Deck 7: Manufacturing Materials and Processes

Question 1

The lathe is used to cut materials by turning cylindrically shaped objects.

Answer 1

TRUE

Question 2

Forged metal is generally weaker than cast metal.

Answer 2

FALSE

Question 3

Cores used in sand casting should generally be more than two inches in cross section.

Answer 3

FALSE

Question 4

Honing is the process of creating a very smooth surface finish using a soft metal impregnated with fine abrasives.

Question 5

Prototype construction or modeling is done after engineering drawings and documents.

Question 6

Fixtures guide the cutting tool.

Question 7

The process of forging the material helps it retain its original grain structure.

Question 8

A fillet is a small radius formed between the outside of two surfaces.

Question 9

Permanent casting refers to a process in which the cast will not break.

Question 10

Tungsten, carbon, and iron are formed together under heat and pressure to create tungsten carbide.

Question 11

Cast iron is primarily an alloy of silicon and 1.7% to 4.5% of carbon.

Question 12

Founding is another word for casting.

Question 13

A lug is a feature projecting out from the body of a part.

Question 14

The method of heating metal to a red color and then beating it into shape is called smithing.

Question 15

A riser is used, depending on the size of the casting, to allow the excess metal to evacuate from the mold.

Question 16

A chamfer is the polishing of external edges and corners.

Question 17

A grinding machine uses a rotating abrasive wheel rather than a cutting tool.

Question 18

The keyway fits into the groove of the keyseat.

Question 19

Objects with circular or cylindrical shapes lend themselves to centrifugal casting.

Question 20

The drilling machine is often referred to as the drill punch.

Question 21

Water jet cutting is used on composite materials.

Question 22

Electron beam cutting techniques are versatile and can be used to cut or machine any metal or nonmetal.

Question 23

Saw machines can be used as cutoff tools to establish the length of material for further machining.

Question 24

A reamer is used to machine new holes and enlarge existing holes.

Question 25

Many companies most often use the abrasive saw.

Question 26

Materials for product manufacturing fall into four general categories: metal, plastic, inorganic materials, and alloys.

Question 27

A blind hole is a hole in which the depth must be defined.

Question 28

End milling cutters are designed only on the end and the sides of the cutting tool.

Question 29

The milling machine uses a rotary cutting tool to remove material from the work.

Question 30

The greater the pressure exerted on the material that is machine forged, the less the improvement of the metallic properties.

Question 31

The abrasive saw can be used for high speed cutting where a wide saw kerf is desirable.

Question 32

The universal milling machine has table action that includes x, y, and z-axis movement plus angular rotation.

Question 33

Cuts on a water jet are made with holding tolerances of 0.020 inches and without generating heat.

Question 34

Hot rolled steel characterizes steel that is formed into shape only by forging when in a red-hot state.

Question 35

Chemical machining uses chemicals to remove material accurately.

Question 36

Die castings can be produced quickly and economically on automated production equipment.

Question 37

Some ferrous metal castings are made using the die casting process.

Question 38

A dovetail is a narrow slot formed by removing material while sawing.

Question 39

Steel is a rare material that can be worked in either a heated or a cooled state.

Question 40

The shape of thermoplastic metal can change after heating and being formed by pressure.

Question 41

Elastomers are able to stretch three times their original length and return to their original length after stretching.

Question 42

Plastics are formed into permanent shape.

Question 43

Thermoplastics possess elastic qualities.

Question 44

Compression molding and vulcanization are the most common fabrication processes for thermosets.

Question 45

Thermoset plastics are best used where heat is involved.

Question 46

Injection molding process involves injecting molten plastic material into a mold that is in the form of the desired part or product.

Question 47

Tool design involves many areas of knowledge such as kinematics, and material handling.

Question 48

Manufacturing composites are referred to as reinforced plastics.

Question 49

The extrusion process creates the desired shape of the plastic by forcing molten plastic through a metal die.

Question 50

The blow molding process for plastic parts is generally for solid parts only.

Question 51

Stamping is generally done on hot metal than cold sheet metal.

Question 52

The process of blow molding works by blowing hot polymer against the internal surfaces of a hollow mold.

Question 53

Powder metallurgy process uses metal-alloyed powders and feeds them into the die where it is compacted to form into a desired shape.

Question 54

Powder metallurgy process is less cost effective than casting, forging and stamping.

Question 55

ASTM and SAE created a combined numbering system for metals and alloys.

Question 56

Jigs are fixed or moving devices that are used to hold the fixtures in place.

Question 57

Carbon and graphite have high tensile strength.

Question 58

Injection molding is the most common process for creating elastomer products.

Question 59

Stamping is a process that produces sheet metal parts by a quick downward stroke of a punch press.

Question 60

A general definition of plastic is any complex, organic, polymerized compound capable of being formed into a desired shape by molding, casting, or spinning.

Question 61

For steel identified as SAE 1020, the first two numbers (10) identify the type of steel and the last two numbers (20) specify the approximate amount of carbon in hundredths of a percent (0.20% carbon).

Question 62

In the dry sand molding, the sand is bonded together with ____.

A) specific moisture
B) clay
C) specially formulated resin
D) both b and c
E) all of the above

Question 63

Computer-Integrated Manufacturing (CIM) incorporates all the technologies of CADD, CAM, CNC, Robotics and Material Handling together.

Question 64

CAD/CAM is commonly used in modern manufacturing because it increases productivity over conventional manufacturing methods.

Question 65

Refractories must be bonded together by ____.

A) applying pressures
B) adhesives
C) soldering
D) twisting
E) none of the above

Question 66

Heat treating is a process of heating and cooling steel using specific controlled conditions and techniques. Steel is very hard when initially formed and allowed to cool naturally.

Question 67

The shaper is used for production of ____ flat surfaces.

A) horizontal
B) vertical
C) angular
D) both a and b
E) all of the above

Question 68

Aluminum is corrosion resistant, lightweight, easily cast, conductive of heat and electricity, may be easily extruded, and is very malleable.

Question 69

Inorganic materials include ____.

A) carbon
B) ceramics
C) composites
D) graphite
E) all of the above

Question 70

Ceramics are ____.

A) clay
B) glass
C) refractory
D) inorganic cements
E) all of the above

Question 71

Nonferrous metals do not contain iron and have properties that are better suited for certain applications where steel may not be appropriate.

Question 72

CAD and CAM were traditionally the best link for design and manufacturing until CIM came along.

Question 73

Normalizing is a process of heating the steel to a specified temperature and then allowing the material to cool slowly by air, which brings the steel to a normal state.

Question 74

Which of the following should be considered when designing a product?

A) utilizing research and development
B) meeting a market demand
C) having good quality
D) the ability to be produced economically
E) all of the above

Question 75

The band saw operates using ____.

A) an up and down motion
B) a rotary motion
C) a variable motion
D) a back and forth motion
E) none of the above

Question 76

____ is a force that holds together the molecules of unlike substances when the surfaces come in contact.

A) Fusion
B) Adhesion
C) Malleability
D) both a and b
E) none of the above

Question 77

Steels are identified by four numbers, except for some chromium steels, which have five numbers.

Question 78

Centrifugal casting is useful for ____.

A) tubing
B) pipes
C) wheels
D) both a and c
E) all of the above

Question 79

CNC is an alphabetical list of machining operations in the form of code that is used to machine a part.

Question 80

The sand casting pattern is called a ____.

A) cope
B) flask
C) drag
D) runner
E) none of the above