MET 231 Finals

A composite material will always consist of the following?

A matrix and a reinforcement

False

A thermoset material can be remelted and formed over and over again (recycled).

Silicon

Due to its unique way of creating multiple covalent bonds, most polymers are based on carbon. There is a notable exception though. What is another element that is the basis for a family of polymers?

Zinc

Cartridge brass (widely used in ammunition casing) is an alloy of 70 percent copper and 30 percent               .

Tungsten

The addition of what element will increase the melting point of steel?

Carbon

The simplest alloy of steel is a combination of iron and a small amount of what?

Polybutadiene

ABS is a plastic alloy made up of three different polymers—polyacrylonitrile, polybutadiene, and polystyrene. The properties of the end product can be altered depending on the amount of each added material. If I want to have a tougher material, I should increase the percentage of what?

Pyrex

If greater than 13 percent boron oxide (B2O3) is added to silica glass, the resultant ceramic has enhanced thermal stability. It is often formed into ovenware under the trade name of what?

Lose electrons

When combined with oxygen, will metals tend to lose or gain electrons?

 

200%

An elastomer is a special type of polymer that exhibits more than                 elongation.

Calcium

Which accounts for the highest concentration of metal in the human body?

447 (with margin: 50)

If I need to remove some material from the outside of a 8.5" diameter pipe (1120 steel) with an carbide tool on a lathe, what would be the recommended spindle speed in RPM?

Apron Hand Wheel

Which part of a lathe allows the operator to manually move the carriage (and tool) in the z-axis?

A lathe dog

What accessory is always necessary when turning an object between centers using a drive plate?

False

A universal chuck is able to hold square stock material securely on a lathe.

1528 (with margin: 135)

What would be the recommended spindle speed (in RPM) if you are removing material from the outside of a 0.75" diameter rod of brass with a HSS cutting tool?

0\.003"–0.005" per revolution

What is a typical feed rate for a metal cutting tool on a FINISH pass?

Bull nose end mill

An end mill with a flat end with a corner radius is called what?

14\.4

A 0.25" diameter 2-flute HSS end mill is used to cut a pocket into 7075 T6 aluminum. If the cutting speed of the tool in the aluminum is 150 ft/min, what is the feed rate to move the tool in in./min. (assuming 0.003" cut per tooth)? (Hint: FxNxRPM) 

Between 2,300 and 2,500

A 0.25" diameter 2-flute HSS end mill is used to cut a pocket into 7075 T6 aluminum. If the cutting speed of the tool in the aluminum is 150 ft/min, what is the recommended RPM for the tool?

High helix angle

Which type of helix angle on an end mill will evacuate the chips faster?

It allows machining from multiple sides without changing over the part.

What is an example of an advantage of a horizontal milling machine?

Table

Where is the workpiece mounted on a mill?

Roughing (removing a lot of material, leaves a rough surface)

You were looking through the tool cabinet for your shop mill and came across an end mill with serrations along the cutting edges. What type of operations will generally be performed with an end mill of this type?

0\.637 (with margin: 0.003)

What's the measurement on the caliper below (in inches)?

0\.338 (with margin: 0.002)

What is the measurement of the micrometer below (Give the answer accurate to 0.001")?

0\.323 (with margin: 0.002)

What is the measurement on the caliper below (in inches)?

1\.186 (with margin: 0.002)

What is the measurement of the micrometer below (Give the answer accurate to 0.001")?

False

If 5" frame was put on a micrometer, one would be able to accurately measure anywhere between 0.000 and 5.000 inches.

2,000

Nickel has a melting point of approximately 2,650 degrees Fahrenheit. What would be a typical temperature to hot forge it (in degrees F)?

0\.76 (with margin: 0.002)

What is the measurement in inches on the caliper (the top number)?

A type of hot forging process where the material is processed in a similar manner to thermoforming of plastics.

What is superforming aluminum?

Swaging

The machine pictured is able to crimp a fitting on the end of a hydraulic hose so that it can handle very high pressures. What type of process is being employed by the machine?

Hot Forging

More scale is created when forging steel with which forging process?

True

Forged parts are generally stronger than cast parts.

Powder Forging

The automotive connecting rods pictured were created using a special hot forging process that results in virtually zero waste. What is it called?

Thread rolling

What process is used to obtain high production volume of threaded machine screws?

Hot Forging

Because the material flows better under these conditions, less force is required to change the part shape in which forging process?

False

Forging is a process that doesn't work well with malleable metals.

Roll Forming

Which deformation process was used to create the metal roof shown in the picture (the material is painted galvanized steel)?

True

Some types of plastic (such as polycarbonate or PC) may be cold bent (forged) in a press brake in a process similar to sheet metal bending.

A series of successive rollers apply force to a continuous strip of material. Each successive roller alters the shape a little more until the desired cross-section is achieved.

Which of the following best describes roll forming?

Metal Spinning

What process is most likely used to create the bell on a French horn?

Roll Forming

What process was used to create the aluminum base on the iMac pictured?

Deep Drawing

What deformation process is used to make aluminum soda pop cans?

To support the tube internally and keep it from collapsing

Why is ice used on the inside of the tube when creating the bends in a brass instrument such as a trumpet or trombone?

Plate Rolling

Which deformation process was most likely used to create the cylindrical tube of the tanker car pictured for hauling milk?

True

Metal injection molding (MIM) can create intricate parts from metals with much higher melting temperatures than those used for die casting.

True

It is possible to inject mold over an insert, allowing for different materials to be fused together.

Injection molding

Disposable plastic cutlery is generally made by what process?

Die casting

Injection molding of polymeric material is most similar to what metal casting technique?

A and B components of thermosetting materials that combine to form foam

 What is injected into the mold for the reaction injection molding (RIM) process?

Investment Casting

Lost wax casting is another name for which casting process?

Die Casting

Which type of casting uses permanent metal tooling?

Tungsten

Which type of metal COULD NOT be die cast?

Thermosets

Which class of polymers can be poured (or cast) at room temperature into low cost tooling (such as silicone) with incredible detail?

Thermoset

Cast                            polymeric materials are often used in movie props due to their ability to capture fine detail with very inexpensive tooling. This is done at room temperature.

Thermoforming

In injection molding, you want to have a tight molecular weight distribution resulting in a well-defined melting point. This makes it so that the material melts at a certain temperature and quickly solidifies upon cooling. Which processing technique requires a broad molecular weight distribution?

Injection

Which blow molding process produced more accurate threads on a bottle?

Thermoset Polymers, Ceramics, fiber composites

What type of material is compression molded?

Parison

What is the name of the hollow tube that extruded into a blow molded part (extrusion blow molding)?

Garbage Bags

The blown film process is used to create what?

Rotational Molding

Slip casting is a process used to make hollow ceramic parts. What plastic processing technique is it most similar to?

Extrusion Blow Molding

In the attached photograph, an operator is trimming excess material off of a plastic barrel. What process was used to create the barrel?

Combines the part complexity of injection molding with the continuous nature of extrusion.

EXJECTION is a new process that does what?

Extrusion Blow Molding

Which blow molding process allows the creation of hollow products with handles, such laundry detergent containers?

False

Injection molding uses low cost tooling and is only good for creating small quantities of parts.

It is a process where dry fabric is placed in a closed mold and has a low viscosity mixture of resins injected to saturate the fibers and is cured in place.

What is RTM as used in composite manufacturing?

Polyacrylonitrile

What is the pre-cursor material for most of the carbon fiber produced in the world today?

It has precise control of resin/fiber ratio.

What is NOT true of an engineering composite?

hollow parts with a finished outside surface

Bladder molding is good for 

Injection molded thermoplastics with glass fiber whiskers

By volume, what accounts for the majority (about 80%) of fiber reinforced plastic (FRP) materials?

It is a reinforcement with semi-cured resin applied at a precise fiber/resin ratio.

What is a pre-preg?

Compression Molding

Which process utilizes bulk molding compounds?

It chops fiberglass and mixes it with catalyzed resin to spray on a mold.

What does a chopper gun do?

It is a pressurized, programmable oven.

What is an autoclave?

False

Composite materials can only be made using polymeric or ceramic matrices. They can't be made using a metal matrix.

False

A filler metal is ALWAYS required for Gas Tungsten Arc Welding (GTAW).

TIG Welding

GTAW

MIG welding

GMAW

Stick Welding

SMAW

Flux Corded Welding

FCAW

No. The wrinkles will come out as pressure is applied and the resin is fully cured.

Judging from the appearance of the material in the picture, has the bicycle frame been cured yet?

False

Gas Metal Arc Welding (GMAW) works very well in outdoor applications (windy/raining).

Bladder Molding

What process is being used to create the Scott Advert bicycle frame shown?

GTAW

Which type of welding process provides the greatest amount of control by the operator and generally produces cleaner, stronger welds, but is also the most difficult to learn?

A gas (usually inert) that prevents the molten puddle from oxidizing

What is the shielding gas used for in welding?

False

Shot peening is a hot-forging process where small steel beads are shot at high velocity at a heated metal metal surface. It drastically increases the fatigue and strength properties of the base metal.

Zinc

In the galvanization process, steel is placed in a bath of molten metal that, once applied, preferentially corrodes before the steel, making it last much longer in outdoor environments. What is the metal in the bath?

Easily disassembly of the finished product

Which one of these is NOT an advantage of an adhesive joining process?

Water

Cyanoacrylates (super glue) are a one-component thermosetting adhesive that quickly polymerizes in the presence of

Suede Leather

From your reading about surface finishing, the Nextel coating has the look and feel of what?

False

When anodizing titanium, the end color is solely dependent on the die added during the process.

Vapor metalizing

The metallic coating on the inside of a bag of Doritos is formed through a process called 

True

Powder coating is a completely dry process

True

Anodizing is a form of corrosion.

Case hardening

Mild steel (which cannot be heat treated) can be treated by a process called                                  that dramatically increases its surface hardness.

Bull Nose End Mill

I need to machine a radius at the bottom edge of a flat pocket on a part that I'm designing. If I want to do that all in one operation, what would be the best type of tool to use in this application?

1750F

If titanium melts at 3035 °F, what would be the most likely temperature for hot forging of titanium?