EMAE 160 Final Exam Questions
(Answered) 2025/2026. 100%.
20. Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high speed steel
end mill.
RPM = (CUTTING SPEED X 12) / (PI x DIAMETER)
FEED RATE = RPM x NUMBER OF TEETH x CHIP PER TOOTH
cutting speed =
chip per teeth =
Machining
....
1. Given the following parameters, find the appropriate RPM and feed rate in inches/minute.
Cutting Speed: 150 SFM
Tool Diameter: 0.875"
End Mill Chip per Tooth: 0.002"
Number of Flutes: 4
RPM = (CUTTING SPEED X 12) / (PI x DIAMETER)
FEED RATE = RPM x NUMBER OF TEETH x CHIP PER TOOTH
RPM = (150 SFM x 12)/(PI x 0.875 inches)
RPM = 654.8
Feed rate = 654.8 x 4 x 0.002 inches
Feed rate = 5.24 inches/minute
2. Describe broaching and provide an example of its application.
-Broaching uses a long multi-tooth cutter to slowly work a hole into a new shape.
(uses a toothed tool, called a broach, to remove material)
-A broach is a cutting tool with teeth increasing in size going from rough to fine cutting.
Example: commonly machined surfaces include circular and non-circular holes, splines, keyways, and
flat surfaces
-cutting a rectangular key slot
3. A cutting edge that can hold up under high temperatures experienced at the chip-tool interface
possesses a quality called what?
hot hardness
4. Reaming is used for which of the following functions?
,a. To locate the part origin
b. Improve tolerance on a drilled hole
c. Counterbore for fasteners
b. Improve tolerance on a drilled hole. By widening/boring a hole with high accuracy
5. Of the following metal cutting conditions, which has the greatest effect on tool wear?
a. Cutting Speed
b. Depth of Cut
c. Feed rate
a. Cutting Speed
(followed by feed --> depth of cut)
6. Describe/Sketch the difference between climb (down) milling and conventional (up) milling.
You are facing the machine and the spindle is turning CW.
Conventional = piece moves toward machine. Climb = piece moves toward you.
Conventional:
-more common form
-max chip thickness is at the end of the cut
-smooth process
Climb:
-cutting starts at the surface where the chip is thickest
See onenote notes in EMAE 160- Quizlet for final to see picture!
7. Describe the difference between peripheral milling and face milling.
Face Milling: The cutter is mounted on a spindle having an axis of rotation perpendicular to the
workpiece surface
Peripheral Milling:
-also known as plain milling
-the axis of cutter rotation is parallel to the workpiece surface
8. ____________ is a procedure applied to worn grinding wheels to expose fresh abrasive grit and
remove chips that have clogged the wheel.
Dressing
9. ____________ is similar to dressing, but also restores the ideal cylindrical shape of the grinding
wheel.
Truing
10. State three reasons that machining is commercially and technologically important.
, 1. Applications on all types of materials
2. Very fine finishes AND Close tolerances
3. Ability to create a wide variety of shapes
11. List four parameters of machining that are included within the scope of "cutting conditions."
1. cutting speed
2. feed rate
3. depth of cut (VFD)
4. use of cutting fluid
12. Identify three desirable properties of a cutting tool material.
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
13. Why are surface and cylindrical grinding processes technologically and commercially
important?
fine surface finish and very close tolerance
14. Describe knurling and its application.
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?
aluminum oxide
(others: silicon carbide,
cubic boron nitride,
diamond
16. What does the designation "12 in. x 36 in." mean in reference to a lathe?
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.
17. Which abrasive material is most appropriate for grinding hardened steel?
cubic boron nitride (CBN)
18. What are the two materials known as "Super Abrasives"?
diamond
cubic boron nitride (CBN)
(Answered) 2025/2026. 100%.
20. Find the appropriate feed rate (inches per minute) when using a .750", 4-flute, high speed steel
end mill.
RPM = (CUTTING SPEED X 12) / (PI x DIAMETER)
FEED RATE = RPM x NUMBER OF TEETH x CHIP PER TOOTH
cutting speed =
chip per teeth =
Machining
....
1. Given the following parameters, find the appropriate RPM and feed rate in inches/minute.
Cutting Speed: 150 SFM
Tool Diameter: 0.875"
End Mill Chip per Tooth: 0.002"
Number of Flutes: 4
RPM = (CUTTING SPEED X 12) / (PI x DIAMETER)
FEED RATE = RPM x NUMBER OF TEETH x CHIP PER TOOTH
RPM = (150 SFM x 12)/(PI x 0.875 inches)
RPM = 654.8
Feed rate = 654.8 x 4 x 0.002 inches
Feed rate = 5.24 inches/minute
2. Describe broaching and provide an example of its application.
-Broaching uses a long multi-tooth cutter to slowly work a hole into a new shape.
(uses a toothed tool, called a broach, to remove material)
-A broach is a cutting tool with teeth increasing in size going from rough to fine cutting.
Example: commonly machined surfaces include circular and non-circular holes, splines, keyways, and
flat surfaces
-cutting a rectangular key slot
3. A cutting edge that can hold up under high temperatures experienced at the chip-tool interface
possesses a quality called what?
hot hardness
4. Reaming is used for which of the following functions?
,a. To locate the part origin
b. Improve tolerance on a drilled hole
c. Counterbore for fasteners
b. Improve tolerance on a drilled hole. By widening/boring a hole with high accuracy
5. Of the following metal cutting conditions, which has the greatest effect on tool wear?
a. Cutting Speed
b. Depth of Cut
c. Feed rate
a. Cutting Speed
(followed by feed --> depth of cut)
6. Describe/Sketch the difference between climb (down) milling and conventional (up) milling.
You are facing the machine and the spindle is turning CW.
Conventional = piece moves toward machine. Climb = piece moves toward you.
Conventional:
-more common form
-max chip thickness is at the end of the cut
-smooth process
Climb:
-cutting starts at the surface where the chip is thickest
See onenote notes in EMAE 160- Quizlet for final to see picture!
7. Describe the difference between peripheral milling and face milling.
Face Milling: The cutter is mounted on a spindle having an axis of rotation perpendicular to the
workpiece surface
Peripheral Milling:
-also known as plain milling
-the axis of cutter rotation is parallel to the workpiece surface
8. ____________ is a procedure applied to worn grinding wheels to expose fresh abrasive grit and
remove chips that have clogged the wheel.
Dressing
9. ____________ is similar to dressing, but also restores the ideal cylindrical shape of the grinding
wheel.
Truing
10. State three reasons that machining is commercially and technologically important.
, 1. Applications on all types of materials
2. Very fine finishes AND Close tolerances
3. Ability to create a wide variety of shapes
11. List four parameters of machining that are included within the scope of "cutting conditions."
1. cutting speed
2. feed rate
3. depth of cut (VFD)
4. use of cutting fluid
12. Identify three desirable properties of a cutting tool material.
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
13. Why are surface and cylindrical grinding processes technologically and commercially
important?
fine surface finish and very close tolerance
14. Describe knurling and its application.
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?
aluminum oxide
(others: silicon carbide,
cubic boron nitride,
diamond
16. What does the designation "12 in. x 36 in." mean in reference to a lathe?
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.
17. Which abrasive material is most appropriate for grinding hardened steel?
cubic boron nitride (CBN)
18. What are the two materials known as "Super Abrasives"?
diamond
cubic boron nitride (CBN)
