Multiple Choice Questions (MCQs)
1. What is the primary purpose of machining?
o a) To join materials
o b) To remove material to achieve desired geometry
o c) To heat-treat metals
o d) To polish surfaces
2. Which of the following is NOT a machining operation?
o a) Turning
o b) Casting
o c) Drilling
o d) Milling
3. What is the main disadvantage of machining?
o a) High precision
o b) Material wastage in the form of chips
o c) Fast production
o d) Limited material options
4. Which machining operation creates a round hole?
o a) Turning
o b) Drilling
o c) Milling
o d) Grinding
5. In turning, the workpiece motion is:
o a) Linear
o b) Rotational
o c) Stationary
o d) Oscillating
6. What type of tool is used in milling?
o a) Single-point tool
o b) Multiple-cutting-edge tool
o c) Abrasive wheel
o d) Laser beam
7. The material removal rate (MRR) in machining is calculated as:
o a) v+f+dv+f+d
o b) v×f×dv×f×d
o c) v/f×dv/f×d
o d) v×f/dv×f/d
8. Which angle on a cutting tool helps reduce friction between the tool and workpiece?
o a) Relief angle
o b) Rake angle
o c) Nose radius
o d) Wedge angle
9. What property must a cutting tool have to maintain sharpness at high temperatures?
o a) High thermal conductivity
o b) Red hardness
o c) Electrical conductivity
o d) Magnetic permeability
10. Which cutting tool material is known for excellent red-hardness and wear resistance?
o a) High-speed steel (HSS)
o b) Cast alloys
o c) Aluminum oxide
o d) Diamond
11. Cemented carbides are products of which process?
o a) Casting
o b) Powder metallurgy
o c) Forging
o d) Electroplating
12. Which machining process is typically performed after casting or forging?
o a) Primary shaping
o b) Secondary/finishing operation
o c) Joining
o d) Heat treatment
13. What motion is responsible for the primary cutting action in machining?
o a) Feed motion
o b) Cutting speed
o c) Depth of cut
o d) Tool rotation
14. Which tool material operates at the highest cutting speeds?
o a) HSS
o b) Cemented carbides
o c) Ceramics
o d) Cast alloys
15. What is the function of the flank on a cutting tool?
o a) To reduce friction
o b) To provide clearance and prevent rubbing
o c) To increase cutting speed
o d) To cool the workpiece
16. Which of the following is a single-point tool operation?
o a) Milling
o b) Drilling
o c) Turning
o d) Grinding
17. The nose radius on a cutting tool improves:
o a) Tool hardness
o b) Surface finish and tool life
o c) Material removal rate
o d) Feed rate
18. Which machining process uses a rotating tool with multiple cutting edges to cut flat
surfaces?
o a) Turning
o b) Drilling
o c) Milling
o d) Broaching
19. What is the primary advantage of machining over casting?
o a) Lower cost
o b) Better dimensional accuracy and surface finish
o c) Faster production
o d) No material waste
20. Which cutting tool property ensures resistance to chipping under load?
o a) Hardness
o b) Shock resistance
o c) Wear resistance
o d) Red hardness
21. High-speed steel (HSS) contains which of the following elements?
o a) Tungsten, chromium, vanadium
o b) Aluminum, copper, zinc
o c) Carbon, silicon, sulfur
o d) Nickel, cobalt, titanium
22. What is the role of cobalt in cast alloy cutting tools?
o a) Increases toughness
o b) Enhances red-hardness
o c) Reduces cost
o d) Improves electrical conductivity
23. Which parameter directly affects the cutting temperature?
o a) Cutting speed
o b) Tool color
o c) Workpiece size
o d) Machine weight
24. The Merchant Equation is used to analyze:
o a) Chip formation and forces
o b) Tool wear rate
o c) Material removal rate
o d) Surface roughness
25. Which machining process is used to create screw threads?
o a) Drilling
o b) Turning
o c) Milling
o d) Grinding
26. What is the purpose of the side relief angle on a cutting tool?
o a) To control chip flow
o b) To prevent tool rubbing against the workpiece
o c) To increase cutting speed
o d) To reduce heat generation
27. Which of the following is a non-traditional machining process?
o a) Turning
o b) Electrical discharge machining (EDM)
o c) Drilling
o d) Milling
28. The term "hot hardness" refers to a tool's ability to:
o a) Conduct heat
o b) Maintain hardness at high temperatures
o c) Resist corrosion
o d) Absorb shocks
29. Which cutting tool material is the most brittle?
o a) HSS
o b) Cast alloys
o c) Cemented carbides
o d) Ceramics
30. What is the primary function of a machine tool?
o a) To melt metal
o b) To hold and position the workpiece and tool
o c) To cool the cutting zone
o d) To polish surfaces
True/False Questions
1. Machining can achieve tighter tolerances than casting.
o True
2. Drilling is a single-point cutting tool operation.
o False (uses multi-point tools)
3. Material removal rate (MRR) depends on cutting speed, feed, and depth of cut.
o True
4. High-speed steel (HSS) tools can withstand higher temperatures than cemented carbides.
o False (carbides have better red hardness)
5. The rake angle on a tool influences chip formation.
o True
6. Turning is performed on a milling machine.
o False (done on a lathe)
7. Cemented carbides are made using a casting process.
o False (powder metallurgy)
8. Machining is always the first step in manufacturing.
o False (usually follows primary processes like casting)
9. The flank of a tool is the surface that contacts the chip.
o False (rake face contacts the chip)
10. Milling can produce flat surfaces and slots.
o True
11. Cutting tools must be harder than the workpiece material.
o True
12. Cast alloy tools are tougher than high-speed steel.
o False (more brittle)
13. The nose radius on a tool has no effect on surface finish.
o False (improves finish)
14. Grinding is an abrasive process, not a machining process.
o False (it’s a machining process)
15. Depth of cut is the primary motion in machining.
o False (cutting speed is primary)
16. Ceramic tools operate at lower speeds than HSS tools.
o False (higher speeds)
17. The Merchant Equation relates to chip thickness ratio.
o True
18. Broaching is a multi-point cutting tool operation.
o True
19. Tool wear is negligible in machining.
o False (significant concern)
20. Shaping and planing are machining operations for flat surfaces.
o True
21. Carbide tools were first developed during World War I.
o False (World War II)
22. Feed motion is perpendicular to cutting speed in turning.
o True
23. Machining generates no heat.
o False (significant heat is generated)
24. HSS tools contain cobalt for improved toughness.
o True
25. The clearance angle prevents the tool flank from rubbing the workpiece.
o True
26. Non-traditional machining includes processes like laser cutting.
o True
27. Planing involves a stationary tool and moving workpiece.
o True
28. Cutting fluids are used to reduce tool wear and improve finish.
o True
29. All machining processes use sharp cutting tools.
o False (non-traditional processes use other energy forms)
30. Tool life is unaffected by cutting conditions.
o False (highly dependent on speed, feed, etc.)
