Exam 1 Flashcards
(132 cards)
1
Q
Within which tier of industry is Manufacturing?
primary, secondary, tertiary, or none
A
secondary
2
Q
Within which tier of industry is Agriculture?
primary, secondary, tertiary, or none
A
primary
3
Q
Within which tier of industry is Fishing?
primary, secondary, tertiary, or none
A
primary
4
Q
Within which tier of industry is a restaurant?
primary, secondary, tertiary, or none
A
tertiary
5
Q
About Production Quantity, which of the following statements is incorrect?
a. It could be categorized into three ranges based on annual production amount.
b. Refers to the number of units produced annually of a given product type.
c. Manufacturing plants tend to specialize in a combination of it and production variety.
d. Refers to the number of different types of products made.
A
Refers to the number of different types of products made.
6
Q
Metal casting components could be
a. Large or mass produced
b. Either low or high dimensional accuracy
c. Continuous parts like solid slab and sheet
d. Above are all possible
A
Above are all possible
7
Q
Which of the following statements about casting is correct?
a. Casting applies to produce only large components
b. Casting can only be used to create external shapes
c. All casting processes are net shape
d. Casting processes can cause environmental problems
A
Casting processes can cause environmental problems
8
Q
Which of the following statements about casting moulds is incorrect?
a. In some cases, the mould can be made of plaster or ceramic
b. Mould cavity should be designed the same size as the casting to ensure accuracy of the final product size
c. More complex product geometries are possible by designing a suitable mould.
d. Moulds can be categorized into open or closed type
A
Mould cavity should be designed the same size as the casting to ensure accuracy of the final product size
9
Q
Which of the following materials can be cast?
a. Cast iron
b. Aluminum
c. Copper alloys
d. Steel
e. All of them are possible
f. None of them are possible
A
All of them are possible
10
Q
Which of the following statements is incorrect?
a. Crucible furnaces are only used for non-ferrous metals
b. Cupolas can be used for non-ferrous metals
c. Induction furnaces can only be used to melt steels
d. Electric-Arc furnaces are suitable for melting steel
A
Induction furnaces can only be used to melt steels
11
Q
Which of the following factors will affect the pouring success?
a. Pouring Temperature
b. Pouring rate
c. Turbulence
d. All these above
A
All these above
12
Q
Which of the following statements is correct?
a. The ‘local solidification time’ is also known as ‘thermal arrest’ for pure metals
b. Freezing rates will depend only on thermal properties of the metals
c. All metals shrink during solidification
d. Segregation of alloying components during solidification leads to isotropic material properties
A
The ‘local solidification time’ is also known as ‘thermal arrest’ for pure metals
13
Q
Which of the following statements about sand casting is incorrect?
a. Sand casting belongs to expendable mould casting
b. Wood could be used for creating the patterns
c. The sand from a used mould can be recycled to make other moulds.
d. The core of sand casting will also allow for shrinkage
A
The sand from a used mould can be recycled to make other moulds.
14
Q
For each given purpose, match the corresponding mould property required
a. Maintain shape & resist erosion
b. Allow hot air and gases to pass through voids in sand
c. Resist cracking on contact with molten metal
d. Give way and allow casting to shrink without cracking the casting
A. Strength
B. Permeability
C. Thermal stability
D. Collapsibility
A
Maintain shape & resist erosion- Strength
Allow hot air and gases to pass through voids in sand- Permeability
Resist cracking on contact with molten metal- Thermal stability
Give way and allow casting to shrink without cracking the casting- Collapsibility
15
Q
During sand mould design, which of the following statements is incorrect?
a. During pouring, the mould cavity might require chaplets to support itself
b. A riser, is a reservoir built into a metal casting mould to create shrinkage cavities.
c. A pouring cup is often used to minimize splash and turbulence as the metal flows into
the top-down sprue
d. To minimize waste, the riser volume should be minimized
A
A riser is a reservoir built into a metal casting mould to create shrinkage cavities
16
Q
Which of the following statements about die casting is correct?
a. has a rougher finish than sand casting.
b. is cheaper than sand casting.
c. Has better dimensional tolerance than sand casting.
d. For each cast, you can reuse the moulds
A
Has better dimensional tolerance than sand casting
17
Q
Which of the following statements about Expanded Polystyrene process is incorrect?
a. Need a new pattern for each new casting
b. The foam pattern is removed from the mould prior to pouring.
c. Molten metal vaporizes the foam pattern.
d. A new pattern is required for each casting event.
A
The foam pattern is removed from the mould prior to pouring
18
Q
Which of the following statements about Investment Casting is incorrect?
a. Investment cast components possess a good surface finish
b. The wax can be recovered for reuse
c. Intricate geometries can be cast this way.
d. Not suitable for the precious metals.
A
Not suitable for the precious metals
19
Q
Which of the following does not belong to the permanent mould category?
a. Cold-Chamber Die Casting
b. Investment Casting
c. Semi-Solid Metal Casting
d. Centrifugal Casting
A
Investment Casting
20
Q
Which of the following statement is incorrect for permanent mould casting?
a. Finer grain structures are derived from slow solidification
b. It is suitable for high volume production
c. Need lubrication to prevent casting from fusing to mould
d. It generally limited to metals of lower melting point
A
Finer grain structures are derived from slow solidification
21
Q
Which of the following statement is incorrect for the Die casting process?
a. Applications are limited to low melting temperature metals like Zinc and Magnesium.
b. It needs high pressure to force the metal into die cavity during the process.
c. The die size will be slightly smaller compared to the desired part size due to shrinkage.
d. Pressure is maintained during solidification
A
The die size will be slightly smaller compared to the desired part size due to shrinkage
22
Q
Which of the following statement is incorrect for “Centrifuge” casting?
a. A series of cavities are located around the edge of a horizontally spinning mould
b. The liquid metal is forced out to the edges to fill these cavities, which form the parts
to be cast.
c. It is not a net shape process.
d. Molten metal is poured into rotating mould to produce a tubular part
A
Molten metal is poured into rotating mould to produce a tubular part
23
Q
Which of the following statements incorrect for Centrifugal Casting?
a. It has three categories including True Centrifugal, Semi-Centrifugal and Centrifugal
casting
b. Molten metal is poured into rotating mould to produce a tubular part
c. Uses centrifugal forces to distribute the molten metal to outer regions of die cavity
d. Outside shape of the casting can be round, octagonal, hexagonal, etc., but inside
shape is (theoretically) perfectly round, due to symmetric radial forces
A
It has three categories including True Centrifugal, Semi-Centrifugal and Centrifugal
casting
24
Q
Which of the following statements is incorrect when considering additional processing steps?
a. For brittle casting alloys and when cross sections are relatively small, appendages can
be broken off.
b. If cores have been used, they must be removed
c. Inspection is important to detect possible casting defects
d. Surface cleaning is not at all important for sand casting
A
Surface cleaning is not at all important for sand casting
25
Which of the following statements is true?
a. Two portions of metal flow together but there is a lack of fusion due to premature
freezing is known as a cold shut.
b. Cold shuts occur when metal splatters during pouring and solid globules form and
become entrapped in casting
c. Hot tearing (or cracking) is caused by a very flexible mould.
d. Micro-porosity is not caused by shrinkage
Two portions of metal flow together but there is a lack of fusion due to premature
freezing is known as a cold shut
26
Which of the following statements is incorrect?
a. Sand blow is a balloon‑shaped gas cavity caused by release of mould gases during
pouring.
b. Sand blow, penetration, mould shift, Hot tearing
c. Pinholes are small gas cavities formed deep in the center of the casting
d. Sand wash is caused by erosion during pouring
Pinholes are small gas cavities formed deep in the center of the casting
27
Which of the following statement is incorrect?
a. Visual inspection can be carried out to detect misruns, cold shuts, and severe surface
flaws
b. Dimensional measurements are not required as we can guarantee that tolerances
have been met
c. X-ray scanning is commonly used to detect any subsurface casting defects
d. Dimensional measurements are required to ensure that tolerances have been met
Dimensional measurements are not required as we can guarantee that tolerances
have been met
28
Which of the following products can be made of plastic?
a. Moulded parts
b. Films and sheets
c. Extruded sections
d. Fibres for textiles
e. All above
f. None of them
All above
29
Which of the following statements is incorrect?
a. Thermoplastics cannot be re-melted
b. Thermosets cannot be re-melted
c. Chemical structure remains unchanged during heating and shaping for thermoplastics
d. Curing processes occur during heating and shaping causing a permanent change in
molecular structure for thermosets
Thermoplastics cannot be re-melted
30
Which of the following statement is incorrect?
a. High molecular weight leads to high viscosity of polymer melts
b. Large flow rates lead to high shear rates and stresses, so require significant pressures
for polymer shaping processes
c. The thicker the melt, the easier it flows through small channels or die openings
d. Heat is required to soften a thermoplastic polymer before shape processing
The thicker the melt, the easier it flows through small channels or die openings
31
Which of the following statement is correct?
a. Viscosity of a polymer melt decreases with decreasing shear rate
b. Viscosity of a polymer melt increases with increasing shear rate
c. Viscosity of a polymer melt decreases with increasing temperature
d. Viscosity of a polymer melt increases with increasing temperature
Viscosity of a polymer melt decreases with increasing temperature
32
Which of the following statement is incorrect?
a. Extrusion is capable of mass producing both thermoplastics and elastomers
b. The die is an extruder component
c. Extrusion is used to produce items such as tubing, pipes, hose, structural shapes,
sheet and film.
d. The melt will pass through a screen pack before reaching the die
The die is an extruder component
33
Which of the following statement is correct to represent the resulting melt flow in extruder?
a. Drag flow (Qd)
b. Back pressure flow (Qb)
c. Qx = Qd + Qb
d. Qx = Qd - Qb
Qx = Qd - Qb
34
Which of the following statements is incorrect?
a. Wire provides rigidity during cooling
b. A slight vacuum is drawn between wire and polymer to promote adhesion of coating
during wire coating.
c. Cooling is aided by passing coated wire through a water trough.
d. Product is wound onto large spools at speeds up to 500 m/s
Product is wound onto large spools at speeds up to 500 m/s
35
Which of the following statement is incorrect?
a. For the calendaring process, production rates are high, and equipment is expensive.
b. Calendering offers poor surface finish and low gauge accuracy
c. Feedstock is passed through a series of rolls to reduce thickness to desired gauge
d. Plasticized PVC could be processed by Calendering
Calendering offers poor surface finish and low gauge accuracy
36
Which of the following statements is incorrect?
a. A filament is a fibre of continuous length
b. Fibres can be natural or synthetic
c. Spinning is used to produce fibres and filaments
d. Spinneret is a die with a single hole
Spinneret is a die with a single hole
37
Which of the following statements is incorrect?
a. Injection moulding needs both heat and pressure
b. The injection unit acts as the principle component to hold two halves of mould in
proper alignment
c. The procedure will produce discrete components to net shape
d. Injection moulding is economical only for large production quantities due to high cost
of mould
The injection unit acts as the principle component to hold two halves of mould in
proper alignment
38
For the two-plate mould, which of the following statements correctly matches the
corresponding flowing path with their channel name?
a. Leads from nozzle into mould- Runners
b. Leads from sprue to cavity (or cavities)- Sprue
c. Leads from nozzle into mould- Gates
d. Leads from sprue to cavity (or cavities)- Runners
Leads from sprue to cavity (or cavities)- Runners
39
Which of the following statements about shrinkage factors is incorrect?
a. Dimension of the mould cavity must be larger than specified part dimensions
b. Higher pressure forces more material into mould cavity to reduce shrinkage
c. Longer compaction time leads to greater shrinkage
d. Thicker parts show greater shrinkage
Longer compaction time leads to greater shrinkage
40
Which of the following statements is incorrect?
a. Both thermoplastic and thermosets can be processed by injection moulding
b. Curing is the most time-consuming step in injection moulding cycles
c. Polymer matrix composite parts could be produced through compression and transfer
moulding
d. Compression moulds contain sprues and runner systems to obtain repeatable
consistency in the moulded product
Compression moulds contain sprues and runner systems to obtain repeatable
consistency in the moulded product
41
Which of the following statement is incorrect?
a. Stretch (Injection) Blow moulding can be used to process both thermoplastics and
thermosets
b. Blow moulding can be used to produce one-piece hollow plastic parts with thin walls
such as bottles.
c. Rotational moulding has lower production rates than blow moulding
d. Rotational moulding is able to process both thermoplastic and thermosetting parts
Stretch (Injection) Blow moulding can be used to process both thermoplastics and
thermosets
42
Which of the following statement is incorrect?
a. During thermoforming, heat is applied by radiant electric heaters
b. Positive mould has concave cavity
c. Negative mould has concave cavity
d. Only thermoplastics can be thermoformed
Positive mould has concave cavity
43
Which of the following statements is incorrect?
a. Casting is suitable for both thermoplastics and thermosets
b. Polymer foams possess good energy absorbing qualities
c. Polystyrene (PS) is a thermoset polymer that can be processed through extrusion
d. Polymer foams can be classified into elastomeric, flexible, and rigid
Polystyrene (PS) is a thermoset polymer that can be processed through extrusion
44
Which of the following statements is incorrect?
a. Sharp corners from both inside and outside are not preferred during extrusion
b. Transfer moulding production quantities lie between injection moulding and
compression moulding
c. Plastic mould allows for part complexity
d. Ribs should be made thicker than the walls they reinforce to minimize sink marks on
outside wall
Ribs should be made thicker than the walls they reinforce to minimize sink marks on
outside wall
45
Which of the following statements is correct?
a. Production of raw natural rubber (NR) is based on the petrochemical industry
b. Production of synthetic rubbers is based on the agricultural industry
c. Coagulation is involved in recovering the rubber
d. Pale crepe rubber is the best grade, while the ribbed smoked sheet has a better grade
than the air-dried sheet
Coagulation is involved in recovering the rubber
46
Which of the following statement is correct?
a. Synthetic rubber is produced by the same polymerization technique used to synthesis
other polymers
b. Rubber is never compounded with additives
c. Carbon black decreases tensile strength and resistance to abrasion and tearing of the
final rubber product
d. Cured rubbers have high viscosity so mechanical working of the rubber can increase
its temperature up to 150°C (300°F)
Synthetic rubber is produced by the same polymerization technique used to synthesis
other polymers
47
Which of the following statements is correct?
a. During the master batch stage in the two-stage mixing process, vulcanizing agents are
added to combine with the raw rubber
b. During Stage 2 - after stage 1 mixing is completed, and cooling time has been allowed,
vulcanizing agents are removed from the rubber.
c. The L/D ratio of the extruder barrel in rubber manufacture is much smaller than for
thermoplastics
d. Rubber sheet thickness is slightly greater than final roll gap due to the die swell
Rubber sheet thickness is slightly greater than final roll gap due to the die swell
48
Which of the following statements is incorrect?
a. Compression moulding for rubber, is the most important manufacturing process
because of its wide use in tyre manufacture.
b. Cross-linking during vulcanization makes the rubber stiffer and stronger but retains
extensibility
c. After vulcanization from the same raw rubber, less cross-link productions are softer
than those with more cross-links.
d. The long‑chain molecules become joined at certain tie points, which increases the
ability to flow
The long‑chain molecules become joined at certain tie points, which increases the
ability to flow
49
Which of the following statements is incorrect?
a. Tyre makes up about 25% of total rubber tonnage
b. Shaping techniques for composites are more complex and less efficient than other
materials
c. Pultrusion is like extrusion but includes continuous fibre reinforcement
d. In a polymer matrix composite, the starting polymer and reinforcing phase are
processed separately before becoming phases within a composite
Tyre makes up about 25% of total rubber tonnage
50
Which of the following statements is incorrect?
a. Nearly all rubbers are reinforced with carbon black
b. Recycled rubber is added in some rubber products, but usually at 10% or less
c. Carbon black provides no protection from ultraviolet radiation
d. hydrous aluminum silicates are used as fillers when the product cannot be black in
colour
Carbon black provides no protection from ultraviolet radiation
51
Which of the following statement is incorrect?
a. Prepregs are available as tapes or cross-plied sheets or fabrics
b. Prepregs are fabricated with continuous filaments rather than chopped random fibres
c. Hand lay-up is a closed mould process and is very economical for high production
d. Successive layers of resin and reinforcement are manually applied to build the
laminated FRP composite structure in the hand lay-up method
Hand lay-up is a closed mould process and is very economical for high production
52
Which of the following statements is incorrect?
a. Curing is required for all thermosetting resins used in FRP laminated composites
b. Three principal process parameters in curing are time, temperature, and pressure
c. Curing normally occurs at very high temperature for the TS resins used in hand lay-up
and spray-up procedures
d. Tooling cost of a closed mould is more than twice the cost of a comparable open
mould due to the more complex equipment required in these processes
Curing normally occurs at very high temperature for the TS resins used in hand lay-up
and spray-up procedures
53
Which of the following statements is incorrect?
a. Conventional injection moulding (RIM) must use chopped fibres
b. Reinforced reaction injection moulding (RRIM) includes typical glass fibres in the
mixture where curing and solidification occur
c. Like extrusion, pultrusion produces continuous straight sections of varying cross
section
d. Pultrusion fit for unsaturated polyesters, epoxies, silicones and all thermosetting
polymers
Like extrusion, pultrusion produces continuous straight sections of varying cross
section
54
Which of the following statements is incorrect?
a. Uncured FRPs are more tough and difficult to cut than cured ones
b. Cemented carbide cutting tools could be used for glass FRPs
c. Holes can be cut when shaping PMCs
d. Water jet cutting is an advanced cutting method with reduced dust and noise
Uncured FRPs are more tough and difficult to cut than cured ones
55
Which of the following statement is incorrect?
a. Green compacts are fully processed materials after applying pressure and sintering
b. Sintering temperature lies between the recrystallization temperature and the melting
point
c. Mass produced PM parts can be net-shape or near-net shape
d. Tungsten filaments can be made via powder metallurgy technology
Green compacts are fully processed materials after applying pressure and sintering
56
Which of the following statement is incorrect?
a. Part geometries are limited when manufactured via the Powder metallurgy method.
b. Density is completely uniform within the integral PM part
c. Powder metallurgy technology is widely used to manufacture alloys of iron and
aluminium but can be used for molybdenum, refractory metals etc.
d. Any metal (pure or alloyed) can be made into powder
Density is completely uniform within the integral PM part
57
Which of the following statements is incorrect?
a. Water atomisation creates particle sizes inversely related to water velocity
b. Corrosion/oxidation is addressed in modern techniques by using synthetic oils instead
of water
c. In the electrolysis process the cathode dissolves under an applied voltage and is
deposited on the anode
d. Blending and mixing are two separate processes
In the electrolysis process the cathode dissolves under an applied voltage and is
deposited on the anode
58
Which of the following statements is correct?
a. Blending combines powders of different chemistries together (a method of creating
alloys)
b. Compaction uses high temperatures to melt and form the powders into desired
shapes
c. The green part strength should be adequate and greater than after sintering
d. Mixing combines powders of different chemistries together
Mixing combines powders of different chemistries together
59
Which of the following statements is correct?
a. Compaction pressure for a given aluminium powder is greater than steels
b. Part shrinkage occurs during sintering due to pore size reduction
c. Porosity will be completely eradicated during compaction.
d. Surface energy tends to increase and contributes to the primary driving force for
sintering
Part shrinkage occurs during sintering due to pore size reduction
60
Which of the following sequence is correct during the common sintering processes?
a. Particle bonding is initiated at contact point → Pores between particles reduce in size
→ Grain boundaries develop between particles in place of necked regions → Contact
points grow into “necks”
b. Pores between particles reduce in size → Grain boundaries develop between particles
in place of necked regions → Particle bonding is initiated at contact point → Contact
points grow into “necks”
c. Particle bonding is initiated at contact point → Contact points grow into “necks” →
Grain boundaries develop between particles in place of necked regions → Pores
between particles reduce in size
d. Particle bonding is initiated at contact point → Contact points grow into “necks” →
Pores between particles reduce in size → Grain boundaries develop between particles
in place of necked regions
Particle bonding is initiated at contact point → Contact points grow into “necks” →
Pores between particles reduce in size → Grain boundaries develop between particles
in place of necked regions
61
Which of the following statements is correct?
a. Porosity is always unwanted as it prevents 100% true density
b. Compared with copper, stainless steel requires shorter sintering times as it is treated
under higher sintering temperature
c. Secondary operations like sizing and coining can further improve the density and
accuracy
d. Infiltration uses fluid to fill the pores, while impregnation uses molten metal to
permeate into the pores of the sintered PM parts
Secondary operations like sizing and coining can further improve the density and
accuracy
62
Which of the following statements is correct?
a. Heat treatment is possible during PM processes to improve the workpiece strength
b. Hydrostatic pressure is applied via a fluid against the mould to compact the powder
from two opposite directions along the same axis during the isostatic pressing
c. Powder Injection moulding (PIM) can only use thermoplastics as a suitable polymer
binder
d. During the PIM process, binder will be kept inside the mould with the green parts
during sintering
Heat treatment is possible during PM processes to improve the workpiece strength
63
Which of the following statements is incorrect?
a. Alloying may occur during liquid phase sintering
b. Gears and bearings are ideal for PM production because of their two-dimensional
geometries as well as their porosity requirement.
c. PM is unique in its capability to fabricate parts with controlled levels of porosity (up
to 50% is possible) Spark sintering uses upper and lower punches to act as electrodes
PM is unique in its capability to fabricate parts with controlled levels of porosity (up
to 50% is possible) Spark sintering uses upper and lower punches to act as electrodes
64
Which of the following statements is incorrect?
a) The work hardened part will follow a new elastic region up to a new yielding point
b) Ductility commonly drops along with an improvement in strength during work hardening
c) The term “Cold working” indicates the working temperatures is much lower than the room
temperature
d) Recrystallizing temperature is about 0.5 the melting point temperature
The term “Cold working” indicates the working temperatures is much lower than the room
temperature
65
Which of the following statements is incorrect?
a) Cold working requires higher forces and power for deformation
b) Warm working temperatures are higher than the melting point but below the recrystallization
temperature
c) Warm working requires extra heat but lower forces and power than in cold working
d) Warm working does not remove work hardening effects
Warm working temperatures are higher than the melting point but below the recrystallization
temperature
66
Which of the following statements is incorrect about hot working?
a) Hot working is performed above the recrystallization temperature
b) Strength properties of a hot worked product are generally anisotropic
c) There exists surface oxidation but no work hardening
d) It suffers from lower dimensional accuracy due to shrinkage
Strength properties of a hot worked product are generally anisotropic
67
Which of the following statements is incorrect?
a) A typical classification of metal forming operations is bulk deformation and sheet
metalworking.
b) Thread rolling products have better fatigue resistance over the thread cut ones.
c) Within ring rolling, a hot working process is used for smaller rings, while a cold
working process is used for larger rings
d) Open-die forging can be classified into two types depending on whether there is
friction or not
Within ring rolling, a hot working process is used for smaller rings, while a cold
working process is used for larger rings
68
Which of the following is not a bulk deformation process?
a. Rolling processes
b. Bending operations
c. Extrusion processes
d. Forging processes
Bending operations
69
Which of the following statements is incorrect?
a. Impression die forging = compression of workpiece by die with an inverse of the
desired part shape
b. Compared to machining, impression die forging less more waste.
c. During flash formation, friction resists continued metal flow into the gap, constraining
the metal to fill the die cavity
d. Flashless forging uses a starting work volume much larger than the die cavity to
compensate for shrinkage
Flashless forging uses a starting work volume much larger than the die cavity to
compensate for shrinkage
70
Which of the following statements regarding extrusion is incorrect?
a. It’s not possible to create hollow cross-sectional products via extrusion.
b. Elongated grains in an extrusion can provide favourable directional properties
c. In some extrusion operations there can be little or no waste of materials
d. Extrusion can be carried out directly or indirectly
It’s not possible to create hollow cross-sectional products via extrusion.
71
Which of the following statements is incorrect?
a. Grain structure and strength are enhanced in both cold and warm extrusion
b. Most pressworking operations are performed using a conventional punch-and-die
tooling set up
c. An extrusion press can be set up horizontally but not vertically
d. Close tolerances are possible, especially in cold extrusion
An extrusion press can be set up horizontally but not vertically
72
Which of the following process sequences is correct for cutting?
a. Very beginning before the punch contacts work → Fracture is initiated at opposing
cutting edges to separate the sheet → Punch pushes into work, causing plastic
deformation → Punch penetrates into work causing a smooth cut surface
b. Very beginning before the punch contacts work → Punch pushes into work, causing
plastic deformation → Punch penetrates into work causing a smooth cut surface →
Fracture is initiated at opposing cutting edges to separate the sheet
c. Very beginning before the punch contacts work → Punch penetrates into work
causing a smooth cut surface → Punch pushes into work, causing plastic deformation
→ Fracture is initiated at opposing cutting edges to separate the sheet
d. Very beginning before the punch contacts work → Fracture is initiated at opposing
cutting edges to separate the sheet → Punch penetrates into work causing a smooth
cut surface → Punch pushes into work, causing plastic deformation
Very beginning before the punch contacts work → Punch pushes into work, causing
plastic deformation → Punch penetrates into work causing a smooth cut surface →
Fracture is initiated at opposing cutting edges to separate the sheet
73
Which two of the following statements are correct?
a. For blanking, cut piece is the desired part, surrounding stock is the scrap
b. For blanking, cut piece is the scrap, surrounding stock is the desired part
c. For punching, cut piece is the desired part, surrounding stock is the scrap
d. For punching, cut piece is the scrap, surrounding stock is the desired part
a. (a)(c) b. (a)(d) c. (b)(c) d. (b)(d)
(a)(d)
74
Which of the following statements is incorrect?
a. During bending, metal on the inside of the bend is compressed, while material on the
outside of the bend is stretched.
b. V-bending is complex and very expensive.
c. There are multiple types of bending including edge-bending and v-bending.
d. Edge bending dies are complex and very expensive
V-bending is complex and very expensive
75
Which is not one of the main important operations associated with “Machining”?
a. Turning
b. Cutting
c. Drilling
d. Milling
Cutting
76
Which of the following statements about metal machining is incorrect?
a. Virtually all metals can be machined.
b. Variety of part shapes and geometric features possible.
c. It is a tertiary operation.
d. Products possess good surface finish and dimensional accuracy
It is a tertiary operation
77
Which of the following statement is incorrect?
a. Turning uses multiple cutting-edge tools
b. Drilling uses multiple cutting-edge tools
c. Milling uses multiple cutting-edge tools
d. Turning uses single-point tools
Turning uses multiple cutting-edge tools
78
Which of the following statements is incorrect?
a. Roughing cuts uses high feeds and depths, with low cutting speeds.
b. Finishing cuts use low feeds and depths, with high cutting speeds.
c. High cutting temperatures reduce tool life.
d. Finishing cuts are carried out before roughing cuts
Finishing cuts are carried out before roughing cuts
79
Which of the following statements about chip formation is incorrect?
a. Chip formation is dependent on multiple factors.
b. Ductile materials produce continuous chips.
c. Brittle materials produce discontinuous chips.
d. Brittle materials don’t produce any chip formation
Brittle materials don’t produce any chip formation
80
Which of the following statements is incorrect?
a. Boring is performed on the inside diameter.
b. Turning is performed on the inside diameter.
c. Threading is cutting the threads onto an external diameter.
d. The drill bit should be stationary during turning operations
Turning is performed on the inside diameter
81
Which of the following statements are incorrect?
a. For a blind hole the drill exits opposite side of work piece.
b. For a through hole the drill exits opposite side of work piece.
c. Tapping is used to cut internal screw threads into an existing hole.
d. Centering is used to drill a starting hole for subsequent further drilling
For a blind hole the drill exits opposite side of work piece
82
Which of the following statements are incorrect?
a. The cutting edges of a milling cutter are called teeth
b. Peripheral milling has cutter axis parallel to surface
c. Face milling has cutter axis perpendicular to surface
d. Milling operations create only a planar surface
Milling operations create only a planar surface
83
Which of the following statements is incorrect?
a. In the shaping process, tools move across workpart
b. In the planing process, tools move across workpart
c. Both shaping and planing use a single point cutting tool.
d. Broaching uses a multiple tooth cutting tool
In the planing process, tools move across workpart
84
Which of the following statement is incorrect?
a. For maximum efficiency, design parts need minimize machining.
b. Sharp corners should be avoided in machined parts.
c. Sharp edges on machined parts are easy to machine.
d. Machined parts should be designed to be produced from stock materials
Sharp edges on machined parts are easy to machine
85
What are the three parameters of cutting in machining?
a. Cutting speed, feed and depth of cut.
b. Cutting speed, chip thickness and depth of cut.
c. Chip thickness, shear plane angle and cutting speed
d. Cutting speed, feed and shear plane angle.
Cutting speed, feed and depth of cut
86
Which of the following statement is incorrect?
a. Material removal rate can be computed with cutting speed, feed and depth of cut
b. Chip thickness is usually larger than 1
c. Closer tolerances usually mean higher costs
d. Can use cutting fluid to avoid the chatter
Chip thickness is usually larger than 1
87
Which of the following statements relating to discontinuous chips is incorrect?
a. Brittle materials produce discontinuous chips.
b. High cutting speeds are using to produce discontinuous chips.
c. There is low tool-chip friction
d. Large feed and depths of cut are used
There is low tool-chip friction
88
Which of the following statements relating to continuous chips is incorrect?
a. Low cutting speeds are used to produce continuous chips.
b. Good surface finish is typical with continuous chips.
c. Small feeds and depths of cut are used.
d. Ductile materials produce continuous chips
Low cutting speeds are used to produce continuous chips
89
Which of the following is not a cutting tool failure mode?
a. Fracture failure
b. Gradual failure
c. Temperature failure
d. Geometry failure
Geometry failure
90
Which of the following materials properties should not be considered when manufacturing a
tool?
a. Biocompatibility
b. Toughness
c. Hot Hardness
d. Wear Resistance
Biocompatibility
91
A tool has reached the end of its life and should be replaced when the amount of wear reaches
0.5mm (True or False)
True
92
Single-point tools are not possible to be re-sharpened (True or False)
False
93
Which of the following materials is not used to manufacture cutting tools?
a. Synthetic diamond.
b. Aluminium.
c. Cemented carbides.
d. Ceramics
Aluminium
94
Which of the following statements is incorrect?
a. A cutting fluid can be liquid, or gas used to improve cutting performance.
b. Coolant-type cutting fluids are water based.
c. Lubricant-type cutting fluids are water based.
d. Coolants are most effective at high cutting speeds due to elevated temperatures
Lubricant-type cutting fluids are water based
95
Which one of these statements is not an additional function/benefit of cutting fluids?
a. Increases thermal distortion.
b. Helps to remove waste material by washing it away.
c. Increases the cutting tool life.
d. Reduces the temperature of the work piece
Increases thermal distortion
96
Which of the following statement is incorrect?
a. Contamination is always in the form of a solid waste material.
b. Cutting fluid needs to be replaced at regular and frequent intervals.
c. A filtration system is used to periodically clean the cutting fluid.
d. Cutting fluid isn’t used in dry machining but this uses a lower cutting speed to prevent
overheating
Contamination is always in the form of a solid waste material
97
In turning, total production cycle time for one part consists of
a. Part handling time per part
b. Machining operation time per part
c. Tool change time per part
d. All above
All above
98
In turning, total production cycle cost for one part consists of
a. Cost of the starting /raw material
b. Labor and equipment costs
c. Cost of tooling
d. All above
All above
99
Which of these statements accurately describes a heat treatment?
a. Heating and cooling process to cause microstructural changes in a material.
b. Heating process to cause microstructural changes in a material.
c. Heating and cooling process to cause mechanical property changes in a material.
d. Heating and cooling process to cause microstructural and mechanical property
changes in a material
Heating and cooling process to cause microstructural and mechanical property
changes in a material
100
Which of the following statement is incorrect?
a. Heat treatment can soften the metal prior to shaping
b. Heat treatment can relieve residual stresses caused by forming
c. Heat treatment acts to strain harden the material.
d. Heat treatment improves the material properties
Heat treatment acts to strain harden the material
101
Which of these definitions is incorrect?
a. Annealing is the softening of metal back to its original pre-work hardened properties.
b. Hardening is increasing the hardness of a metal using heating and cooling.
c. Tempering increases the hardness of a metal using heating.
d. Quenching is the act of rapidly cooling a work part in a media
Tempering increases the hardness of a metal using heating
102
Different quenching media have different cooling rate, which of the following
sequence is correct?
a. (Fastest) Brine>Still oil>Still fresh water> Air
b. (Fastest) Air> Still fresh water > Still oil>Brine
c. (Fastest) Air>Still oil>Still fresh water>Brine
d. (Fastest) Brine>Still fresh water>Still oil>Air
(Fastest) Brine>Still fresh water>Still oil>Air
103
Annealing sees the metal heated to a temperature above its melting temperature.
(True or False)
False
104
Martensite formation in steel occurs with rapid cooling. (True or False)
True
105
Annealing can improve a materials ductility and reduce its hardness (True or False)
True
106
Pearlite has a higher hardness than Martensite (True or False)
False
107
TTT diagram shows the transformation of austenite into other phases as a function of
time and temperature for a specific composition of steel. (True or False)
True
108
All alloys can be strengthened using precipitation hardening (True or False)
False
109
Solution treatment is carried out at a higher temperature than precipitation
treatment (True or False)
True
110
The hardening mode in nitriding is precipitation hardening. (True or False)
True
111
Desired abrasive materials for grinding should possess similar properties to the
cutting tools (True or False)
True
112
Friability is a material property that all abrasive materials possess, which prevents
grains from fracturing to expose a new sharp cutting edge. (True or False)
False
113
Which of the following statement about the bonding materials is incorrect?
a. It should be designed to withstand centrifugal forces
b. It should be designed to withstand high temperatures
c. It should be designed to resist shattering during shock loading of wheel
d. It should hold abrasive grains loosely in place for cutting
It should hold abrasive grains loosely in place for cutting
114
Which of the following statement about the wheel is incorrect?
a. Dense wheel structure has closely packed grains.
b. Open wheel structure provides greater chip clearance.
c. Dressing the wheel uses a diamond-pointed tool
d. Dense wheel structure results in a high quality surface finish
Dressing the wheel uses a diamond-pointed tool
115
Residual stresses build at the work surface due to grinding. (True or False)
True
116
Grinding wheels contains a large amount of abrasive material, so it must be replaced
very often. (True or False)
False
117
Which of the following statement about the general grinding rules is incorrect?
a. To maximum the removal rate, use larger grit size
b. To maximum the removal rate, use more open wheel structure
c. To optimize surface finish, use smaller grit size
d. For soft metals, use larger grit size and softer grade wheel
For soft metals, use larger grit size and softer grade wheel
118
The most common grinder is a surface grinder with horizontal spindle and
reciprocating worktable (True or False)
True
119
Lapping creates a characteristic cross-hatched surface that retains lubrication and
prevents scuffling (True or False)
False
120
Which of the following statement best describes the primary considerations of
manufacturing economics?
a. Production cycle time
b. Basic manufacturing cost analysis
c. Systems that improve efficiency
d. All above
All above
121
The cycle time of an operation is the total time, in minutes, to make one completed
piece (pc) (True or False)
True
122
A basic machining process starts from load starting material and ends at unload
finished parts (True or False)
False
123
The total production cycle time (Tc) is equal to the operation processing time plus
handling time and the actual tool change time (True or False)
False
124
Production rate is the hourly cycle rate (True or False)
True
125
Availability will affect the cycle time and cycle rate (True or False)
True
126
Which of the following statement is incorrect?
a. Cellular processing suits mass production of identical parts
b. Flexible manufacturing systems increase work-in-process due to continuous
production.
c. A JIT system requires a pull system of production control
d. A QMS system shows commitment to producing high quality across their
products/services
Flexible manufacturing systems increase work-in-process due to continuous
production
127
Which of the following statement about ALM is incorrect?
a. It can also be known as 3D printing, or rapid prototyping
b. It has the potential to reduce material waste and improve the process efficiency
c. Components are manufactured without any support structures
d. Stainless steel is currently a popular material under ALM investigation
Components are manufactured without any support structures
128
Which is the most common defect in ALM processes?
a. Porosity
b. Rough surface finish
c. Distortion
d. Re-used powders deteriorate
e. All above
f. None of them
All above
129
Which of the following statements is incorrect?
a. Columnar grains are observed within many ALM builds
b. ALM parts should be designed only vertically to optimize mechanical properties
c. Build direction influences the surface finish of components
d. Warping may occur during in some components
ALM parts should be designed only vertically to optimize mechanical properties
130
Which of the following statements is incorrect?
a. HIP is used to reduce the porosity and improve strain to failure in materials
b. HIP is the application of temperature and pressure in an inert atmosphere.
c. HIP is used to improve the strain to failure.
d. HIP improves the surface roughness
HIP improves the surface roughness
131
Which of the following statements is incorrect?
a. Semi-solid processing is conducted within a materials solid-liquid region.
b. Semi-solid processing offers rapid production speeds and excellent dimension
tolerance.
c. It has relatively lower processing temperature compared with the traditional die
casting
d. Alloys with a narrow temperature range is preferable and easier to produce using
semi-solid processing
Alloys with a narrow temperature range is preferable and easier to produce using
semi-solid processing
132
Which of the following statements is incorrect?
a. There is no intermediate solidification step in rheo-route processing
b. Rheo-route processing produces net shape products.
c. Thixo-route processing is a one step process.
d. Thixo-route processing has an intermediate solidification step
Thixo-route processing is a one step process
