Deck 17: Theory of Metal Machining

Question 1

The material removal processes are a family of shaping operations in which excess material is removed from a starting work part so that what remains is the desired final geometry:

Answer 1

True

Question 2

Which of the following manufacturing processes are classified as material removal processes (two correct answers):

A)casting
B)drawing
C)extrusion
D)forging
E)grinding
F)machining
G)molding
H)pressworking
I)spinning

Answer 2

grinding
machining

Question 3

Which of the following are the three most common machining operations:

A)broaching
B)drilling
C)lapping
D)milling
E)planing
F)shaping
G)turning

Answer 3

drilling
milling
turning

Question 4

Machining is noted for which of the following characteristics relative to other manufacturing processes (two best answers):

A)creates three-dimensional geometries
B)good dimensional accuracy
C)net shape process
D)poor surface finish
E)wasteful of energy
F)wasteful of material

Question 5

A lathe is used to perform which one of the following manufacturing operations:

A)broaching
B)drilling
C)lapping
D)milling
E)turning

Question 6

With which one of the following geometric forms is the turning operation most closely associated:

A)external cylinder
B)flat plane
C)round hole
D)screw threads
E)sphere

Question 7

A single-point cutting tool is used for which one of the following operations:

A)drilling
B)milling
C)turning

Question 8

A roughing operation generally involves which one of the following combinations of cutting conditions:

A)high v, f, and d;
B)high v, low f and d;
C)low v, high f and d;
D)low v, f, and d, where v = cutting speed, f = feed, and d = depth of cut

Question 9

Which of the following are characteristics of the orthogonal cutting model (three best answers):

A)a circular cutting edge is used
B)a multiple-cutting-edge tool is used
C)a single-point tool is used
D)only two dimensions play an active role in the analysis
E)the cutting edge is parallel to the direction of cutting speed,
F)the cutting edge is perpendicular to the direction of cutting speed,
G)the two elements of tool geometry are rake angle and relief angle

Question 10

The mechanism of chip formation in machining is best described by which one of the following:

A)compression
B)fracture failure
C)shear deformation
D)tensile failure

Question 11

The chip thickness ratio in orthogonal cutting is which one of the following:

A)t_c/t_o
B)t_o/t_c
C)t_o/w, where t_c = chip thickness after the cut, t_o = chip thickness before the cut, and w = width of cut

Question 12

Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material:

A)continuous
B)continuous with built-up edge
C)discontinuous
D)serrated

Question 13

According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers):

A)decrease in friction angle
B)decrease in power requirements
C)decrease in shear plane angle
D)increase in cutting temperature
E)increase in shear plane angle

Question 14

In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut t_o corresponds to which one of the following cutting conditions in turning:

A)depth of cut d
B)feed f
C)speed v

Question 15

Specific energy in metal machining is a measure of the amount of energy required to remove a unit volume of material:

Question 16

Which one of the following metals would usually have the lowest specific energy in a machining operation:

A)aluminum
B)brass
C)cast iron
D)steel

Question 17

Which one of the following cutting conditions has the strongest effect on cutting temperature:

A)cutting speed
B)depth of cut
C)feed