Red Seal Flashcards
(258 cards)
1
Q
Milling feed rate is in
A
inches per minute
2
Q
Band saw feed rates for structural steel, piping, tubing
A
in square inches per minute
Structural steel - reduce by 25%
Piping - reduce by 50%
Tubing - reduce by 65%
3
Q
Twist drill helix angle for soft materials such as aluminum, magnesium, zinc
A
High helix 40 degrees
4
Q
Which milling produces the best surface finish
A
climb milling
5
Q
Curved drag lines with slag buildup on the bottom when cutting with a torch indicates what
A
travel speed too fast
6
Q
Amount of stickout for MIG welding
A
3/8”
7
Q
What welding cable is bigger, 1/0 or #2
A
1/0 is bigger, use small cable as the whip for better rod manipulation
8
Q
Most used flame for oxy-acetylene welding mild steel
A
neutral
9
Q
GTAW electrode point taper length
A
2 to 2.5 times the diameter of electrode
10
Q
Whats best for welding copper and aluminum
A
GTAW
11
Q
Best flame for fusion welding
A
Neutral
12
Q
Which oxy-acetylene tank do you turn off first
A
Close oxygen valve first, bleed oxygen line, close torch valve. Repeat for acetylene
13
Q
What is the primary risk welding outdoors in windy conditions
A
porosity
14
Q
Which SMAW power configurations offers the most penetration
A
DCEP (DC Electrode Positive, DC Reverse Polarity)
AC = Medium penetration
Straight polarity = Least penetration
15
Q
Method used to join dissimilar metals together
A
brazing
16
Q
What process cuts both ferrous and non-ferrous metals
A
plasma arc cutting
17
Q
If a piece of steel cut by a torch has a rough edge with large amounts of slag on the bottom what is the cause
A
cutting tip is dirty
18
Q
What kind of cutting tip is designed to cut close to a surface without damaging it
A
rivet/bulkhead tip
19
Q
Hardhats need to be replaced how often
A
Every 5 years
Liner every year
20
Q
What safety device is built into a acetylene cylinder
A
fusible plug
21
Q
Automatic level formula
A
distance = (upper reading - lower reading) x 100
22
Q
Most accurate tool to layout number parallel lines on a workpiece
A
Height gauge on a surface plate
23
Q
Best direct measuring device for a bore diameter
A
inside micrometer
24
Q
prick punch angle
A
30-60 degrees
25
Most accurate way of measuring shaft OD
outside micrometer
26
type of transfer measuring tool for bore diameters
telescoping gauge
27
tool used to find the centre of a shaft
centering head with scribe
28
thread pitch of a imperial micrometer
0.025"
29
What tool can aid in the production of angled lines
Trammel points using ARC method
30
How to calibrate 2"-3" outside micrometer
Clean anvil and spindle faces, use a 2 inch gage block or standard and check if it lines up to the 2 inch line
31
first step when setting up to use an optical level
set and level tripod
32
centre punch angle
90 degrees
33
most water resistant grease
lithium
34
which band saw blade set cuts the fastest
straight/alternate set (leaves rough cut)
wavy set for thin material like piping
raker set for smoothest cut
35
reamer used for keyed or slotted hole
spiral
36
two ways to cut material when milling
conventional and climb
37
When should you not increase cutting speed
hard materials
38
anti-foam additive in oils
silicone
39
brown and sharpe milling arbor taper
1/2" per foot
40
dowel pin taper
1/4" per foot
41
carbon content of 4140
0.40%
42
When cutting without cutting fluid on a bandsaw how much should you reduce cutting speed
40-50%
43
How is the angle of a cut adjusted on a vertical band saw
the work table is adjusted
44
Steels contain less than _% iron
2%
| over 2% is called iron
45
grease used in cold environments
naptha
46
feed speed when using reamers
1/2 twist drill speed rpm, 2 times the feed
47
For steel to harden it must have a minimum carbon content of ___%
0.20%
48
which lathe dog engages the drive plate directly
bent tail dog
49
cutting speed formula
rpm = cutting speed x 4 / diameter of cutting tool
50
this relieves internal stresses and brittleness created by the hardening process
tempering
51
this process makes a hardened workpiece soft and machinable again
annealing
52
thread angle of a metric thread
60 degrees
53
standard helix drill angle
30 degrees
54
When should EP with sulfur not be used
brass and bronze components
55
this is the process of removing strain and irregular grain structure from a piece of steel
normalizing
56
thread designed to take high axial loads in one direction
buttress
57
the ability for a material to return to it's original shape after being deformed
elasticity
58
thermal expansion formula
0.0000063 x temp change x size of workpiece
59
the process where a steel is heated up until it changes to austenite then quenched to form martensite
hardening
60
what should be done to the drill when drilling brass
slightly hone the cutting edge to reduce rake angle to zero
61
the ability of a metal to resist penetration and plastic deformation
hardness
62
the ability of a material to be stretched permanently without breaking
ductility
63
the ability of metal to withstand shock and impact without breaking or shattering
toughness
64
the ability of a metal to withstand pull without breaking
tensile strength
65
the ease you can cut and shape a metal
machinability
66
Single vertical hitch formula
SWL = Weight x (H/L) x 3
** when all 3 legs are not equal use the longest leg length**
67
Basket hitch formula
Basket = Weight x Number of legs x Sin(angle)
68
Smallest lift angle on a shouldered bolt
45 degrees
69
these allow chain sling legs to be adjusted for positioning of the lifting hook over the centre of gravity
load leveler
70
How to measure a wire rope
at it's widest point, which is across the crowns. Measure 3 positions on a six-strand rope, 4 positions on a eight strand rope
71
what kind of steel is wire rope usually made of
plow steel
72
what type of knot ties two ropes of different diameter together
sheet bend
73
Rigging chain size is determined by
the link diameter, measure the non welded side with vernier calculator
74
What is an anchor (Dee) shackle for
lifting from many different angles
75
Chain shackles are used for
inline lifts
76
at what angle does each sling take the full weight of the load
30 degrees
77
what type of splice should should hoisting slings use
flemish eye splice
78
sling to use where loads are abrasive or hot
wire mesh sling
79
nylon sling SWL rule
1600lbs per inch
| ex 2 inch sling = 3200lbs SWL
80
How to calculate the mechanical advantage of a rope block pulley
add up the lines not directly connected to the load or being pulled
81
what does a headache ball do
connects to the end of a crane wire rope to keep the line taught
82
formula for a 2 leg bridle hitch SWL
(H/L) x SWL = reduced SWL of each sling
83
replace running ropes when
- six or more broken wires in one lay
| - 3 or more broken wires in one strand in one lay
84
replace standing ropes when
- three or more broken wires in one lay
| - breaks near sockets or splices
85
minimum tapped hole depth for eye bolts
1.5 times nominal bolt diameter
86
destroy shackled when the crown or pin is worn by more than __%
10%
87
crosby clips are __% of the strength of the rope
80%
88
crosby clip formulas
```
# of clips = rope diameter x 3 + 1 (round to next whole number)
clip spacing = rope diameter x 6
turnback = # of clips x spacing
```
89
does a single block have mechanical advantage
no, it only changes the direction of pull
90
when a rope connects two blocks together
block and tackle
91
when do you use a snatch block
vertical and lateral moves
92
what hitch would you use to hoist a bundle of steel pipe
double-wrap basket hitch
93
when the throat of a shackle is opened more than __% remove it from service
10% (15% by law in canada)
94
strongest synthetic fibre rope
nylon
95
chain stretch should not exceed _%
5%
| wear should not exceed 10%
96
rigging safety factors
general lifting = 5:1
lifting people = 10:1
elevators = 20:1
97
what do you use when wire rope connections are frequently changed
wedge sockets
98
best synthetic rope for shock loads
nylon
99
crane capacity formula
(tipping axis/load radius) x crane capacity
100
this allows you to control the position of the load by friction by wrapping the line around a post or beam
snubbed line
101
When using a shackle to connect to a lifting hook place this part of the shackle on the hook
the shackle pin rests on the hook, the sling eyes are on the bow section of shackle
102
wire core wire rope should not be used at these temps or higher
205 C (400 F)
103
when testing a piece of lifting equipment the point at which it breaks is called it's
breaking strength
104
SWL of wire rope formula
D^2 x 8 = weight in tons
105
when should wire rope be replaced
when the surfaces are worn by 1/3 or more of original diameter
106
rigging sheave arc of contact
120 to 150 degrees
| minimum sheave diameter = 20 times rope diameter
107
how to secure a turnbuckle
lock wire
108
scaffold safety factor
4 times the load imposed on it
109
at what height are guardrails erected for a temporary platform
10 feet
110
at what height are toe boards required when workers can be underneath
3.5 meters (11 feet)
111
rule of thumb for outrigger pad floats
3 times the area of the pad
| ex. 24" diameter pad = .7854 x D^2 x 3
112
which knot is used to lift or lower piping and tubing
timber hitch
113
free standing or rolling scaffolding maximum height
3 times the smallest footprint
| ex. 8'x12' = 8x3 = 24 feet high
114
procedure for turning off a torch
turn off acetylene first
115
how low are foundations set
3/4" to 1-1/2" low to allow for grout
116
width of a square key
1/4 diameter of the shaft
117
1014 woodruff key =
```
10/32 = 5/16" wide
14/8 = 1-3/4" diameter
```
118
the ability to absorb dirt and abrasives to prevent them from wearing or scoring components in a friction bearing
embeddability
119
babbitt pouring temperature is usually this much above the melting temp
200 F higher
120
how to mount a taper bore bearing on a cylinder with no shoulder
adapter sleeve
121
when should the drive side not be fixed
when the weight is on the opposite side and the motor is direct drive with no sheaves to line up
122
which shaft seals can operate at the highest speeds
non-contact seals such as labyrinth
123
bearing shield code
```
Z = shield
RS = seal
```
124
hydrostatic bearings eliminate this
start up wear
125
what type of lubrication supports the rolling elements in the load zone
elasto-hydrodynamic film lubrication
126
normal bearing clearance is between these clearances codes
C2 - normal - C3
127
the ability of a liquid to maintain contact with a solid surface
wettability
128
6210 shaft diameter
10 x 5 = 50mm diamater
129
what might cause a lip seal to fail on a shaft
shaft run out
130
when connecting a coupling how should the keyways line up
180 degrees apart to minimize rotational imbalance
131
which bearing can accommodate displacement and misalignment
CARB compact aligning roller bearing
132
best bearing for high speed combined radial/axial loads
Angular contact ball bearings
133
which bearing can handle the greatest axial load capacity in both directions
four point contact ball bearings
134
key length formula
keyway length + coupling width / 2
| x 0.95 for accurate length
135
key taper
1/8" in 12" or 1:96
136
K taper ratios
```
K = 1:12
K30 = 1:30
```
137
amount of material left for reaming
below 0.5" hand reamer = 0.001"-0.003"
| above 0.5" hand reamer = 0.001"-0.005"
138
cutting speed for steel if not given
100 ft/min
139
key width rule of thumb
key width is 1/4 the diameter of the shaft
140
key clearances
0.002" on the side, 0.005" on the top
141
What should you do with an unmarked liquid container
place in a WHIMIS approved cabinet
142
When using an optical level which side do you shim
the side that gives you the higher reading (it actually sits lower)
143
What should you do with a damaged safety latch on a post inspection lift
tag and repair
144
a worm and wheel reduction unit is showing flakes of metal between the gears what is the cause?
lack of EP additive
145
What drill would you use to drill a brass block
90 degree angle, dull edge
146
how to make a vertical crane pull a load horizontally
snatch block
147
What kind of bolt used on a shackle for a critical lift
safety bolt
148
What wire rope resists crushing
IWRC
149
proper method to dry a wet sling
hang it and let it air dry
150
cylinder acting erratically means
bleed air in system
151
how to prevent a cylinder from hitting hard at the end of a stroke
adjust cushioning valve
152
what causes aeration in a pump
leaking inlet
153
compressor is indicating a higher pressure reading and the temperature is up slightly, what is the cause
dirty intake filter
154
a conveyor belt running off in the middle what would be the cause
skewed rollers
155
procedure for shortening a conveyor belt
un-tension belt, fasten belt (clamp), undo splice, cut, replace splice, re-tension
156
how to measure the pitch of a chain
between two pin centres
157
emergency fix for a tear in conveyor belt
plate bolt fastener
158
fire extinguisher used on a welder
class C
159
What rod to use welding on a high vibration area
7018
160
how to check for noise in a bearing
stethoscope
161
oil mist lubricators are used in what type of application
high speed
162
technique to assess the amount and type of contamination in a system
Spectrographic oil analysis
163
how to measure phase angles
stroboscopic light
164
where to place lantern ring in stuffing box
inline with the fluid
165
levelling baseplate formula
```
A = T x L2/L1
A = shims required
T = feel gauge thickness
L1 = length of level
L2 = length of baseplate
```
166
what allows you to mount a tapered bearing anywhere along the shaft
adapter sleeve
167
which bearing has the greatest axial load capacity in both directions
four point contact ball bearings
168
where is a manometer installed on a fan
on the outlet duct
169
difference between induced and forced draft fans
the boiler is cooled by the forced draft fan, sits behind furnace.
in induced draft the pressure in furnace is below atmospheric pressure, sits in front of furnace
170
reasons a diesel engine produces white smoke
if white smoke smells like gas it's exhausting unburnt fuel
| if it's a sweet smell it's exhausting coolant
171
reasons a diesel engine produces black smoke
engine is burning rich, ratio too high in fuel. Clogged air filter or damaged turbo can also cause black smoke
172
when preheating a flame for cutting at what point can you press the oxygen lever
when the steel is bright red
173
what process is used to cut ferrous and non ferrous metals
plasma arc cutting
174
where do you fix the bearing on a twin screw compressor
on the discharge end to maintain the the clearance between the discharge end plate and the screw
175
what bearing is used on the suction end of a twin screw compressor
cylindrical roller bearing to allow for axial displacement from thermal expansion (not locked on this side)
176
most common impeller on a single stage centrifugal compressor
open impeller
177
when trying to restart a piston compressor but the motor overloads kick out what is the problem
malfunctioning unloader valve
178
high levels of compressor oil in the discharge of a two stage compressor what is the problem
worn piston rings
179
oil leaking from the intake filter of an oil injected twin screw compressor after shut down what is the problem
oil stop valve is stuck open or not sealing
180
two stage piston compressor knocking what is the problem
main bearing or connecting rod
181
which screw compressor does not require timing gears
oil flooded screw
182
what ensures vane compressors oil circulation through the compressor before air is released into system
minimum pressure valve
183
twin screw compressor inlet port vacuum gauge reading slightly higher than normal what is the problem
inlet filter is dirty and needs replacement
184
order of installing bearings in a pump
check shaft, install bearings, set clearance, assemble pump
185
if a centrifugal pump is rotating in the wrong direction what should you do
two of the motor phases should be swapped
186
which impeller has balancing holes
semi closed
187
why is a centrifugal pump losing it's prime when shut down
suction line leak, or foot valve
188
when should you start the external flushing system of a centrifugal pump with a mechanical seal
before starting the pump
189
calculating thickness of packing
subtract shaft diameter from the ID of stuffing box, then divide by 2
190
compressor valves should have the nut facing which way
away from the cylinder. always bar over compressor one complete rotation to ensure nothing is hitting
191
a compressor discharge valve always opens ____ the nut, while the suction valve always opens ____ from the nut
```
discharge = towards
suction = away
```
when removing valve vent before, and back off not but don't remove and then tap to jar from seat
192
when an inline piston motor has it's swashplate adjusted to the greatest angle what happens
it will rotate slower with higher torque
193
what are counterbalanced valved set to
100-150 psi greater than the load induced pressure from the rod end of the cylinder
194
what would be the cause of a sudden decrease in system hydraulic pressure with a fixed displacement pump
stuck pressure relief valve
| not a blocked pump because that would affect flow but not pressure
195
what is the purpose of a baffle plate
separates contaminants and air from oil before reaching the pump inlet
196
what must be used on a hydraulic motor to prevent it from running away
brake valve
197
what can cause air bubbles in a oil reservoir tank even if the oil level is ok and the return line is below the oil surface
a loose fitting on the suction side of the pump between the reservoir and pump inlet allowing air to be sucked in (could be a crack or loose fitting)
198
a gearbox seals keep leaking what is the problem
plugged breather
199
JIC angle
37 degrees
200
what is a -12 hydraulic hose
12/16 = 3/4" ID hose
201
type of normally open hydraulic valve
pressure reducing
202
on a cold startup the hydraulic pump makes a high-pitched whining and rattling sound what is the problem
cavitation
203
what causes water in a hydraulic system
condensation in reservoir
204
a cylinder hits hard at the end of an extension stroke what do you do
adjust rod end cushion
205
hydraulic shock when the valves change position is causing oil leaks what can you do
install an accumulator
206
what do straight pneumatic fittings seal with
o-rings or gasket
207
where do you plumb working airlines
from the top of the main line to prevent contaminants reaching equipment
208
1 psi = how many kPa
6.895
209
what can be used to increase a pneumatic systems pressure
intensifier
210
which drying process uses a desiccant and can have their drying media regenerated and reused
adsorption (silica gel, two tanks)
211
which air drying process produces a corrosive briny liquid as it dries the air
absorption (deliquescent)
212
how do you convert AC to DC
bridge rectifier
213
how are NPTF threads sealed
thread interference
214
the slope for piping in compressed air systems
1 - 2 inches every 10 feet
215
1 psi = how many Hg
2.026
216
Pipe anchor procedure
Pipe set into the concrete allows bolt inside to move slightly for misalignment
Top opening should be covered with packing waste to prevent concrete from filling up the pipe while foundation is poured
During final grouting, the pipe should also be filled with grout to strengthen anchor bolt and prevent liquids from filling hole and rusting
217
vertical milling set up
- loosen vertical head slightly
- dial indicator extensions set up in spindle with dial on table surface
- rotate the dial by hand and adjust head in small increments
- total runout of 0.001-0.002" required
218
setting up vice
- clamp parallel between jaws so it extends above it entire length of jaw (if no parallel put on fixed jaw)
- set up dial indicator on flat part of milling machine, adjust dial indicator so plunger rest on front or rear of parallel
- tighten only one hold down bolt to act as a pivot, second bolt hand tight
- move table so dial runs length of parallel and use readings to determine which way vice is out of alignment
219
what type of grinding wheel do you use with softer materials
a harder wheel
220
how to track a vertical band saw blade
the blade should be adjusted to just touch the backup bearing
221
what is the gage of a saw
the thickness of the material behind the blade set
222
clearance between a bandsaw blade guide bearing and the blade
0.001-0.002"
223
how to break in a new bandsaw blade
- begin cut with reduced feed rate (20-40% of normal)
- once cut has begun increase feed rate 10%
- gradually increase until normal rate achieved
224
how do you sharpen a chisel on a grinding wheel
cutting edge of chisel applied PARALLEL to the axis of the grinding wheel
225
how many saw teeth in contact with a workpiece minimum
3
226
minimum overlap of wood planks between bays on scaffolding
12"
227
strength of a explosive actuated tool cartridge identified by
power load number and colour
228
drill used to start a hole in workpiece
spotting drill/centre drill
229
which quenching medium cools materials the fastest
brine, followed by water
230
UNF meaning
unified fine thread
231
pipe taper per foot
3/4"
232
how do you hook up a brake valve for hydraulic motor
external pilot connected to inlet, internal pilot to motor outlet
233
operating radius of a crane
the centre rotation of the crane to the centre of gravity of the load
234
crane capacity formula
((tipping axis / load radius) x crane capacity) x efficiency rating
235
mechanically clipped eye with thimble rating
80%
236
cutting speed formula
rpm = (CS x 4) / diameter of drill
| measured in surface feet per minute
237
tap drill size formula
TDS = major diameter - (1 / TPI)
238
when tapping a hole how often do you reverse the tap
every one half turn
239
arc of contact for wire rope on sheaves
120 - 150 degrees
| minimum pulley diameter 20 times diameter of rope
240
a hydraulic cylinder with a piston leak is extending and the pump delivers enough flow to exceed leakage, what happens?
it extends slower but with the same force
241
where do you install a kiss idler
a flat pulley that just touches the belt on the slack side of the drive.
must be 1.5 times the diameter of the sheave
they do NOT increase arc of contact
242
on a roller chain drive the what is the sprocket ratio to maintain the minimum arc of contact
3:1
243
v-belt outside idlers should be how big
1.5 times the smaller (drive) sheave
244
worn sides along the whole length of the v-belt what is the problem
sheave misalignment
245
v-belt squealing is a symptom of what
shock loading
246
hardening or glazing on the sides of a v-belt indicate what
belt slippage
247
frequency X rpms
```
unbalance 1 x rpm
misalignment 2 x rpm
looseness 2 x rpm
belt drive 3 x rpm
bearing failure multiple x rpm
```
248
when moving an accelerometer from vertical to horizontal and there is a 90 degree phase shift what is the vibration caused by
imbalance
249
angular misalignment shim formula
```
D = diameter of coupling
A = distance from coupling to back foot
B = distance from coupling to front foot
```
(A / D) x feeler calculation = back shim change
(B / D) x feeler calculation = front shim change
250
what is used on air hoses over 1/2 inch
excess flow/stop valve
251
you are testing a motor and find high ohm resistance what does this mean
open circuit
252
what do you do to change the amount of oil used in an oil mister
change air pressure
253
a new chemical arrives on site what do you look for
MSDS
254
you welded a pipe and need to cool it down to reduce stress what is this called
annealing
255
how to store safety harness
hang by D ring in a dry clean place
256
why do you re-torque a cylinder head after a run-in period
vibration and pressure will cause the cylinder head bolts to stretch and other components to seat
257
working drawings are usually done in
orthographic projection
258
what unit are fans measured in
inches of water (manomater)
