Manufacturing technology practice questions Section A

24 questions will be randomly asked from the following

Within which tier of industry is manufacturing?

a - primary

b - secondary

c - tertiary

d - none of them

b - secondary

Within which tier of industry is Agriculture?

a. Primary

b. Secondary

c. Tertiary

d. None of them

a - primary

Within which tier of industry is Fishing?

a. Primary

b. Secondary

c. Tertiary

d. None of them

a - primary

Within which tier of industry is a restaurant?

a. Primary

b. Secondary

c. Tertiary

d. None of them

c tertiary

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

d - refers to the number of different types of products made

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

d - above all are possible

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

d - casting processes can cause environmental problems

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 castings 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

b - mould cavity should be designed the same size as the castings to ensure accuracy of the final product size

Which of the following materials can be cast?

a. Cast iron

b. Aluminium

c. Copper alloys

d. Steel

e. All of them are possible

f. None of them is possible

e - all of them are possible

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

c - induction furnaces can only be used to melt steels

Which of the following factors will affect the pouring success?

a. Pouring Temperature

b. Pouring rate

c. Turbulence

d. All these above

d - all these above

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 known as the thermal arrest for pure metals

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

c - the sand from a used mould can be recycled to make other moulds

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.A

b.B

c.C

d.D

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 downsprue

d. To minimize waste, the riser volume should be minimized

b - a riser is a reservoir built into a metal casting mould to create shrinkage cavities

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

c - has better dimensional tolerance than sand casting

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 vapourizes the foam pattern.

d. A new pattern is required for each casting event.

b - the foam pattern is removed from the mould prior to pouring

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.

d - not suitable for the precious metals

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

b - investment casting

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

. 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

. 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.

c - the die size will be slightly smaller compared to the desired part size due to shrinkage

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.

d - molten metal is poured into rotating mould to produce a tubular part

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

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

d - surface cleaning is not at all important for sand casting

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

a - two portions of metal flow together but there is a lack of fusion due to premature freezing is known as a cold shut

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 centre of the casting

d. Sand wash is caused by erosion during pouring

c - pinholes are small gas cavities formed deep in the centre of the casting

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.

c - 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

e - all of the above

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

a - thermoplastics cannot be re-melted

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

c - the thicker the melt, the easier it flows through small channels or die openings

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

c - viscosity of a polymer melt decreases with increasing temperature

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

b - the die is an extruder componenet

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

d. Qx = Qd - Qb

. 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 wounnd onto one large spools at speeds up to 500m/s

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

b - calendering offers poor surface finish and low gauge accuracy

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.

d - spinneret is a die with a single hole

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

b - the injection unit acts as the principle component to hold two hales of mould in proper alignment

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

d - leads from spruce to cavity ( or cavities) - runners

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

c - longer compaction time leads to greater shrinkage

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

d - compression moulds contain sprues and runner systems to obtain repeatable consistency in the moulded product

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.

a - stretch (injection) blow moulding can be used to process both thermoplastics and thermosets

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

b - positive mould has concave cavity

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.

c - polystyrene is is a thermoset polymer that can be processed through extrusion

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

d - ribs should be made thicker than the walls they reinforce to minimize skin marks on outside wall

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

c- coagulation is involved in recovering the rubber

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℃ (300℉)

a - synthetic rubber is produced by the same polymerization technique used to synthesis other polymers

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

d - rubber sheet thickness is slightly greater than final roll gap due to the die swell

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

d - the long-chain molecules become joined at certain tie points which increases the ability to flow

. 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

a - tyre makes up about 25% of total rubber tonnage

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.

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.

c - hand lay up is a closed mould process and is very economical for high production

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

c - curing normally occurs at very high temperature for the ts resins used in hand lay- up and spray-up procedures

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

c - like extrusion pultrusion produces continuous straight sections of varying cross section

Which of the following statements is incorrect?

. Uncured FRPs are more tough and difficult to cut than cu

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

a - uncured FRP’s are more tough and difficult to cut than cured ones

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

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

b - density is compltely uniform within the integral pm part

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

c - in the electrolysis process the cathode dissolves under an applied voltage and is deposited on the anode

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

d - mixing combines powders of different chemistries together

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

b - part shrinkage occurs during sintering due to pore size reduction

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

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

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

c - secondary operations like sizing and coining can further improve the density and accuracy

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

a - heat treatment is possible during PM processes to improve the workpiece strength

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

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 lover punches to act as electrodes

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

c - the term “old working” indicates the working temperature is much lower than the room temperature

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

b - warm working temperatures are higher than the melting point but below the recrystallization temperature

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

b - strength properties of a hot worked product are generally anisotropic

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

c - with ring rolling, a hot working process is used for smaller rings, while a cold working process is used for larger rings

a. Rolling processes

b. Bending operations

c. Extrusion processes

d. Forging processes

b - bending operations

Which of the following is not a bulk deformation process?

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

d - flashless forging uses a starting work volume much larger than the die cavity to compensate for shrinkage

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.

a - it’s not possible to create hollow cross-sectional products via extrusion

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

c - an extrusion press can be set up horizontally but not vertically

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

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

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)

b - (a)(d)

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.

b - V-bending is complex and very expensive

Which is not one of the main important operations associated with “Machining”?

a. Turning

b. Cutting

c. Drilling

d. Milling

b - cutting

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.

c - it is a tertiary operation

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

a - turning uses multiple cutting-edge tools

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.

d - finishing cuts are carried out before roughing cuts

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

d - brittle materials don’t produce any chip formation

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.

d - turning is performed on the inside diameter.

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.

a - for a blind hole the drill exists opposite side of work piece

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

d - milling operations create only a planar surface

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.

b - in the planning process, tools move across workpart

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.

c - sharp edges on machined parts are easy to machine

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.

a - cutting speed, feed and depth of cut

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

b - chip thickness is usually larger than 1

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.

c - there is low tool-chip friction

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.

a - low cutting speeds are used to produce continuous chips

Which of the following is not a cutting tool failure mode?

a. Fracture failure

b. Gradual failure

c. Temperature failure

d. Geometry failure

d - geometry failure

Which of the following materials properties should not be considered when manufacturing a tool?

a. Biocompatibility

b. Toughness

c. Hot Hardness

d. Wear Resistance

a - biocompatibility

True of False?

A tool has reached the end of its life and should be replaced when the amount of wear reaches 0.5mm

true

True of False?

Single-point tools are not possible to be re-sharpened

false

Which of the following materials is not used to manufacture cutting tools?

a. Synthetic diamond.

b. Aluminium.

c. Cemented carbides.

d. Ceramics

b - aluminium

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.

c - lubricant-type cutting fluids are water based

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.

a - increases thermal distortion

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.

a - contamination is always in the form of a solid waste material

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

d - all above

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

d - all above

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.

d - heating and cooling process to cause microstructual and mechanilal property changes in a material

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.

c - heat treatment acts to strain harden the material