ISEN 281 Exam 2 Study

Comparing with metals, plastic materials have _____ thermal conductivity. (A) higher (B) lower

B) lower

Which plastic materials are stronger and more rigid? (A) Thermosets (B) Thermoplastics

A) Thermosets

Which plastic materials are more ductile? (A) Thermosets (B) Thermoplastics

B) Thermoplastics

Which plastic materials are easier to recycle? (A) Thermosets (B) Thermoplastics

B) Thermoplastics

Which one of the following shape-forming processes (for plastics) is the simplest? (A) Casting (B) Injection molding (C) Blow molding (D) Extrusion

A) Casting

Which one of the following shape-forming processes (for plastics) is the most commonly used? (A) Casting (B) Injection molding (C) Blow molding (D) Extrusion

B) Injection molding

Plastic casting processes can be used to produce parts from _____. (A) all plastics (B) thermoplastics only (C) thermosets only (D) some thermoplastics and some thermosets

D) Some thermoplastics and some thermosets

Plastic injection molding processes are used primarily for _____. (A) Thermosets (B) Thermoplastics

B) Thermoplastics

Plastic blow molding processes are used for _____. (A) thermosetting materials (B) thermoplastic materials

B) Thermoplastic materials

In plastic blow molding, the starting resin is usually in the form of _____. (A) pellets (B) melted liquid

A) Pellets

If the bars were made from aluminum instead of steel, would Chon and Roy's escape be more difficult? (A) Yes (B) No

B) No

If the steel bars were heat treated (in a way most favorable to Chon and Roy) before installation, would Chon and Roy's escape be easier? (A) Yes (B) No

A) Yes

If the bars were made from a different grade of steel that had higher carbon concentration and hence was harder, would Chon and Roy's escape be difficult? (A) Yes (B) No

A) Yes

If the steel bars were made by cold rolling instead of hot rolling, would Chon and Roy's escape be more difficult? (A) Yes (B) No

A) Yes

Drilling is best described as _____. (A) single-point machining (B) multi-point machining (C) abrasive machining

B) Multi-point machining

In orthogonal cutting, the cutting edge is a straight line _____ to the relative velocity between tool and workpiece. (A) perpendicular (B) parallel (C) at a certain angle

A) Perpendicular

Most cutting processes are _____. (A) three-dimensional (B) orthogonal cutting

A) Three-dimensional

As rake angle _____, the cutting edge (i.e. the cutting tool) becomes sharper. (A) increases (B) decreases

A) Increases

As shear angle increases, chip thickness _____. (A) increases (B) decreases

B) Decreases

For any given uncut chip thickness (depth of cut), a smaller shear angle means a _____ cutting force. (A) higher (B) lower

A) Higher

When uncut chip thickness (depth of cut) increases, cutting force typically _____. (A) increases (B) decreases

A) Increases

If rake angle increases, shear angle will _____. (A) increases (B) decreases

A) Increases

If rake angle increases, cutting force will _____. (A) increases (B) decreases

B) Decreases

If inclination angle increases, cutting force will _____. (A) increases (B) decreases

B) Decreases

Generally speaking, _____ cutting force is desired in metal cutting. (A) lower (B) higher

A) Lower

Generally speaking, as cutting speed increases, cutting force _____. (A) increases (B) decreases (C) does not change much

C) Does not change much

When uncut chip thickness (depth of cut) increases, cutting force typically _____. (A) increases (B) decreases (C) does not change much

A) Increases

Generally speaking, using coolant _____ cutting force slightly. (A) reduces (B) increases

A) Reduces

Generally speaking, using coolant increases tool life _____. (A) slightly (B) significantly

B) Significantly

Generally speaking, as hardness of tool materials increases, their toughness _____. (A) increases (B) decreases

B) Decreases

Generally speaking, as cutting speed increases, tool life _____. (A) increases (B) decreases (C) does not change much

B) Decreases

The desired qualities for an ideal tool material are: harder than workpiece; retain hardness at high temperature; resist wear and thermal shock; impact resistant; and chemically inert. Which tool material incorporates all these qualities? (A) Diamond (B) Ceramics (C) HSS (D) None of them (E) All of them (A, B, and C)

D) None of them

Which deposition method has higher depositing temperature? (A) CVD (Chemical Vapor Deposition) (B) PVD (Physical Vapor Deposition)

A) CVD (Chemical Vapor Deposition)

A friend's grinding wheel company serves customers who mainly manufacture steel parts for the automobile industry. Which type of superabrasive grinding wheel is more suitable? (A) Diamond (B) CBN

B) CBN

If inclination angle increases, effective rake angle _____. (A) increases (B) decreases

A) Increases

If effective rake angle _____, the cutting tool becomes sharper. (A) increases (B) decreases

A) Increases

If the cutting tool becomes sharper, cutting force will _____. (A) increases (B) decreases

B) Decreases

In a turning operation, if the initial diameter minus the final diameter equals 4 mm, what is the depth of cut? (A) 1 mm (B) 2 mm (C) 4 mm

B) 2 mm

In a turning operation, a decrease in cutting speed will _____ MRR. (A) increase (B) decrease

B) Decrease

Flank wear occurs on _____. (A) the tool face that interacts with the newly-generated chip (B) the tool face that interacts with the newly-generated surface of workpiece

B) The tool face that interacts with the newly-generated surface of workpiece

Generally speaking, a decrease in cutting speed will _____ the tool life. (A) increase (B) decrease

A) Increase

For a standard twist drill, the rake angle along the main cutting edges (lips) is _____. (A) different at different point (B) the same everywhere

A) Different at different point

_____ is the process of machining INTERNAL cylindrical and conical surfaces; _____ is the process of machining EXTERNAL cylindrical and conical surfaces. (A) Turning/Boring (B) Boring/Turning

B) Boring / Turning

Which order represents surface roughness from roughest to smoothest? (A) Honing > Reaming > Drilling (B) Reaming > Drilling > Honing (C) Drilling > Reaming > Honing (D) Drilling > Honing > Reaming

C) Drilling > Reaming > Honing

Holes are drilled and the surface is too rough. Will increasing drill rotational speed improve surface quality? (A) Probably will (B) Will not

A) Probably will

Holes are drilled and the surface is too rough. Will increasing feedrate improve surface quality? (A) Probably will (B) Will not

B) Will not

Holes are drilled and the surface is too rough. Will using a reaming operation after drilling improve surface quality? (A) Probably will (B) Will not

A) Probably will

In a turning operation, if the tool tip is set higher than the rotation axis of workpiece, the effective rake angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

B) Larger

In a turning operation, if the tool tip is set higher than the rotation axis of workpiece, the effective clearance angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

A) Smaller

In a turning operation, if the tool tip is set lower than the rotation axis of workpiece, the effective rake angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

A) Smaller

In a turning operation, if the tool tip is set lower than the rotation axis of workpiece, the effective clearance angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

B) Larger

In the equation v = πDN for milling cutting speed, D is the diameter of _____. (A) the workpiece (B) the hole being machined (C) the tool

C) The tool

In _____ milling, the surface is generated by teeth located on the periphery only. (A) slab (B) face (C) end

A) Slab

In a milling operation, if the surface generated is perpendicular to the cutter rotation axis, it is called _____. (A) slab milling (B) face milling

B) Face milling

Pockets can be machined by _____ milling. (A) slab (B) face (C) end

C) End

Up (conventional) milling and down (climb) milling refer to _____. (A) slab milling only (B) face milling only (C) both slab and face milling

C) Both slab and face milling

Cutters for slab milling may have straight or helical teeth. Which one results in oblique cutting action? (A) Straight teeth (B) Helical teeth

B) Helical teeth

For either slab or face milling, which one of the two figures shown is up milling (conventional milling)? (A) Figure A (B) Figure B

A) Figure A

In up milling vs down milling, in which case is the chip thin at the beginning and thick at the end? (A) Up milling (B) Down milling

A) Up milling

In up milling vs down milling, in which case does the surface scale not affect tool life? (A) Up milling (B) Down milling

A) Up milling

In up milling vs down milling, in which case is a higher clamping force needed to hold the workpiece? (A) Up milling (B) Down milling

A) Up milling

In a boring operation, if the tool tip is set higher than the rotation axis of workpiece, the effective rake angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

A) Smaller

In a boring operation, if the tool tip is set higher than the rotation axis of workpiece, the effective clearance angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

B) Larger

When machining very hard materials such as hardened metals and ceramics, grinding operation is _____ preferable than turning and milling. (A) more (B) less

A) More

Grinding operation is widely used in the automotive industry but has no applications in the semiconductor industry. (A) True (B) False

B) False

The surface roughness and accuracy produced by grinding is generally _____ that produced by turning or milling. (A) up to 10 times better than (B) worse than (C) about the same as

A) Up to 10 times better than

Superabrasives include CBN and diamond. _____ wheels are used to grind ferrous metals; the other wheels are used to grind non-ferrous metals and nonmetals. (A) CBN (B) Diamond

A) CBN

There are three major bond systems for grinding wheels: vitrified, organic, and metal. Which association is true? (A) Vitrified → glass; Organic → resin (B) Vitrified → resin; Organic → glass

A) Vitrified → glass; Organic → resin

Grain size, bond type, and pore size of a grinding wheel affect performance. Which one of the following is NOT true? (A) Finer grain size produces rougher surface (B) The vitrified bond system is more rigid and more brittle than the resin bond system (C) Pore space determines whether the wheel has an open or closed structure

A) Finer grain size produces rougher surface

The purpose of truing and dressing is to prepare the grinding wheel. Which one of the following is NOT true? (A) Truing/dressing is sometimes called balancing (B) Some abrasive grains are removed from the wheel during truing/dressing (C) Truing/dressing can be done by using a single-point or multi-point diamond tool

A) Truing/dressing is sometimes called balancing

Four primary grinding types are cylindrical, internal, centerless, and surface grinding. Which one is true regarding cylindrical grinding? (A) Both wheel and workpiece rotate (B) The wheel rotates but the workpiece does not rotate (C) The workpiece rotates but the wheel does not rotate

A) Both wheel and workpiece rotate

In creep feed grinding, _____ is much smaller. (A) depth of cut (B) feed rate (C) required horsepower

B) Feed rate

For double disk grinding, both sides of _____ at the same time. (A) the grinding wheel are grinding the workpieces (B) the workpieces are being ground

B) The workpieces are being ground

In a boring operation, if the tool tip is set lower than the rotation axis of workpiece, the effective rake angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

B) Larger

In a boring operation, if the tool tip is set lower than the rotation axis of workpiece, the effective clearance angle will be _____ than that when the tool tip is set at the same height as the rotation axis. (A) smaller (B) larger

A) Smaller

LBM (Laser Beam Machining) and AWM (Abrasive Waterjet Machining) are primarily used to cut _____. (A) flat sheets (B) cylindrical parts (C) hollow cavities

A) Flat sheets

In AWM (Abrasive Waterjet Machining), consumables _____ be used. (A) will not (B) will

B) Will

Comparing to traditional machining processes, thermal cutting processes will generate _____ accurate dimensions. (A) more (B) less

B) Less

Generally speaking, which one of the following processes generates the most accurate dimensions? (A) LBM (Laser Beam Machining) (B) Oxygen fuel cutting (C) PAC (Plasma Arc Cutting) (D) AWM (Abrasive Waterjet Machining)

A) LBM (Laser Beam Machining)

Generally speaking, which process generates more HAZ (Heat Affected Zone)? (A) Oxygen fuel cutting (B) PAC (Plasma Arc Cutting) (C) AWM (Abrasive Waterjet Machining)

A) Oxygen fuel cutting

LBM (Laser Beam Machining) is used _____. (A) primarily for cutting small holes (B) primarily for cutting large holes (C) for cutting both small and large holes

C) For cutting both small and large holes

LBM (Laser Beam Machining) _____ generate cutting forces. (A) does not (B) does

A) Does not

Which one of the following processes does not generate HAZ (Heat Affected Zone)? (A) LBM (Laser Beam Machining) (B) Oxygen fuel cutting (C) PAC (Plasma Arc Cutting) (D) AWM (Abrasive Waterjet Machining)

D) AWM (Abrasive Waterjet Machining)

Which one of the following processes is like a "corrosion" process? (A) Chemical machining (B) Electrochemical machining (C) Abrasive flow machining (D) Ultrasonic Machining

A) Chemical machining

Which one of the following processes is the reverse of electroplating? (A) Chemical machining (B) Electrochemical machining (C) Abrasive flow machining (D) Ultrasonic Machining

B) Electrochemical machining

For grinding very hard steel parts, which type of grinding wheels should be used? (A) CBN (B) Diamond

A) CBN

In order to reduce surface roughness (i.e. to make the surface smoother), which grinding wheel should be used? (A) The wheel with mesh size of #300 (B) The wheel with mesh size of #800

B) The wheel with mesh size of #800

Both USM and RUM are _____ Non-Traditional Machining processes. (A) mechanical (B) chemical (C) thermal

A) Mechanical

In _____, an abrasive slurry is used. (A) USM (B) RUM

A) USM

In _____, a fix-abrasive tool is used. (A) USM (B) RUM

B) RUM

In _____, non circular holes (and cavities) cannot be machined. (A) USM (B) RUM

B) RUM

In _____, either the tool or the workpiece vibrates at high frequency. (A) USM (B) RUM (C) Both USM and RUM

C) Both USM and RUM

EDM has several benefits. Which one of the following is NOT among these benefits? (A) No cutting forces (B) Burr-free edges (C) The tool never wears (D) Intricate (complex) details can be cut

C) The tool never wears

Which one of the following is NOT among the limitations of EDM? (A) Low material removal rate (B) Can cut only one hole at a time (C) Long time to prepare tools (D) Workpiece material must be conductive

B) Can cut only one hole at a time

In EDM, as on-time increases, the surface generated becomes _____. (A) rougher (B) finer

A) Rougher

In EDM, as on-time increases, the overcut _____. (A) increases (B) decreases

A) Increases

In wire-EDM, _____. (A) wire products are produced (B) a moving wire is used as the tool

B) A moving wire is used as the tool

On a machining center, cutting forces have exceeded the limit. Only two computer programs are used; the only difference is depth of cut, and most of the time the larger depth of cut program is used. Should the computer program be checked to see if the wrong program was used today? (A) Should (B) No need

B) No need

Tempering is always used to heat-treat the parts before machining. Should the plant manager check whether the tempering step was accidentally skipped for today's parts? (A) Should (B) No need

A) Should

Cutting fluid is always used for the milling operation. Should the plant manager check if today's coolant flow rate was lower than normal? (A) Should (B) No need

A) Should