EMAE 160 MIDTERM EXAM
QUESTIONS WITH CORRECT
ANSWERS
Name the three types of cutting fluid according to chemistry. - ANSWER-Natural,
emulsified, and chemical
Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high
speed steel end mill. - ANSWER-Feed rate = RPM x # of teeth x Chip per tooth
Name the three most common machining processes. - ANSWER-Turning, milling,
and drilling
How is feed rate denoted for a manual lathe and drill press? - ANSWER-• Manual
Lathe = feed/rev
Drill press = inches/rev
What is barstock? - ANSWER-Strips of raw, purified material
What is a blind hole? What do we not like about blind hole? - ANSWER-A hole that is
drilled to a specific depth and does not go the whole way through the workpiece.
Can't get a flat bottom on the hole
Counterbore is for what type of fastener? Countersink? - ANSWER-• Counterbore:
socket head cap screw (sits flush with or below the surface)
Countersink: bolt, screw, or rivet
What is a chamfer? - ANSWER-A beveled (flattened) edge on a workpiece
connecting two surfaces
What are burrs? - ANSWER-Small pieces that remain attached to material after
machining
What materials are cutting tools commonly made from? - ANSWER-Carbon tool
steel, high speed steel, cast alloys, cemented carbides, ceramics, cermets, diamond,
polycrystalline diamond, polycrystalline cubic boron nitride
Explain how a match plate is used in sand casting and why it is advantageous. -
ANSWER-it is used by mounting two sides of the pattern onto match plate. It is
advantageous because it makes aligning pattern quicker/more accurate.
Explain the term parting line when referencing the die casting process. - ANSWER-It
is the line where the 2 halves of the die meet on the part
The "lost foam" or full-mold process requires what type of pattern? - ANSWER-
Evaporative pattern
, Which of the following statements best describes the shell molding process?
a. A casting process using molten metal poured using centrifugal force
b. A casting process using metal masters and a resin to bind the molding sand
c. A casting process using polystyrene patterns - ANSWER-B
What is the parting line in injection molding? - ANSWER-The joint between the two
mold halves.
In terms of casting work, what is a runner? - ANSWER-Channels where the molten
metal flows into the cast cavity
What type of mold is used in sand casting? - ANSWER-A sandmold
Which types of casting qualify as precision casting processes? - ANSWER-
investment casting and plaster mold casting
What is a flask? - ANSWER-a type of tooling used to contain a mold in metal casting;
it consists of two parts and forms a frame around the mold.
In sand casting, how does the volumetric size of the pattern compare to the finished
cast part. - ANSWER-It is larger.
Describe shell molding. - ANSWER-It is a mold casting process that uses a resin
covered sand to form the mold.
Name another term for investment casting and explain the origin. - ANSWER-Lost
wax casting. It was used 1000s of years ago: beeswax was the pattern and sand the
mold. Made idols, ornaments, jewlery
List the metals that are typically die cast. - ANSWER-zinc, lead, tin, aluminum,
magnesium, and copper.
In terms of die casting, what is a flash? - ANSWER-excess material attached to a
cast product caused by leakage of material beginning along parting line.
Describe the surface finish symbol. - ANSWER-Surface finish is shown with a check
and a number. That number is in micro inches (μin).
What is a rib/gusset? - ANSWER-Ribs and gussets increase strength. Ribs are a
structure of side walls that are attached to the main wall to add strength and rigidity
to a primary wall. A gusset is a triangular shaped rib.
Describe a draft? - ANSWER-it is the amount of taper for molded or cast parts
perpendicular to parting line; by tapering the sides of a mold by an appropriate "draft
angle", the mold will be easier to remove
____________ is similar to dressing, but also restores the ideal cylindrical shape of
the grinding wheel. - ANSWER-Truing
QUESTIONS WITH CORRECT
ANSWERS
Name the three types of cutting fluid according to chemistry. - ANSWER-Natural,
emulsified, and chemical
Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high
speed steel end mill. - ANSWER-Feed rate = RPM x # of teeth x Chip per tooth
Name the three most common machining processes. - ANSWER-Turning, milling,
and drilling
How is feed rate denoted for a manual lathe and drill press? - ANSWER-• Manual
Lathe = feed/rev
Drill press = inches/rev
What is barstock? - ANSWER-Strips of raw, purified material
What is a blind hole? What do we not like about blind hole? - ANSWER-A hole that is
drilled to a specific depth and does not go the whole way through the workpiece.
Can't get a flat bottom on the hole
Counterbore is for what type of fastener? Countersink? - ANSWER-• Counterbore:
socket head cap screw (sits flush with or below the surface)
Countersink: bolt, screw, or rivet
What is a chamfer? - ANSWER-A beveled (flattened) edge on a workpiece
connecting two surfaces
What are burrs? - ANSWER-Small pieces that remain attached to material after
machining
What materials are cutting tools commonly made from? - ANSWER-Carbon tool
steel, high speed steel, cast alloys, cemented carbides, ceramics, cermets, diamond,
polycrystalline diamond, polycrystalline cubic boron nitride
Explain how a match plate is used in sand casting and why it is advantageous. -
ANSWER-it is used by mounting two sides of the pattern onto match plate. It is
advantageous because it makes aligning pattern quicker/more accurate.
Explain the term parting line when referencing the die casting process. - ANSWER-It
is the line where the 2 halves of the die meet on the part
The "lost foam" or full-mold process requires what type of pattern? - ANSWER-
Evaporative pattern
, Which of the following statements best describes the shell molding process?
a. A casting process using molten metal poured using centrifugal force
b. A casting process using metal masters and a resin to bind the molding sand
c. A casting process using polystyrene patterns - ANSWER-B
What is the parting line in injection molding? - ANSWER-The joint between the two
mold halves.
In terms of casting work, what is a runner? - ANSWER-Channels where the molten
metal flows into the cast cavity
What type of mold is used in sand casting? - ANSWER-A sandmold
Which types of casting qualify as precision casting processes? - ANSWER-
investment casting and plaster mold casting
What is a flask? - ANSWER-a type of tooling used to contain a mold in metal casting;
it consists of two parts and forms a frame around the mold.
In sand casting, how does the volumetric size of the pattern compare to the finished
cast part. - ANSWER-It is larger.
Describe shell molding. - ANSWER-It is a mold casting process that uses a resin
covered sand to form the mold.
Name another term for investment casting and explain the origin. - ANSWER-Lost
wax casting. It was used 1000s of years ago: beeswax was the pattern and sand the
mold. Made idols, ornaments, jewlery
List the metals that are typically die cast. - ANSWER-zinc, lead, tin, aluminum,
magnesium, and copper.
In terms of die casting, what is a flash? - ANSWER-excess material attached to a
cast product caused by leakage of material beginning along parting line.
Describe the surface finish symbol. - ANSWER-Surface finish is shown with a check
and a number. That number is in micro inches (μin).
What is a rib/gusset? - ANSWER-Ribs and gussets increase strength. Ribs are a
structure of side walls that are attached to the main wall to add strength and rigidity
to a primary wall. A gusset is a triangular shaped rib.
Describe a draft? - ANSWER-it is the amount of taper for molded or cast parts
perpendicular to parting line; by tapering the sides of a mold by an appropriate "draft
angle", the mold will be easier to remove
____________ is similar to dressing, but also restores the ideal cylindrical shape of
the grinding wheel. - ANSWER-Truing
