EMAE 160 FINAL EXAM QUESTIONS
WITH CORRECT ANSWERS
What is a blind hole? What do we not like about blind hole? - ANSWER-a hole that
does not completely penetrate a material, such as wood or plastic, stopping short of
the opposite side.
-drilled to a specific depth
-can't get a flat bottom on the hole
-accuracy and precision are difficult in depth of hole
Counterbore is for what type of fastener? Countersink? - ANSWER-allow head of
fasteners to be flush with the workpiece
-counterbore: cylindrical flat-bottomed hole- houses hex head or socket head cap
screw
-countersink: cone-shaped hole-allows flat head of socket cap screw
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
-cemented tungsten carbide
-ceramics
-cubic boron nitride
-diamond
____________ is similar to dressing, but also restores the ideal cylindrical shape of
the grinding wheel. - ANSWER-Truing
State three reasons that machining is commercially and technologically important. -
ANSWER-1. Applications on all types of materials
2. Very fine finishes AND Close tolerances
3. Ability to create a wide variety of shapes
List four parameters of machining that are included within the scope of "cutting
conditions." - ANSWER-1. cutting speed
2. feed rate
3. depth of cut (VFD)
4. use of cutting fluid
,Identify three desirable properties of a cutting tool material. - ANSWER-1. toughness
(to resist fracture failure)
2. hot hardness (to resist temperature failure)
3. wear resistance (to prolong the life of the tool during gradual wear)
4. geometry
Why are surface and cylindrical grinding processes technologically and commercially
important? - ANSWER-fine surface finish and very close tolerance
Describe knurling and its application. - ANSWER-A diamond shaped criss cross
pattern turned or rolled into a surface to increase grip-ability. It is done on a lathe.
15. What material is the most commonly used abrasive in grinding wheels? -
ANSWER-aluminum oxide
(others: silicon carbide,
cubic boron nitride,
diamond
What does the designation "12 in. x 36 in." mean in reference to a lathe? -
ANSWER-the max diameter and length that can be turned on the lathe
The first number is referred to as the swing of the lathe which is the maximum
diameter of a piece or work that can fit in the lathe.
The second number is referred to as the distance between centers. This is the
distance between a center in the headstock to a center in the tailstock. This gives
you an idea as to how long the working area of the lathe is.
Which abrasive material is most appropriate for grinding hardened steel? -
ANSWER-cubic boron nitride (CBN)
What are the two materials known as "Super Abrasives"? - ANSWER-diamond
cubic boron nitride (CBN)
Name the three types of cutting fluid according to chemistry. - ANSWER-NATURAL
(PETROLEUM, ANIMAL FAT, OR VEGETABLE BASED), EMULSIFIED (NATURAL
OIL MIXED WITH WATER), CHEMICAL (no OIL)
Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high
speed steel end mill. - ANSWER-
Name the three most common machining processes. - ANSWER-turning, drilling,
milling
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 metal
, Explain how a match plate is used in sand casting and why it is advantageous. -
ANSWER-the two pieces of the split pattern are attached to opposite sides of a wood
or metal plate. used for higher production quantities
-A match plate pattern is a two piece pattern representing the casting, divided at the
parting line, similar to the split pattern. In the match plate pattern, however, each of
the parts are mounted on a plate. The plates come together to assemble the pattern
for the sand casting process. The match plate pattern is more proficient and makes
alignment of the pattern in the mold quick and accurate.
Explain the term parting line when referencing the die casting process. - ANSWER-
it's the line where the 2 halves of the die meet on the part
-where the 2 different sides of the mold come together
-it often marks the border between the inside and outside of 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. A casting process
using metal masters and a resin to bind the molding sand
The parting line in injection molding is which of the following?
a. The narrow gate section where the parts are separated for the runner.
b. The area where the clamping unit is joined to the injection unit and the molding
machine.
c. The joint between the two mold halves. - ANSWER-c. 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
-connected channels that convey the molten metal to different parts of the mould.
What type of mold is used in sand casting? - ANSWER-sand mold
Which types of casting qualify as precision casting processes? - ANSWER-
investment casting
plaster mold casting
die casting
9. In casting, what is a flask? - ANSWER-a type of tool used to contain a mold in
metal casting (has 2 parts that forms a frame around the mold)
WITH CORRECT ANSWERS
What is a blind hole? What do we not like about blind hole? - ANSWER-a hole that
does not completely penetrate a material, such as wood or plastic, stopping short of
the opposite side.
-drilled to a specific depth
-can't get a flat bottom on the hole
-accuracy and precision are difficult in depth of hole
Counterbore is for what type of fastener? Countersink? - ANSWER-allow head of
fasteners to be flush with the workpiece
-counterbore: cylindrical flat-bottomed hole- houses hex head or socket head cap
screw
-countersink: cone-shaped hole-allows flat head of socket cap screw
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
-cemented tungsten carbide
-ceramics
-cubic boron nitride
-diamond
____________ is similar to dressing, but also restores the ideal cylindrical shape of
the grinding wheel. - ANSWER-Truing
State three reasons that machining is commercially and technologically important. -
ANSWER-1. Applications on all types of materials
2. Very fine finishes AND Close tolerances
3. Ability to create a wide variety of shapes
List four parameters of machining that are included within the scope of "cutting
conditions." - ANSWER-1. cutting speed
2. feed rate
3. depth of cut (VFD)
4. use of cutting fluid
,Identify three desirable properties of a cutting tool material. - ANSWER-1. toughness
(to resist fracture failure)
2. hot hardness (to resist temperature failure)
3. wear resistance (to prolong the life of the tool during gradual wear)
4. geometry
Why are surface and cylindrical grinding processes technologically and commercially
important? - ANSWER-fine surface finish and very close tolerance
Describe knurling and its application. - ANSWER-A diamond shaped criss cross
pattern turned or rolled into a surface to increase grip-ability. It is done on a lathe.
15. What material is the most commonly used abrasive in grinding wheels? -
ANSWER-aluminum oxide
(others: silicon carbide,
cubic boron nitride,
diamond
What does the designation "12 in. x 36 in." mean in reference to a lathe? -
ANSWER-the max diameter and length that can be turned on the lathe
The first number is referred to as the swing of the lathe which is the maximum
diameter of a piece or work that can fit in the lathe.
The second number is referred to as the distance between centers. This is the
distance between a center in the headstock to a center in the tailstock. This gives
you an idea as to how long the working area of the lathe is.
Which abrasive material is most appropriate for grinding hardened steel? -
ANSWER-cubic boron nitride (CBN)
What are the two materials known as "Super Abrasives"? - ANSWER-diamond
cubic boron nitride (CBN)
Name the three types of cutting fluid according to chemistry. - ANSWER-NATURAL
(PETROLEUM, ANIMAL FAT, OR VEGETABLE BASED), EMULSIFIED (NATURAL
OIL MIXED WITH WATER), CHEMICAL (no OIL)
Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high
speed steel end mill. - ANSWER-
Name the three most common machining processes. - ANSWER-turning, drilling,
milling
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 metal
, Explain how a match plate is used in sand casting and why it is advantageous. -
ANSWER-the two pieces of the split pattern are attached to opposite sides of a wood
or metal plate. used for higher production quantities
-A match plate pattern is a two piece pattern representing the casting, divided at the
parting line, similar to the split pattern. In the match plate pattern, however, each of
the parts are mounted on a plate. The plates come together to assemble the pattern
for the sand casting process. The match plate pattern is more proficient and makes
alignment of the pattern in the mold quick and accurate.
Explain the term parting line when referencing the die casting process. - ANSWER-
it's the line where the 2 halves of the die meet on the part
-where the 2 different sides of the mold come together
-it often marks the border between the inside and outside of 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. A casting process
using metal masters and a resin to bind the molding sand
The parting line in injection molding is which of the following?
a. The narrow gate section where the parts are separated for the runner.
b. The area where the clamping unit is joined to the injection unit and the molding
machine.
c. The joint between the two mold halves. - ANSWER-c. 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
-connected channels that convey the molten metal to different parts of the mould.
What type of mold is used in sand casting? - ANSWER-sand mold
Which types of casting qualify as precision casting processes? - ANSWER-
investment casting
plaster mold casting
die casting
9. In casting, what is a flask? - ANSWER-a type of tool used to contain a mold in
metal casting (has 2 parts that forms a frame around the mold)
