses a nonconsumable electrode
FCAW, (b) GMAW, (c) GTAW, or (d) SMAW )a(

MIG welding is a term sometimes applied when referring to which one of the
:following processes
FCAW, (b) GMAW, (c) GTAW, or (d) SMAW )a(

Stick" welding is a term sometimes applied when referring to which one of the "
:following processes
FCAW, (b) GMAW, (c) GTAW, or (d) SMAW )a(

Which one of the following AW processes uses an electrode consisting of continuous

:consumable tubing containing flux and other ingredients in its core
FCAW, (b) GMAW, (c) GTAW, or (d) SMAW )a(

Which one of the following arc-welding processes produces the highest

:temperatures
CAW, (b) PAW, (c) SAW, or (a) TIG welding )a(

Resistance-welding processes make use of the heat generated by electrical

resistance to achieve fusion of the two parts to be joined; no pressure is used in
:these processes, and no filler metal is added
true or (b) false )a(
 Answer. (b). Pressure is applied in RW processes and is key to the success of these
.processes

Metals that are easiest to weld in resistance welding are ones that have low
:resistivities since low resistivity assists in the flow of electrical current
?true or (b) false )a(
Answer. (b). Metals with low resistivities, such as aluminum and copper, are difficult
to weld in RW. Higher resistance is required in the conversion of electrical power to
heat energy; hence, metals with high resistivity are generally preferable

Oxyacetylene welding is the most widely used oxyfuel welding process because
acetylene mixed with an equal volume of oxygen burns hotter than any other
:commercially available fuel
true or (b) false )a(

(a) The term "laser" stands for "light actuated system for effective reflection":
?true or (b) false
Answer. (b). Laser stands for "light amplification by stimulated emission of
.".radiation

Which of the following solid-state welding processes applies heat from an external
:source (two best answers)
diffusion welding, (b) forge welding, (c) friction welding, and (d) ultrasonic )a(
welding

The term weldability takes into account not only the ease with which a welding
(a) true or operation can be performed, but also the quality of the resulting weld:
(b) false

:Copper is a relatively easy metal to weld because its thermal conductivity is high
?true or (b) false )a(
Answer. (b). True that copper has a high thermal conductivity, one of the highest of
any metal, but this is one of the main reasons why copper is generally difficult to
weld. The heat readily flows into the body of the parts that are to be welded, rather
.than remaining at the localized region where the joint is to be made
Problem 1: Check the correct answer in the following statements
by putting

1 In a casting process, fluidity of molten metals is increased by:

Increasing cooling rate of casting mold 
increasing the roughness of the internal channels of the casting mold 
Increasing the viscosity of the molten metal. 
Increasing the pouring temperature

2 Plaster mold casting cannot be used for which of the following

metals:
Steel
 Aluminum 
Copper 
Magnesium

3 Turbulence during pouring of the molten metal is undesirable for

which of the following reasons:
It causes discoloration of the mold surfaces
 It dissolves the binder used to hold together the sand mold 
It increases erosion of the mold surfaces 
It increases total solidification time

4 A pouring cup in a mold is used to:

Maximize volume flow rate
 Minimize splash and turbulence 
Minimize solidification time 
Maximize dendritic growth

5 Which of the following risers has the disadvantage of allowing

more heat to escape during casting:
Blind side riser
Open top riser 
Blind top riser 
 None of the above

6 The difference between the pouring temperature and melting

temperature during the casting process is known as:
Superheat 
Liquidus temperature 
Solidus temperature
 Eutectic temperature

7 For which one of the following reasons is a green mold named: 

green is the color of the mold,
Moisture is contained in the mold
The mold is cured
The mold is dry

8 Given that weight of the molten metal displaced by a core, and

W. = weight of the core. The buoyancy force is given by which one
of the following:
Downward force= Wm +Wc
Downward force = Wm.-Wc
Upward force = Wm. +Wc.
Upward force = Wm.-Wc

9 Which one of the following casting processes belongs to the

expendable mold operations
True centrifugal casting
Die casting
Permanent mold casting
Sand casting

10 Shell molding is best described by which one of the following:

Casting operation in which the molten metal has been poured out after a thin
shell has been solidified in the mold,
Casting process in which mold is a thin shell of sand bonded by a
thermosetting resin
Sand-casting operation in which the pattern is a shell rather than a solid form,
Casting operation used to make artificial sea shells

11 Investment casting is also known by which one of the following

names:
fast-payback molding,
full-mold process,
lost-foam process,
lost-wax process

12 Which one of the following is advantage of die casting over

sand casting
Better surface finish
Higher melting temperature metals can be cast
lower production rates
Larger parts can be cast

13 Which one of the following is the name of the casting process in

which molten metal is poured into a rotating mold to produce a
tubular part:
centrifuge casting
semicentrifugal casting
true centrifugal casting
squeeze casting

14 Cupolas are furnaces used to melt which of the following metals

aluminum
cast iron
steel
zinc

15 A misrun is defined by which of the following defects in casting:

globules of metal becoming entrapped in the casting,
metal is not properly poured into the downsprue,
metal solidifies before filling the cavity,
microporosity

Problem 2: Indicate whether the following statements are true (T)

or false (F):
a) Fusion welding processes use heat to melt the base metals. T
b) An autogenous weld is described as a fusion-welding operation in which
filler metal is added. F
c) A filler metal is usually utilized in solid state welding F
d) A fillet weld has a cross-sectional shape that is approximately triangular. T
e) A fillet weld is used to join a butt type joint. F
f) Groove welds are most closely associated with corner type joints. F
g) A surfacing weld is not used to join parts, but rather to deposit filler metal
onto the surface of a base part in one or more weld beads. T
h) For metallurgical reasons, it is desirable to melt the weld metal with
minimum energy input. For that, low power density is preferable. F
i) Oxyfuel welding generates a higher power density compared to arc welding.
F
j) The chemical composition in the heat-affected zone is the same as the base
metal T

Term 161
A finishing operation generally involves which one of the following combination -1
.of cutting parameters: 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, f and d
D. low v, high f and d

:Boring is a machining operation carried out on a work part to -2

A. produce a round hole
B. enlarge an existing hole
C. produce a cross-hatched pattern
D. produce a flat surface

:The basic milling machine is which one of the following -3

A. Bed type
B. Knee and column
C. profiling mill
D. universal milling machine

:For a better tolerance, holes made by drilling process are often finished by -4
A. grinding
B. Milling
C. shaping
D. reaming
In a turning operation, the change in diameter of the work piece is equal to which -5
:one of the following
A. 1 x depth of cut
B. 2x depth of cut
C. 1 x feed
D. 2 x feed

:Which of the following operations does not create a shape by forming -6

.A. external threading
.B. drilling
.C. broaching
.D. straight turning

Which one of the four types of chip would be expected in a turning operation -7
?conducted at low cutting speed on a brittle work material
A. Continuous
B. continuous with built-up edge
C. discontinuous
D. serrated

The mechanism of chip formation in machining is best described by which one of -8

:the following
A. compression
B. fracture failure
C. shear deformation
D. tensile failure

:Most heat generated in machining is carried away by -9

A. cutting tool
B. finished part
C. machine tool
D. Chip

Which one of the following metals would usually have the lowest specific energy -10
?in a machining operation
A. carbon steel
B. cast iron
C. stainless steel
D. aluminum

Which one of the following cutting conditions has the strongest effect on cutting -11
?temperature
A. cutting speed
.B. feed rate
C. depth of cut
D. tool noise radius

Chip breaker provides obstruction to the chip flow creating a substantial change in -12
:the curvature of the chip. This cause a continuous chip to break because it becomes
A. softer
B. weaker
C. stronger and brittle (not sure)
D. more ductile

:Water is used as the base in coolant type cutting fluid due to its -13
A. low specific heat & thermal conductivity
B. high specific heat & thermal conductivity
C. good electrical conductivity
D. good lubricating property

:Notch wear on a tool is a type of -14

A. crater wear
B. flank wear
C. both crater and flank wear
D. sheek wear

As compared to machining with cutting fluid, chip removal will be _______ -15
.during dry machining
A. difficult
B. easy
C. similar
D. none of the above

:Ceramic tools are most commonly produced from -16

A. tungsten carbide
B. titanium nitride
C. aluminum oxide
D. cubic boron nitride

:Most common method of applying cutting fluid is -17

A. mist
B. flooding
C. deliver through a hole in the cutting tool
D. manual application through brush

by adding tungsten to high speed steel tool material which of the following -18
:property is enhanced
A. toughness
B. hot hardness
C. strength
D. creep

:Which of the following is not a criteria used to measure tool life -19
A. finger nail test
B. degradation of surface finish
C. work piece count
D. type of machine cutting fluid

:Chip breaker are frequently used on -20

A. single point tools
B. Multiple point tools
C. twist drill
D. reaming tool
True or False: (please check questions marked * )
Stress applied in most metal forming operations are tensile (F) -1

The most desirable property of the work material in metal forming is its high -2
tensile strength and low ductility (F)

Extrusion and forging are bulk deformation processes -3*

The starting work geometry in sheet metal processes has a high volume to area -4
ratio (F)

The flow curve expresses the behavior of a metal in plastic region (F) -5

The average flow stress is the flow stress multiplied by a factor 1/(1+n) where n is -6*
the strain-hardening exponent

Hot working of metals refers to following temperature regions relative to the -7*
melting point of the given metal 0.2Tm ----- 04Tm where Tm = melting temperature
on an absolute temperature scale

Increasing strain rate tens to decreases flow stress -8*

The coefficient of friction between the part and the tool in cold working tends to -9*
be higher, than its value in hot working

One of the advantage of characteristic of hot working relative to cold working is -10*
that it consumes less overall energy to achieve the deformation

Term 142
Machining is generally performed after other manufacturing process, such as -6
:casting in order to provide
A. the general shape of the work part
B. the final geometry, dimensions, and finish of the work part
C. the semi-finish state of the work part
D. the near net shape of the work part

In turning operation, material removal is carried out using -7

A. a cutting tool with single cutting edge
B. a cutting tool with two cutting edges
C. a cutting tool with multiple cutting edges
D. a cutting tool with a dull edge

:The three dimensions of the machining process, called cutting conditions, are the -8
A. shear angle, rake angle, and relief angle
B. cutting speed, rake angle, and relief angle
C. cutting speed, feed, and depth of cut
D. depth of cut, chip thickness ratio, and with of the work part

The tool flank surface is oriented at an angle with respect to the newly generated -9
:work surface in order to
A. protect the surface from abrasion and avoid surface finish degradation
B. move slowly during cutting operation
C. move faster during cutting operation
D. increase the friction between cutting tool and work surface

Which one of the four types of chip would be expected in a turning operation -10
conducted at high cutting speed a relatively small feed and depth of cut on a ductile
?work material
A. continuous
B. continuous with built-up edge
C. discontinuous
D. serrated

In forming, the shape of the work part is determined by the -11

A. feed trajectory of cutting tool
B. geometry of the cutting tool
C. speed motion in the operation
D. depth of cut

?The figure below indicates which of the following operations -12

A. straight turning
B. knurling
C. cut-off
D. form turning

Boring is a machining operation carried out on a work part to -13

A. produce a round hole
B. enlarge an existing hole
C. produce a regular cross-hatched pattern
D. produce a flat surface
:The geometric form produced by slab milling operation is -14
A. a plane surface
B. a round surface
C. a tapered surface
D. a cone-shaped surface

Of the following modes by which a cutting tool can fail during a machining -15
?operation, which one is most preferable
A. fracture failure
B. gradual wear
C. temperature failure
D. creep failure

:The tool wear shown in figures (a) and (b) are described as -16
A. crater wear for a and flank wear for b
B. flank wear for a and crater wear for b
C. continuous wear for a and shock wear for b
D. sliding wear for a and temperature wear for b

:During machining, abrasion may occur due to -17

A. high pressure and temperature at the tool-chip
interface
B. diffusion at the tool-chip interface
C. presence of hart particles in the work material
D. chemical reaction, e.g. oxidation, at the tool-chip interface

:The Taylor tool life equation states that -18

A. a higher cutting speed results in a longer tool life
B. a higher cutting speed results in a shorter tool life
C. cutting speed has no influence on tool life
D. tool life increases linearly as cutting speed is increased

To resist abrasive wear during cutting, the most important tool material -19
:property to consider is
A. hardness
B. toughness
C. ductility
D. impact resistance

:Water is usually used as the base in coolant-type cutting fluids due to its -20
A. low specific heat and thermal conductivity
B. high specific heat and thermal conductivity
C. good electrical conductivity
D. good lubricant property
T or F

The difference between up milling and down milling is that in down milling the -1
direction of motion of the cutter teeth is opposite to the feed direction when the
teeth cut into the work (F)

In machining, feed has the greatest effect on tool wear compared to other cutting -4
conditions (F)

Seven elements of tool geometry are required to completely specify a single-point -5

tool
)T( .)i.e. a tool signature (

A tap is a cutting tool used to create flat planar surfaces (F) -6

Twist drill would be the most likely choice to drill a hole with a 100mm (4.0 in) (F) -8

Continuous chip is expected in a turning operation conducted at low cutting speed -9

on a brittle work material. (F)

slab milling is classified as peripheral milling. (T) -10

Term 152
1- The location of the secondary shear zone in turning is
A. in the chip and close to workpiece
B. in the chip and close to the cutting tool
C. in the workpiece and close to the cutting tool
D. in the tool and close to the chip

2- Based on its direction and if it has high magnitude, the thrust force would be able
to
A. push the tool away from the workpiece
B. push the chip away from the tool
C. push the tool closer to the workpiece
D. push the tool closer to the tool
3- which one of the four types of chip would be expected in turning operation
conducted at low cutting speed on a brittle material?
A. continuous
B. continuous with built up edge
C. discontinuous
D. serrated

4- Tungsten carbide tools are often selected for high cutting speed machining
because of their?
A. high fracture toughness
B. high thermal expansion
C. high hot hardness
D. low fracture toughness

5- To reduce the average temperature developed for orthogonal cutting?

A. the cutting speed is reduced
B. the depth of cut is increased
C. reduce the use of coolant fluid
D. the feed is increased

6- The rake angle, relief angle, and shear angle are respectively represented in Figure
1 below by:
A. a, b and c
B. c, b, and a
C. c, a, and b
B. a, c, and b

7- Which of the following operations create a shape by

generation ?
A. form turning
B. drilling
C. broaching
D. straight turning

8- Figure 2 shows
A. solid shank tool
B. brazed insert tool
C. mechanically clamped insert tool
D. none of the above

9- the three dimensions of the machining process, called cutting conditions, are the:
A. shear angle, rake angle, and relief angle
B. cutting speed, rake angle, and relief angle
C. cutting speed, feed, and depth of cut
D. depth of cut, chip thickness ratio, and with of the work part

10- in turning operation, material removal is carried out using:

A. a cutting tool with a single cutting edge
B. a cutting tool with two cutting edges
C. a cutting tool with multiple cutting edges
D. a cutting tool with a dull edge

11- the shape in the process of Figure 3 is created by

A. forming using form turning
B. generating using form turning
C. forming using contour turning
D. generating using contour turning

12- The machining process in Figure 4 is able to

A. drill a whole
B. enlarge a hole
C. make internal thread
D. make tapered hole

13- The tool "Y" seen in figure 5 used as work

holding tool is called
A. a dog
B. a three-jaw chuck
C. a collet
D. faceplate

14- crater wear happens as result of

A. chip sliding against the tool
B. workpiece rubbing against the tool
C. the application of wrong coolant fluid
D. vibration at the cutting zone

15- Due to the time of cutter engagement in the workpiece, the tool life
A. in conventional milling (up milling) is shorter than climb milling ( down milling)
B. in conventional milling is longer than climb milling
C. in conventional milling is the same as climb milling
D. increase with increasing the cutting speed

16- Clamping of the workpiece is

A. more needed in conventional milling than in climb milling
B. more need in climb milling than in conventional milling
C. as needed in climb milling as in conventional milling
D. not critical in both climb milling and conventional milling

17- An engineer would prefer the following type of tool failure in a machining
process
A. fracture failure
B. temperature failure
C. gradual wear
D. fatigue wear

18- The mechanism that is described as a mechanical action caused by hard particles
in the work material gouging and removing small portion of the tool is called
A. abrasion
B. adhesion
C. diffusion
D. chemical reaction

19- when it comes to tool life in machining, the second most important process
parameter is
A. speed
B. feed
C. depth of cut
D. tool material

20- The cutting edge is replaceable for the following types of drills
A. twist drill and straight flute drill
B. straight flute drill and gun drill
C. gun drill and spade drill
D. spade drill and straight flute drill

Mechanical parts can be classified as rotational or nonrotational. Which of the

following are operations the create nonrotational geometries? Milling

In turning operation, the change in diameter of the work part is equal to which one
:of the following
2x depth of cut

A facing operation is normally performed on which one of the following machine

tools: lathe
 A broaching operation is best described by which one of the following: a tool with
multiple teeth moves linearly past a stationary workpart

Countersinking is related to which one of the following machining operations: drilling

Which of the following process is used to provide very thin coating on the surface of
coated carbide inserts? chemical vapor deposition or physical vapor deposition

Which one of the following materials has the highest hardness? Cubic boron nitride

Most ceramic cutting tools are fabricated from which one of the following materials?
aluminium oxide

Which of the is following drill types would be the most likely choice to drill a hole
with a 100 mm (4.0in) diameter? spade drill

Which of the following is providing the main functions of a cutting fluid in

machining? reduce friction at the tool-chip interface, as well as remove heat from
.the process

Which one of the following is a common gas used for shielding in arc welding? Argon

Which one of the following welding processes uses a nonconsumable electrode?

GTAW

MIG welding is a term sometimes applied when referring to which one of the
following processes? GMAW
Which one of the following arc welding processes uses an electrode consisting of
continuous consumable tubing containing flux and other ingredients in its core?
FCAW

The fused zone between the two parts in a resistance spot welding operation is
called which one of the following: weld nugget

The figure below indicates which of the following: cut-off

In metal cutting process which one of the following is independent variable: using of
cutting fluid
 With which one of the following geometric forms is the turning operation most
closely associated: external cylinder

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

According to the Merchant equation, an increase in rake angle would have which of
the following result, all other factor remains same: increase in shear plane angle

Resistance welding uses a combination of heat and pressure to accomplish

coalescence: (True)

Dye-penetrant or fluorescent-penetrant tests used to detect al types of cracks and

cavities in weldments: (False)

A roughing operation generally involves low cutting speed, high feed and high depth
of cut (True)

As compared to cutting speed and feed, depth of cut has the strongest effect on
cutting temperature (False)

Continuous chip with built-up edge would be expected in machining operation

conducted at low cutting speed on brittle work material (False)

During a turning operation, if the chips become difficult to dispose, then the tool
should be replaced (True)

Lasor vapor deposition process can be used to coat high speed steel tools (False)

Groove type chip breakers are attached as a sperate attachment to the rake face of a
tool to break the chips (False)

A vertical milling machine is more appropriate than a horizontal milling machine for
performing end milling (True)

Reaming tool is using to perform an internal thread (False)

Other quizzes questions

The difference between up milling and down milling is that in down milling the
direction of motion of the cutter teeth is opposite the feed direction when the teeth
cut into the work (False)

A turret lathe has a tool holding in place of headstock (False)

Knurling is performed on a milling, but is not a metal cutting operation (False)

 In peripheral milling, cutting tool axis is perpendicular to the work surface; in the
face milling, the cutter axis is parallel to the work surface (False)

:What is the distinguishing feature between a drilling fixture and a drill jig
The drill jig provides a means of guiding the tool during the operation

Which of the following is the most preferable mode of cutting tool failure during a
machining operation? Gradual wear

Based on Taylor’s Tool life equation, which of the following conditions has the
greatest effect on tool wear? Cutting speed

?What is the difference between peripheral milling and face milling

Peripheral milling – axis of cutter rotation parallel to surface being milled

Which one of the following cutting tools can be used on a horizontal milling
?machine
Straddle tool

Boring and turning share common features, so what is the difference between
:boring and turning
Boring is performed on the inside diameter of an existing hole using a rotating tool

?Which of the following statement is correct

Cutting force, Fc, increases with increasing depth of cut and decreasing rake angle

?Which one of the following welding operations generates the lowest power density
Oxyfuel gas welding

:The maximum temperature in orthogonal cutting is located

At the tool-chip interface

Specific energy in metal machining is a measure of the amount of energy required to

remove a unit length of material (False)

Most of heat generated in machining is carried away by chips (True)

:Reaming is used for which of the following function

Improve surface finish on a hole

:A lathe can be used to perform which of the following machining operations

Boring
Which of the following is classified as face milling? end milling

A tap is cutting tool used to create which one of the following geometries: internal
threads
 Which one of the following is example of generating the work part geometry in
machining, as opposed to forming the geometry? Profile milling

.
ME322, QUIZ 3 | 15 minutes, 10 points |solution:212-141-4444
________________________________ :Name
___________________________________:#ID
:PLEASE CIRCLE THE RIGH CHOICE
Question 1: Which of the following four types of chips is expected in a turning
?operation conducted at low cutting speed on a brittle material
1. Serrated
2. Discontinuous
3. Continuous with built up edge
4. Continuous

Question 2: In machining processes approximately how much energy is converted

?into heat
1. 98%
2. 60%
3. 50%
4. 35%

:Question 3: Angle b in the figure is

1. Rake angle
2. Relief angle
3. Friction angle
4. Shear angle

:Question 4-Roughing cuts are conducted at

1. High feed and depth, low speed
2. High feed, low depth, high speed
3. Low feed, high depth, low speed
4. Low feed, low depth, high speed

Question 5-The chip thickness before cutting in orthogonal cutting model corresponds
to_____ in turning.

1. Depth of cut
2. Cutting speed
3. Chip thickness after cutting
4. Feed
Problems 6-10: A tool with negative rake angle of 5 is used to perform a machining
operation. Depth of cut is 0.2 mm, and width of cut is 5 mm. The chip ratio = 0.4.
Orthogonal cutting model can be used to approximate the machining operation.
Calculate Chip thickness, shear angle, friction angle, co-efficient of friction and shear
.strain

Chip thickness
1. 0.5
2. 0.7
3. 0.9
4. 0.3

Shear angle
1. 51.1
2. 41.1
3. 31.1
4. 21.1

Friction angle
1. 12.8
2. 22.8
3. 32.8
4. 42.8

Co-efficient of friction
1. 0.33
2. 0.53
3. 0.73
4. 0.93

Shear Strain
1. 2.09
2. 5.09
3. 4.09
4. 3.09

.
ME322, QUIZ 4 | 10 points, 10 min ,142
 Key 122 124 242 1
_____ :Name: _____________________________ Sec
_________________________________________:# ID
:PLEASE CIRCLE THE RIGH CHOICE

Question 1: Most ceramic cutting tools are fabricated from aluminum oxide.

1. True
2. False

Question 2: Knurling is a machining operation used to produce a regular cross-

hatched pattern in the work surface.

1. True
2. False

.Question 3: A turret lathe can hold only one tool at a time

1. True
2. False

Question 4: Degradation of the surface finish of the work piece can be used as an
indicator for tool life.

1. True
2. False

.Question 5: Reaming is a process to generate internal threads in a hollow workpiece

1. True
2. False

:Question 6: A tap is used for

1. Smooth internal surfaces after drilling
2. Flat planar surfaces
3. Square surfaces
4. Internal threads

:Question 7: In straight turning change in diameter is equal to

1. 1 x depth of cut
2. 2 x depth of cut
3. 1 x feed
4. 2 x feed

:Question 8: The main function of cutting fluid is

1. Wash away chips
2. Improve surface finish
3. Reduce forces
4. Reduce friction

:Question 9: Which of the following materials has the highest hardness

1. Aluminum oxide
2. Cubic boron nitride
3. HSS steel
4. Tungsten carbide

:Question 10: Following figure shows

1. Spot facing
2. Counterboring
3. Countersinking
4. Tapping

.
ME322, QUIZ 4, 10 min, 10 points
_________________________ :Name
________________________:ID Num

:Please write the right choice in the box

1. Which one of the following materials has the highest hardness: (a) aluminum oxide,
(b) cubic boron nitride, (c) high-speed steel, or (d) tungsten carbide?


2. 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: (a) depth of cut d, (b) feed f, or (c) speed v?


3. 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) continuous, (b)
continuous with built-up edge, (c) discontinuous, or (d) serrated?


4. Of the three possible modes by which a cutting tool can fail during a machining
operation, which one is most preferable: (a) fracture failure, (b) gradual wear, or (c)
temperature failure?


5. Which one of the following cutting conditions has the strongest effect on cutting
temperature: (a) cutting speed, (b) depth of cut, or (c) feed?

6. In a turning operation, the change in diameter of the workpart is equal to which one
of the following: (a) 1 x depth of cut, (b) 2 x depth of cut, (c) 1 x feed, or (d) 2 x feed?


7. The distinguishing feature between a drilling fixture and a drill jig is that the fixture
provides a means of guiding the tool during the hole-making operation: (a) true or (b)
false?


8. Following figure shows which of the following operations (a) spot facing, (b)
countersinking, (c) centering (d) straddle milling

9. Following figure shows which of the following operations (a) boring (b) partial face
milling, (c) pocket milling, (d) slab milling,?

10. Following figure shows which of the following operations (a) end milling, (b) cut-off (c)
chamfering (d) form turning
 

ME322, QUIZ 3 | 10 minutes, 10 points ||CACCC ACBBB

:Question 1: Which one of the following arc-welding process produces the highest temperature
A. Shielded metal arc welding
B. Gas metal arc welding
C. Plasma arc welding
D. Submerged arc welding

Question 2- A welding process in which the electrode is continuous consumable tubing that contains
:flux is called
A. Flux cored arc welding
B. Resistance spot welding
C. Gas metal arc welding
D. Electrogas welding

Question 3-Following figure shows:

A. Shielded metal Arc Welding (SMAW)

B. Gas Metal Arc Welding (GMAW)
C. Submerged Arc Welding (SAW)
D. Plasma Arc Welding (PAW)Heat of fusion

:Question 4: Which of the following is a common gas used for shielding in arc welding
A. Argon
B. Carbon monoxide
C. Nitrogen
D. Fluorine

:Question 5: Following figure shows

 A. Plasma arc welding (PAW)
B. Stud welding (SW)
C. Resistance Seam Welding (RSEW)
D. Resistance Projection Welding (RPW)

:Question 6: Following figure shows which weld defect

A. Undercut
B. Underfill
C. Overlap
D. Toe cavity

Question 7-Overhead welding is the most convenient position for welding:

A. Toe crack
B. Coldshut
C. Incomplete fusion
D. Donut weld

Question 8-Overhead welding is the most convenient position for welding:

A. True
B. False

Question 9-Dye-penetrant test can be used to detect sub surface cracks.

A. True
B. False
Question 10-Shear test is a non-destructive test performed to measure the shear strength of a spot
weld

A. True
B. False

1- Rough cut is carried out at low speed, high feed, and high depth (T/F)
2- Machining takes less time than forging and casting processes (T/F)
3- Brittle material produce continuous chip (T/F)
4- Temperature during cutting can be reduced by
A-reducing cutting speed
B-dry machining
C-increasing depth of cut
D-increasing feed

5- Chip is formed by
A-shear deformation
B-fracture failure
C-tensile failure
D-none of the above

6- The geometric form produced by slap milling operation is:

A-round surface
B-plane surface
C-tapered surface
D-cone-shaped surface

7- Holes made by drilling can be finished by reaming (T/F)

8- Boring is a machining operation carried out on a work part
A-produce a round hole
B-produce internal threads
C-produce a flat surface
D-enlarge an existing hole
9- Turret lathe will not provide a space for broaching tool (T/F)
10- In forming, the shape of the work part is determined by the
A-trajectory of cutting tool
B-speed of cut
C-depth of cut
D-geometry of cutting tool

11- A coolant is a cutting fluid that uses ………. as its base

A-water
B-oil
 C-nitrogen
D-mixture of oil and water
12- High speed steel tools can be used for very high speed cutting at high temperatures
(T/F)
13- The main function of cutting fluid is to remove chips (T/F)
14- A single point tool is used in:
A-face turning
B-gun drilling
C-slab milling
D-broaching

15- Spade drill is used to make narrow holes (T/F)

CH 25 & 26
An autogenous weld is described as a fusion-welding operation in which filler
metal is added.
(NO )

Which one of the following processes is classified as fusion welding? (electro

gas welding)

For metallurgical reasons, it is desirable to melt the weld metal with minimum
energy input. Which one of the following heat sources is most consistent with
this objective: (High power density)

     The fused zone between the two parts in a resistance spot welding operation is
called:

(Weld nugget)

Which one of the following arc welding processes uses an electrode consisting
of continuous consumable tubing containing flux and other ingredients in its
core?
( flux-cored arc welding (FCAW))

In arc welding processes, a flux is used to:

(prevent the formation of oxides and unwanted
contaminants)

The rate of heat energy supplied in a resistance spot welding

operation is determined by which one of the following equations
 where RH = rate of heat energy, E = voltage, I = current, R = resistance,
and t = time? (RH = I2R )

Which one of the following is common gas used for shielding in arc welding?
(argon)

A fillet weld is used to join a butt type joint.

(No)

Groove welds are most closely associated with corner type joints.
(Yes)

      Which one of the following arc welding processes uses a nonconsumable electrode?
(GTAW)

Fusion welding processes use heat to melt the base metals.

Yes

Which of the following is non-destructive technique used for testing weld quality:
Magnetic particle test

Which of the following welding processes are classified as solid-state:

Friction welding

CH 17
 Continuous chip is expected in a turning operation conducted at low
cutting speed on a brittle work material
fa
ls
e

1. To establish location accurately for subsequent drilling, the hole

machining process done is called:
Center drilling

Specific energy in metal machining is a measure of the amount of energy

required to remove a unit volume of material.
True

       The mechanism of chip formation in machining is best described

by which one of the following:
1. Shear deformation

Which of the following operations does not create a shape by

‘forming’
Straight Turning

One advantage of using dry machining is the possibility of operating at

higher cutting speeds and production rate
false

1)       According to Merchant equation, an increase in shear angle will

lead to:
Decrease in power
consumption
Machining can produce dimensions to very close tolerances much more
accurate than most other processes
True

1)       Which of the following is not a metal cutting operation?

Knurling

1)       Most of the heat generated in machining is carried away by:

Chip

CH 18

In a turning operation, the change in diameter of the workpart is equal to which one of
the following:
a. 
1 x depth of cut
b. 
2 x feed
c. 
1 x feed,
d. 
2 x depth of cut

A lathe can be used to perform which of the following machining operations  

a. 
 turning
b. 
Broaching
c. 
 Milling
d. 
Planing

Which one of the following turning machines permits very long bar stock to be used: 
a. 
 turret lathe
b. 
engine lathe
c. 
screw machine
d. 
chucking machine

Gear hobbing is a special form of which one of the following machining operations
a. 
milling
b. 
 planing
c. 
shaping
d. 
grinding

Boring and reaming share the common feature that they are both used to enlarge
anexisting hole
a. 
false
b. 
true

The difference between up milling and down milling is that in down milling the
direction of motion of the cutter teeth is opposite the feed direction when the teeth cut
into the work
a. 
true
b. 
False

A tap is a cutting tool used to create which one of the following geometries
a. 
external threads
b. 
flat planar surfaces
 c. 
holes used in beer kegs
d. 
internal threads

The twist drill is the most common type of drill bit

a. 
Neigther
b. 
Yes
c. 
No

Which one of the following are classified as peripheral milling rather than face milling  

a. 
contour machining
b. 
pocket milling
c. 
slab milling
d. 
face milling

A facing operation is normally performed on which one of the following machine tools: 
a. 
milling machine
b. 
lathe
c. 
shaper
d. 
planer

A broaching operation is best described by which one of the

following:

a. 
a workpart is fed past a rotating cutting tool
b. 
a rotating tool
moves past a
stationary
workpart
c. 
a workpart
moves
linearly
past a
stationary
single-
point tool?

d. 
a tool with
multiple teeth
moves linearly
past a stationary
workpart,

The distinguishing feature between a drilling fixture and a drill jig is that the fixture
provides a means of guiding the tool during the hole-making operation
a. 
false
b. 
true

Machined parts can be classified as rotational or nonrotational. Which one of the

following are examples of operations that create nonrotational geometries

a. 
Milling
b. 
broaching
c. 
boring
d. 
drilling
When the drill bit in a drilling operation exits the opposite side of the work, the
resulting hole is called which one of the following
a. 
) a blind hole
b. 
Through hole
c. 
None

Which one of the following terms is used for cutting external threads using self-
opening threading dies
a. 
thread chasing
b. 
tapping
c. 
thread milling
d. 
thread forming