6th 6-months Flashcards
1
Q
In _______ _________, the reduced finished diameter always stays the same along the total length of the workpiece
A
Straight turning
2
Q
A _______ notch is cut into the workpiece to ensure that the grinding tool can advance right up to the square face of the larger diameter
A
Relief
3
Q
When tapering, the _______ _______ method is most often used for tapers larger than 3 inches per foot
A
Compound Rest method
4
Q
Generally, shorter pieces of work are held in a ______, in a collet, or mounted on a _____ for facing.
A
Chuck
Mandrel
5
Q
When facing between centers, use a _______ _______ to provide clearance for your cutting tool.
A
Half center
6
Q
Always counterbore your workpiece in the ________ _______ _____ used for the primary boring operation. This ensures concentricity of the bored and counterbored holes.
A
Same lathe setup
7
Q
To bore large and irregular shaped workpieces, use a _______ ______ mill.
A
Horizontal Boring Mill
8
Q
Which taper method can be used for boring tapered holes?
A
Compound rest method
9
Q
Using the ______ attachment on a large is the most accurate method for boring tapered holes
A
Taper
10
Q
The shape of the threads to be cut is controlled by the ______ of the _______ tool.
A
Profile of the cutting tool
11
Q
The most common way to set up a lathe for drilling is to mount the drill in the ________ quill.
A
Tailstock
12
Q
When drilling a bulky or cumbersome workpiece, you should mount the drill in the lathe headstock if you need to _______ a _______ hole
A
Drill a long hole
13
Q
Drilling with the drill head stationary is generally ________ _________ than the headstock method
A
More accurate
14
Q
The _______ ________ _______ is the machine most commonly used for drilling holes where a great deal of accuracy is required
A
Sensitive drill press
15
Q
If a job requires you to drill holes in a workpiece that is too large for an upright drill press, you should use a ________ drill press
A
Radial
16
Q
The biggest difference between counterboring and spot facing is that in spot facing a _____ amount of metal is removed from the top of the drilled hole so that a fastener can seat firmly
A
Small
17
Q
To bore in a drill press, you install a ______ _______ in a ______ head
A
Boring bar
Boring head
18
Q
If necessary to repeat the same drilling operations on several workpieces, and the holes and pieces are all the same, use a _____ _____
A
Drill jig
19
Q
Reaming may be done by _____ or on a ______ _____ or on a ______
A
Hand
Drill press
Lathe
20
Q
During the honing process ________ ________ _______ contact the work surface and remove very small amounts of metal
A
Small abrasive stones
21
Q
If you must machine a groove in the top surface of a workpiece, you use the ________ _______ operation
A
Side milling
22
Q
In profile milling, the cutters are made to produce ______ and _______ profiles
A
Concave and convex
23
Q
Face milling cutters that are less than 6inches in diameter are often called ______ end mills
A
Shell
24
Q
For slotting on a milling machine, special milling cutters are available for machining _______ for all standard __________ keys
A
Key ways
Woodruff keys
25
What is the benifit of shaping vs. milling?
Shaping is less costly
The cutting tools are easier to make
The tools can reach into places that other tools can’t go
All of the above
26
Broaching ______ or _______ a long special designed cutter through a hole in the work
Pushes or pulls
27
The cutting teeth on a broach _______ in height from the end of the tool first entering the work to the end entering the work last
Increases
28
Surface grinding is done in order to?
Produce a fine finish
Produce extremely close tolerances
To remove metal machines can’t
All of the above
29
By using a vertical type surface grinder, you can grind a _________________________________.
Larger area in a given period of time
30
As the accuracy required to hold a tolerance increases....
The difficulty of operating a machine increases
The accuracy required to hold the close dimensions to size affect the choice of machine
The function of the workpiece changes
All of the above
31
Angular dimensions are measured in ______ and __________.
Degrees and minutes
32
In an angular tolerance, the spread gets _______ as the distance from the center ________.
Larger
Increases
33
Multiple dimensions which are related to eachother
_________ __________
Tolerance stack up
34
In the unilateral system, the tolerance is applied in only one direction from the nominal size.
Either a _______ or ________
Plus or minus
35
In a ______ cut, the extra material on the workpiece is removed to finish the part to the required dimensions and surface finish
Rough
36
The finish cut on a workpiece is the removal of _______ ________ amounts of material
Very small
37
The type of surface finish made by a machine tool is influenced primarily by?
Vibration between workpiece and tool
Feed marks left by the shape of the cutting tool
The way chips are formed by the tool
All of the above
38
An instrument that electronically measured average roughness height is called a?
Surface averaging instrument
39
The ease or difficulty with which you can remove metal from a piece of material
Machinability
40
Brittle metals like cast iron will form __________ chips
Discontinuous
41
There are many fluids used for machining, the main considerations in cutting fluids are:
Use of the correct type of fluid
Use of the proper amount of fluid
Correct point of lubrication
All of the above
42
Solid lubricants are mostly used to grease the sides and backs of _______ and _______ blades
Hacksaw
Bandsaw
43
To machine workpieces efficiently, figure out the best ______ ______ in which the operations can be performed.
Machining efficiency originates with a careful study and analysis of the total job
Operational sequence
44
You should try to keep the workpiece in the __________ machine for as many operations as possible
Same
45
What part of a lathe must be perfectly level at all times?
The bed
46
When selecting stock, you should choose a piece that is ________ _________ than needed.
Slightly longer
47
When mounting longer workpieces in the lathe, mount it ______ ________
Between centers
48
The faceplate should only be threaded onto the spindle by _____
Hand
49
Do not select a lathe dog that is _______ than necessary to accept the workpiece diameter
Larger
50
When using a dead center, use a half center for _______ _______
Tool clearance
51
Clearance for the entry of a facing tool at the work center is provided by using a _______-______
Half-center
52
Be sure the tail of the ______ ______ does not sit on the bottom of the faceplate slot
Lathe dog
53
Too much tool overhang can cause the tool to _____ ____ during machining
Snap off
54
When selecting speed and feed, you must learn to _____ the cutting speed with the feed
There are many tables provided that show cutting speeds and feeds.
The speeds can also be calculated
RPM=(SFPMx4)/work diameter
Balance
55
When moving the cutter into the workpiece, be careful not to _____________.
Strike the dead center
56
When you turn down the diameter of a workpiece you must remember that each cut is reducing the diameter of the work by _______ the depth of the cut
Twice
57
When cutting right handed turning setups, the cutter is fed into the work from ______ to _____
Right to left
58
When mounting the cutter and holder in the lathe, Once the tool holder and cutter are mounted to the tool post, turn the holder so that the tip of the tool is pointing ___ or ____ toward the tailstock
4° or 5°
59
To rough turn the workpiece, you will want the tool to cut at an angle __° ____ the workpiece center
5° above
60
When reversing your work in the lathe chuck, use a thin metal sleeve to _____________________
Protect the surface from the lathe dog set screw
61
The cutting tool for finishing cuts should be set at _° above the workpiece centerline
5°
62
Always take _______ cuts in the same direction as ________ cuts
Finishing
| Rough
63
When working with a lathe, the _____ and the _____ must be perfectly level at all times
Bed and the ways
64
When selecting stock, always use material that is ________ _________ than needed
Slightly longer
65
When selecting the mounting method in a lathe, mount pieces of moderate to longer length stock ________ ________
Between centers
66
When installing the faceplate, thread the faceplate onto the spindle _________ ________
By hand
67
When selecting a lathe dog, do not select one that is _______ than necessary to accept the workpiece diameter
Larger
68
To provide clearance for the facing tool, use a _______ _________ at the dead center location
Half center
69
While facing the ends of the workpiece, the tail of the lathe dog should not ____________________________.
Contact the bottom of the faceplate slot
70
Clearance for the entry of of a facing toll at the work canter is provided by using a ________ ________
Half center
71
Too much tool overhang is dangerous because it can cause the tool to ______ _______ during machining
Snap off
72
You must learn how to ______ the cutting speed with the _______
There are many charts provided by various lathe manufacturers showing cutting speeds and feeds for machining different metals
Balance
| Feed
73
Rpm=(sfpmx4)/work diameter
The term 4 is a constant
^^^
74
When mounting the cutter to the workpiece, be sure not to ______ the ______ _______ against the workpiece
Strike
| Dead center
75
When turning a workpiece, you reduce the diameter by _______ the depth of the cut
Twice
76
In a right hand rough turn, the cutter moves from _______ to _______
Right to left
77
When installing a tool in a lathe, the tip of the tool should be pointing _____ Towards the tail stock
5°
78
Too rough turn of work peace, you will want the tool to cut at an angle ___° _____ the workpiece centerline
5° above
79
When reversing work in a lathe use a sleeve to protect the Surface from the ______ ______ set screw
Lathe dog
80
You should always take finishing cuts in the _______ _______ as the roughing cuts
Same
| Direction
81
When taking a trial cut, you should take a cut about _____” the length of the Workpiece
1/4”
82
When laying off or marking shoulders on a workpiece, use a __________ caliper or a ________ scale to set the _________ caliper to the location of the outer shoulder. Place the bent leg of the caliper against the ________ end of the workpiece
Hermaphrodite caliper
Machinist
Hermaphrodite
83
If you are required to make several duplicates of a shouldered part, you might use a _________ tool to lay off the shoulders
Parting
84
the_____ _______ cutting tool is normally used for turning filleted shoulders
Round nosed
85
Fillets of different sizes are made by changing the _________ ________ Of the cutters
Nose profiles
86
Mini machine assemblies require that a bearing or other part Be mounted flush against a shoulder face. Therefore the face of the shoulder and the smaller diameter must be ______ with one another
Square
87
Knurling _______ the sorta e of the workpiece
Deforms
88
A knurling tool with a medium roller will be a pitch of _____
21
89
Filing on a workpiece between centers is mostly done the remove __________ or _______ _________ from the work surfaces
Irregularities
| Tool marks
90
Never engage the split nut when any other _______ _____ mechanism is in operation
Automatic feed
91
The ______ ______ assembly is used only when cutting threads
Split nut
92
The ______ of the single thread screw is measured from one point on one thread to the same point on the next thread parallel to the screw axis.
Pitch
93
The _____ Other thread is the distance would you point on one thread travels during one revolution of the screw
Lead
94
If the work because you were machining was long and slender you need to use a ________ _____ or a _______ _____ For Support during the threading process
Steady rest or follower rest
95
American national thread angle is always _______°
60°
96
When threading the compound rest should be swung to the right at and angle of ___°
29°
97
The __________ __________On the lathe crossfeed mechanisms can perform the same function as a thread cutting stop
Micrometer collar
98
The top face of the thread dial indicator is marked off in eight divisions. _____ of them are numbered
Four
99
The Morse taper is approximately _____in/ft. It is used on the shanks of twist drills, readers, end mills, and lathe centers
5/8in/ft.
100
In a jarno taper, the large Diameters fractional value is always __, the small diameter denominator is always __, and the tapers length Denominator is always ___.
8
10
2
101
When turning tapers, the ___________ ___________ Method requires the work to be removed from the lathe for set up
Tailstock set-over
102
Remember this formula for tapers.
Taper per inch = (Large Diameter-small diameter) divided by length
^^^
103
The amount of inward and outward feed on the compound or us is controlled by the angle setting of the ______ ______ on the taper attatchment
Guide bar
104
Machining a plain taper requires you to always disconnect the ____ _____ screw when using the plain taper attachment
Cross feed
105
The best way taper short, steep tapers when using the compound rest is to _______ the coonhound rest and feed the ______ into the work with the compound rest feed screw
Swivel
| Cutter
106
The compound rest method of turning tapers requires working with ______ since the base of the compound rest is graduated in degrees
Angles
107
When turning the tapers, make sure to back the compound rest all the way out in order to have _____ ______ available for turning the taper
Full travel
108
To obtain a very close tolerance, use a _____ test indicator, or a _____ bevel protractor
Dial
| Vernier
109
The cutting tool used for finishing cuts should be set at __° above the centerline of the workpiece
5°
110
In belt drives, ______ is transmitted by _______. The power transmitted equals the force multiplied by the speed of the belt.
Force
Friction
111
In a v belt sheave, the pitch diameter is always _____ than the outside diameter of a sheave
Less
112
Conventional belts are designated by the letters A, B, D and E.
____ being the narrowest
____ being the widest
A
E
113
The belt with ______ strength because of a backing applied during manufacturing is called a group belt.
Uniform
114
In the spring loaded sheave, the fittings on the unit include ________
Lubrication
115
Chain drives have an advantage over belt drives because energy is not wasted and the chain drive is ______ ______ than a belt drive
More efficient
116
Engineering class chains have thicker sidebars, and the rollers are _____ together
Closer
117
Type B sprockets are ________ on one side, but have a slightly _________ hub on the _______ side.
Type C sprockets have hubs extending on ______ sides
Flat on one side, extended, other side
On both
118
Install the chain with a slight amount of sag on the slack side and with the _________ side in ________.
Driving side in tension
119
The depth to which a gear tooth extends into the open space between the teeth of a mating gear is called _________ __________
Working depth
120
DP= N
—-
D
30
——. = 2.0444
14.7
Remember that
121
The angled tooth face assured that several teeth are in contact at the same time between the pinion and driven gear, producing ______ and quiete operation
Smooth
122
Herringbone gears
First the tooth forms a point at the center of the gear. This point is cut by machine and is smooth. When the mating gear is brought into contact there is no interference between the teeth. The helix angle of the tooth is very near _____ °
30°
123
The distance between the screw threads is called __________ _________ _________
Worm axial pitch
124
Miter gear boxes are used for changing the ________ ____ _______ of motion, they provide ratios of 1:1
Changing the direction
125
The first most important step you must take when you are installing a gear drive is to make sure that it is _________
Aligned
126
The mechanical power rating of a gear drive depends on the _______ and _______ of the gear drive
Speed and torque
127
The service factor of a gear drive depends on the _______ _______
Duty cycle
128
________ _________ is commonly used in parallel shaft gear drives but has its limitation. The slow speed of some units does not cause enough splashing to provide enough lubrication. __________ systems are usually used for supplementary lubrication
Splash lubrication
Pressurized systems
129
The type of adjustable speed drive is selected by the ______ required. The _____ range, the _____ it must deliver and the conditions in the workplace
Speed
Speed
The power it must
130
In the belt type adjustable speed drive, as the flanges move in, the belt speed increases. As the flanges move out, the belt ______
Slows
131
The input sheave of an adjustable speed drive is movable and is connected to a _______ mechanism. Another type of drive uses a _____ mechanism
Some use _____ or _______ control mechanisms rather than mechanical ones
Shifting
Gear
Pneumatic
Electric
132
The belts used in enclosed adjustable speed drives are ribbed and resemble a ______ belt. The chain is of a modified ____ or lattice design.
Timing
| Leaf
133
Roller type adjustable speed drives have a ______ shape, and move _____ and the speed ratio changes to provide the maximum output speed
Conical
| Axially
134
In the reverse indicator method, one dial indicator is mounted on the coupling flange of the _______ and takes measurements on the pump. The other is mounted on the coupling flange of the pump and takes measurements on the _______
Motor
| Motor
135
When aligning 3 machines, there may be too few shims under the motor to allow you to lower it far enough, or there may not be enough clearance in the bolt holes to allow you to move it sideways far enough.
Study this
136
The setup for a face rim alignment, on dial indicator is mounted on the ______ shaft and takes readings from the _____ shaft
Same
137
The setup for a long shaft alignment uses _____ indicators on _______ flanges and takes readings from the opposite sides of the ______ shaft
Two
Opposite
Same
138
Laser alignment makes aligning ______, _______, and more _______
Easier, faster, more accurate
139
The two classes of jaw couplings are ______ and ________.
Rigid
| Flexible
140
In chain couplings, the _____ can be replaced without disturbing the moving components because it wraps around the outside of the hubs
Chain
141
Shear pin couplings have a breakable pin that connects the driving hub to the driven hub. The pins are made to ____ along the plane where the two hubs meet.
Break
142
The limited end float coupling is made with a ________ ________ located between the two coupling halves
Thrust plate
143
Spacer couplings are meant to ________ the process of connecting a driving shaft from the ______ shaft
Simplify
| Driven
144
A _______ mechanism is used to allow one device to rotate while the other remains stationary.
Clutch
145
_______ clutches transfer motion by bringing two metal plates into contact, often through a fiber lining attatched to one plate. The _____ clutch has a ________ mechanism. Moving the _______ arm emgages or disengages the ________ plates
```
Friction
Friction
Shifting
Shifting
Friction
```
146
The electric clutch is used in applications that require intermittent motion. Such as motors that ______ and ______ frequently
Stop and start
147
An overrunning clutch is used if the machine needs to run faster than the ______. It is used where the driven equipment can speed up and not damage the motor by forcing it to run too fast
Motor
148
The single impeller clutch motion transmission in order:
1. Impeller
2. ________
3. Housing
The ______ is connected to the _____ shaft. Rotation of the impeller causes rotation of the hydraulic fluid inside the clutch. The rotating fluid in turn causes rotation of the clutch ______. The driven part of the machine is connected to the housing.
1. Impeller
2. Fluid
3. Housing
Impeller
Driving shaft
Clutch housing
149
Always use a power hacksaw or a horizontal hand saw for cutting _______ ______ and always clamp it in a vise
Round stock
150
The horizontal bandsaw gives much faster cutting action than a power hacksaw, because there is no non cutting stroke, therefore no ______ ________.
Lost motion
151
During band installation, the teeth should point __________ and to the ________
Downward and to the right
152
Bad speed is controlled on most light duty bandsaws by changing the _______ ________ position
Drive belt
153
The final step in making a cut with a bandsaw is to move the ___________________ to _______.
Head control lever to release
154
When selecting inserts for saw blades, the sizes are preset and you must select a pair of upper and lower inserts to match the _______ and _______ of the ______ you are using
Width and thickness of the band
155
To place the band around the carrier wheels, grasp the band in both hands with the teeth facing you. The teeth in your _____ hand should point ________.
Right
| Downward
156
One major safety precaution with vertical bandsaw safety is to make sure all _____ are in place before using the bandsaw
Guards
157
As you approach the end of a cut, ______ the _______ pressure so that the blade doesn’t break through the work unexpectedly
Reduce the feed pressure
158
Use the shear mounted on the bandsaw to cut the band. You then _______ the portions of the band ends in contact with the welder jaws so they are free of dirt and other contaminants
Sand
159
Sensitive drill presses are called that because the ______ is directly under the __________ control
The feed is directly under the operators control
160
Before mounting a tapered shank machining tool, make sure the make and female surfaces of the drill shank and the spindle are free of _____, ____, and ______ which could prevent proper seating of the tool
Chips, nicks, and burrs
161
Radial drills, unlike most drill presses, have the power and rigidity for _____
Boring
162
When you plan the order of the machining steps, remember to choose the order that requires ____________________
The fewest changes in setup
163
To seat the work firmly in a drill press, such as on the table or on parallels, _______ ________ the ______ _______ with a lead or plastic face hammer to seat the work
Lightly tap the upper surface
164
You should try to use a _______-________ drill press on all holes over 1/2”
Gear-head
165
70x4
——- = 560
0.5
Remember this answer
166
With Large diameter drills and fairly thick stock to drill through, you must periodically back the drill out of the hole to clear away loose chips, this reduces the chances of ________ the _______
Breaking the drill
167
If the drill bits cutting edge chips, it is an indication of the _______ being too ______
Feed being too fast
168
If you have a hole drilled at 25/64” then you will need to mount a _____” pilot in the counterbore body
25/64”
169
The precision vise is the most commonly used work holder for shaping machine operations. A typical precision vise has a _____ base
Swivel
170
For safety reasons, before operating a shaper, you should set the transmission on the _____ speed (______ strokes per minute)
Slowest
Fewest
171
A shaper should never be left with a ________ ________ in its tool post
Cutting tool
172
After performing your prestartup inspection, you need to true up your work holding surface with the path of the ram. The best way for you to do this is with a _____ ______.
Dial indicator
173
Last step in the vise mounting on a work table is to ____ it with a ______ ______ to obtain a solid seat and fit
Tap it with a soft mallet
174
Once the vise is properly placed, you can begin positioning the ram. This is a two part process which includes setting the _____ length of ______
Proper length of stroke
175
Calculating number of strokes
40x7. 140
——— = ——— = 46.6 strokes per minute
5+1 3
Remember this
176
The actual overtravel of the ram at both ends of the stroke is ___”
3/4”
177
When making a cut, you must always wear ______ ______ and set ______ surrounding the machine to keep others safe from flying chips
Eye protection
| Barriers
178
Horizontal shapers are well suited for _________ slots and __________ that are not possible on other machines and usually the only means of cutting them
Internal slots and keyways
179
The general rule when milling is to check the workpiece to the drawing to ensure it has enough ______ ______ for grinding
Surplus material
180
Set the dresser so that the arrow points in the proper direction, position the grinder saddle and lower the wheel until it’s ______ ______ lightly touches the diamond
High point
181
The first operation on the V-block is to grind the ______ ______ _______. This is usually the longest surface of a workpiece
Basic flat surface
182
The last step in setting up a workpiece on a surface grinder is to ________ __ the ______
Turn on the coolant
183
The recommended allowance for finishing cuts in general purpose grinding is ________ to ________ in.
.0005 to .001
| 5 tenths to 1 thousandth
184
4500/9=500 RPM
Remember this
185
In order to hold work securely in the center of a cylindrical grinder, provide _______ _____ from the _____ center adjustment to hold the work in place
Enough pressure from the footstock
186
For general purpose grinding, you can calculate the RPM you need for the work piece by using the equation:
RPM=_____x4/workpiece ________
Sfpm
| Diameter
187
When the width of the wheel is greater than the length of the area to be ground, you use a process called _______ grinding
Plunge
188
When milling, using a ______ _____ you can do more operations without having to construct additional setups
Rotary table
189
When boring, Use a stub boring bar when ever possible. There is less chance of _______
Vibration
190
When working a small bore with a light boring bar, you must use a cutter with ________ back rake and ______ rake angles
Greater
| Side
191
When measuring alignment on finished surfaces, the workpiece is adjusted until the dial indicator _______ _______ throughout the table stroke
Remains constant
192
In line boring, bother the primary and the secondary layout lines must be parallel with the axis of the _______ ______
Boring bar
193
If the workpiece has a machined hole, and has to be perfectly aligned, you have to check the workpiece for ____________
Concentricity
194
If the boring bar is inserted in an end support, you cannot withdraw the bar from the work to make the measurement, however you can still use ________ ________ to measure the bore size
Inside calipers
195
Multiple point boring is particularly advantageous in the machining of _____ ______ areas
Long work
196
When indexing, you will probably use the dividing head most often to machine shapes like ______ ______
Gear teeth
197
The direct indexing method _____ on the index holes around the spindle. Suppose that you have to machine six equally spaced bitches in the OD of a workpiece, the diving head you are using has 24 index holes around the spindle nose, since 24 divided by six equals 4, you know that you must rotate the spindle a distance of ______ holes to cut each groove
Relies
4
198
With a gear ratio of 40:1, you must turn the worm ______ times to move the worm gear and the spindle through one complete 360° revolution
40
199
Suppose you are indexing and the workpiece requires 12 splines instead of 10, the crank turns needed for indexing the work would then be computed as:
T=40
——
12
=
3an 1/2turns
200
If a dividing head has 24 holes around its spindle nose, and you must cut eight equally spaced notches in a workpiece, how far must you rotate the spindle between cuts?
Three holes
201
In simple angular indexing, one crank of the spindle produces 9° degrees. Which means in simple indexing you can use a circle with a total number of holes that can be divided by ____. For example 27,36,45, or ____.
Nine
54
202
In compound indexing, you first turn the crank, next you turn the _______ ________ itself to provide the final index
Turn the index plate itself
203
Differential indexing is similar to, but more accurate than, ________ indexing
Compound
204
A universal dividing head can rotate its spindle ____°
90°
205
When using a dividing head, Workpieces can be held between the center of the spindle nose and the center in the _________.
Footstock
206
When holding work with a dividing head, the power flow moves from the dividing head spindle to the ______, from there to the _____, and then from the dog to the workpiece
Driver
Dog
207
When using a dividing head and a chuck to hole the workpiece, depending on the shape of the work that you must machine, you can hold it solely in the chuck, or support it with the footstock center or a ______ ______.
Steady rest
208
When using the direct indexing method on a workpiece such as a hexagon bolt head, the setup requires you to _________ the worm and worm gear inside the dividing head. Then insert the ________ pin in on of the direct indexing holes around the spindle nose
Disengage
Plunger
209
In the plain indexing method, leave the worm gear in the ________ position
Engaged
210
When straddle milling, you mill two sides at one time and need only position the workpiece ______ times
3
211
When indexing the workpiece, it is important to remember that after you make the first side of the hexagon, you must rotate the spindle one half turn and mill the flat on the _________ _____ of the workpiece
Opposite side
212
You will find find the dividing head extremely useful whenever you must drill or bore a series of holes in a _______
Circle
213
Most dividing heads heave a cap that is placed over the spindle to __________ ________ from falling in.
Prevent chips
214
Cutting the teeth in spur gears is a type of _____ milling
Form
215
Gears are cut with __________ profile cutters
Special
216
OD=30+2
————
6
= 5.333333
Remember this
217
Several things affect cutter selection when you mill gear teeth. They are the _________ pitch of the gear, the ________ of teeth, and the _______ of the gear blank
Diametral pitch
Number of teeth
Material
218
For a series of ___ cutters has been developed to suit the different numbers of gear teeth and there is also a separate series for each _________ pitch
8
| Diametral
219
When milling large diameter spur gears, they are mounted on a _________ table.
Rotary
220
Use a _________ to check the dimension over pins (gears)
Micrometer
221
A gear tooth _________ __________ is used to check tooth thickness at the gears pitch circle
Vernier caliper
222
The distance between adjacent helices that are wound on a common cylinder is called the:
Helix pitch
223
The ________ __________ lead determines the lead of the helix it will produce
Milling machine
224
To mill a helix, you use a system of gearing between the lead screw of the milling machine and the _______ shaft and the _______ head
Worm shaft
| Dividing head
225
If the ratio of the change gears is 1:1, the lead of the milling machine is 10inches. A helix milled under these circumstances will have a helix lead of _____”
10”
226
The worm shaft of the dividing head is designed to operate with ____ gears, not 2.
4
227
Driven gear A will have 40 teeth, driving gear B will have _____ teeth, driven gear C will have 60 teeth, and driving gear D will have ____ teeth
40
| 24
228
To reverse the direction of gear rotation, you must insert an ________ _______.
Idler gear
229
Swivel the _______ counterclockwise until its longitudinal axis is offset 12° from its normal position in order to cut the 12° helix angle
The table
230
A measurement you will use when describing the proportions of a helical gear tooth is:
Normal diametral pitch
231
After milling each tooth of a helical gear, why should you not draw the cutter back through the work?
May damage the tooth surface
232
Cams are designed to ______ the _________ of motion of machine parts
Change the direction
233
In a nonpositive cam system, the cam forces the follower upward, the system depends on ______, a spring or some other _____ to bring the follower back down
Gravity
| Force
234
The distance that one lobe moves the follower from its starting point as the cam rotates is called the:
Cam rise
235
The total distance that a lobe on a uniform rise cam would move the follower if the lobe extends 360° is called:
Cam lead
236
The axis of the dividing head spindle and the axis of the cutter must always be ________. They must also be at some angle other than ________ when milling plate cams. If the dividing head spindle and the cutter are in a horizontal plane the cam will not develop the needed spiral
Parallel
| Horizontal
237
When milling short lead cams, the relative movement of the ______ _______ and the workpiece rotation form an Archimedes spiral which produces the desired cam lead
Table feed
238
When milling cams, you position the cutter on the ________ side of the workpiece to provide a more rigid setup
Lower
239
.25x360
—————. = .75”
120°
Remember this
240
The ________-cut method is the most often used to mill cams having a non uniform rise
Incremental
241
Specially designed fixtures and attachments must be justified before using them. Justifying points for obtaining specialized equipment are:
The repetitive need for making a fast wearing part
The need for making spare parts on obsolete equipment
Emergency requirements to keep a production line operating
All of the above
242
You should always try to use a machine slightly __________, rather than stretch the capacity of a smaller machine
Oversized
243
Always make sure the machine you use has enough ________ to perform the job _______
Power
| Effectively
244
A universal horizontal milling machine is like a plain horizontal milling machine except it has a ______ ______ mounted on top of the saddle
Table swivel
245
The ______ is the main upright support member of a horizontal milling machine. The column houses the drive motor and ______ speed controls
“Spindle on the column”
Column
Spindle
246
The _____ supports the saddle and the the table on a horizontal milling machine
Knee
247
The vertical milling attachment is mounted on the spindle nose and bolted to the machined face of the _______ for support
Column
248
The ______ spindle position permits you to mill slots, dovetails, and other shapes on a horizontal milling machine
Vertical
249
Spindle speed of a milling machine is always expressed in ______
RPM
250
A milling cutters speed is the rate at which a particular tooth passed over the __________ _________.
Workpiece surface
251
In order to compute spindle speed you must have:
Spindle speed?
Cutter speed?
Cutter diameter?
All of the above?
All of the above
252
An effective method for holding a cylindrical workpiece is to mount it in a _-_____.
V-block
253
The angular graduations on the base of a milling machine vise allow you to align the workpiece accurately at any _______
Angle
254
A slab milling cutter is a type of plain milling machine cutter that is specially designed for taking _______ cuts
Heavy
255
A milling cutter with teeth the spiral to the right across the face of the cutter, it has a ______-_______ helix
Right hand
256
With a left hand helix cutting tool, the work is fed from the _____
Left
257
The style B arbor has a keyed ________ sleeve which fits into the bearing in the arbor support
Bearing
258
The entire arbor assembly is held in position by a __________.
Drawbar
259
The arbor nut should never be tightened or loosened unless the arbor support is in position because the arbor can be _______ if it is not supported
Sprung
260
70x4
———=93.33
3
93.33
261
What is not a factor in rough cutting?
A. Speed
B. Feed
C. Depth of cut
D. Length of workpiece
Length of workpiece
262
If you stop the automatic feed before a cut is finished, do not leave the cutter ________
Turning
263
If you lower the feed rate in a finishing cut on a mill, but the keep the same ______ speed, you will increase the surface quality
Spindle
264
The first step to cutting a T-slot is to mill a ______ ______.
Straight slot
265
Place a ______ on the ways to lay tooling on or across the machine table and wipe the tooling with a cloth to remove dirt or shavings
Board
266
You can align the cutter and workpiece by subtracting one half of the cutter width from the distance between the slots ___________ and the edge of the workpiece
Centerline
267
The t slot is completed by using a T slot milling cutter fitted into the spindle of the milling machine with a spindle chuck ________.
Adapter
268
Since the Tslot cutter is held in the horizontal spindle instead of on an arbor, it is necessary to set the workpiece ___ ___ _____ to complete the Tslot
On its side
269
For boring on a horizontal milling machine setup, select a ___° ______-angle cutter
45° single-angle cutter
270
Use _____ _______ for vertical milling of slots
End mills
271
For milling the T-slot with a vertical milling attachment, use ____ ____ Tslot cutter that you used in the horizontal setup
The same
272
Use an _____ _____ in the vertical attachment to mill a bevel on the workpiece
End mill
273
The difference in milling a dovetail rather than a t slot is that you kill angular dovetails in the wall of the slot or groove instead of a T, so you use a different cutter _______
Shape
274
In straddle milling, _______ between the cutters control the distance between the cuts
Spacers
275
When straddle milling, be sure there is clearance between the top surface of the _____ and the ______ between the cutters
Workpiece
| Spacers
276
The greatest advantage to straddle milling is that you save ______ and ______ time by milling two parallel vertical surfaces at once
Setup and machining
277
When choosing milling cutters, cutters with _________ helix angles will tend to balance the thrust load on the arbor when both are cutting
Opposite
278
The cutter used to mill the angled step must be wide enough to finish the _____ end of the step
Wide
279
The most precise method of selecting a milling cutter is to use __________.
Trigonometry
280
The smallest cutter that will do the job safely and efficiently is preferred because as the diameter, width, and number of teeth increases, so does ___ ______.
The cost
281
A very precise method of finding dimensions based on given angles is the use of _________.
Trigonometry
282
The shell end mill must be wider than the surface you just cut, this helps avoid ______ _______.
Surface lines
283
She’ll end mills are normally mounted on a style __ arbor
C
284
If you were to use a side milling cutter mounted on the horizontal arbor of the machine, you would produce a key seat with _________ ends
Feathered
285
Milling machine cutters for woodruff keyseats are _________.
Standardized
286
The last two digits of a woodruff key cutter show the cutter diameter in ___________________.
Eighths of an inch
287
The ______-fluted end mill has cutting edges on its sides and across the end, these allow the cutter to plunge into the workpiece and cut as a ____ _____ does.
Two-fluted
Drill bit
288
When a dividing head can’t be used, it is best to _______ mill square ends on round work.
Straddle
289
You may need to install ______ between the spacer and the cutters to obtain the specified straddle distance
Shims
290
To determine the largest square that you can cut out of any shaft, you multiply the diameter of the shaft by 0._____ (constant)
0.707
291
The procedure for milling a tang is the same general procedure as milling a ________ except you omit the last two sides
Square
292
If a single flat surface is specified on the circumference of a cylindrical workpiece, it is usually machined with a _______ milling cutter
Plain
293
The jaws of a three jaw universal chuck operate in _______.
Unison
294
The jaws of the four jaw independent chuck can be _________ to hold larger diameter work
Reversed
295
____________ shaped work can normally be handled by a four jaw independent chuck
Irregular
296
The _______ jaw universal chuck is quick to set up and Convenient to use
Three
297
The size of a lathe chuck is designated by its ________.
Diameter
298
Before picking up the chuck, place a board across the lathe bed and ________ underneath
Ways
299
Never use _____ of any kind to install a chuck on the spindle
Power
300
The two main objectives when installing work in a chuck are to have the work _________ properly and have the work axis parallel to the ____________ of the lathe
Centered
Centerline
301
Irregular or odd shaped work in the chuck can be centered by using the _____ _______.
Dead center
302
The method of holding work in a collet is limited to ________ diameter work
Small
303
The mandrel is mounted ________ _________ in the lathe
Between centers
304
Facing give a _______ surface as well as square ends for later machining operations
Reference
305
Because cutting is done on the side of the facing tool, the _____ ______ angle is the most important
Side rake
306
Set the tools cutting edge on the ____________ of the work piece
Centerline
307
If a large area on a workpiece is to be faced, the tool is fed across the workpiece by means of the __________ ______
Automatic feed
308
Rough turning removes the bulk of material _________.
Quickly
309
The rough cutting must leave enough material to make a ______ ________ cut.
Good finishing
310
A right hand, high speed steel, roughing tool is good for heavy cuts on steel, but it will not produce a good _______.
Finish
311
The proper use of cutting fluids allows you to ________ cutting speed and in which case saves _______ time, and allows you to ________ the depth of cut
Increase
Machining
Increase
AOTA
312
When making a finishing trial cut, you use the same procedures as making a trip rough cut, the only difference is that you are looking for ______ _____ quality
Finish cut
313
Boring makes a hole larger and ________ it so the sides of the hole are parallel
Trues
314
A bored hole is always ________ with the circle in which the workpiece or cutting tool is rotating
Concentric
315
When you use a boring tool you must allow more clearance than you do when turning to prevent the _______ of the tool from_______ against the workpiece
Heel
| Rubbing
316
Always use a boring bar with the _______ ________ that is practical for the job
Largest diameter
317
The cutting tool ______ determines the type of corner at the end of the bore
Profile
318
When installing a boring bar, adjust the compound rest to a ____° offset
60°
319
After boring, ______ the lathe and clean the chips out of the bore. Do this only when the lathe is completely ________.
Stop
| Stopped
320
____________ increases the inside diameter at one end of an existing hole, forming a recess in the workpiece surface
Counterboring
321
The counterbore that produces a recess must be _____ with the hole that has been bored
Concentric
322
Counterboring procedures are the same as the procedures for rough ________
Boring
323
A recess at the center of a coupler between two threaded pieces provides _______ _________ and separates the threads
Chip clearance
324
The diameter of a drilled hole for threading must equal the ________ diameter of the finished threads
Minor
325
Internal threading requires _______ _________ at the bottom of a bored hole
Tool clearance
326
Thread cutting tools must be ground to meet the particular _______ _______
Thread form
327
When installing a tool for threading, rotate the compound rest ___° to the left of the cross feed centerline
29°
328
You can bore an internal taper using _____ methods.
Two
329
When using the compound rest method for boring tapers, rotate the compound rest one half of the _________ _________.
Included angle
330
When aligning the tool with the workpiece for tapers, set the tool post and tool holder in line with the compound rest __________
Centerline
331
Of all ways to machine a taper, the most accurate method is the _________ ___________ method
Taper attachment
332
The telescopic taper attachment works the same way as the compound rest method except it has a _______ _____ screw that telescopes internally to different lengths
Cross feed
333
When mounting a workpiece on a faceplate on a lathe the faceplate provides a reference surface that is perpendicular to the lathes ________ axis
Spindle
334
For truing a faceplate, you need to select a ______-________ finishing tool.
Broad nosed
335
Large workpieces mounted on a faceplate must be mounted and held with _________ _______.
Faceplate jaws
336
Clamps for faceplates are inserted into the open ends of the __________ slots
Faceplate
337
A _________ prevents the workpiece from shifting backwards from the force of the cutting tool against it.
Driver
338
Some workpieces cannot be held against the vertical surface of a faceplate, in such cases use an __________ _________
Angle plate
339
If a job requires an angle plate to be mounted far out toward the edge of the faceplate, a _____________ must be used
Counterweight
340
Extremely odd shaped workpieces that can’t be mounted on an angle plate can be held in a vblock angle plate. Each half of the clamp has a set of _________ jaws
V-shaped
341
A specialized mandrel for machining eccentric circular areas has more than one set of ______ holes
Center
342
When boring work on the lathe carriage, the workpiece is mounted firmly to the _________.
Carriage
343
A partially clogged trash rack will cause _________ in head
Losses
344
Wood stave pipe would probably not be used for ____________ conduit
Pressure
345
The most advantageous form of cross section to use from a hydraulicpoint of view would be that which would provide the __________ wetted perimeter
Smallest
346
The minimum velocity of water in a power canal to prevent the deposit of silt is about ___ to _____ ft./second
2 to 3
347
Penstock velocities May range from __ to __ ft./second
6 to 20
348
The conduit between the fire at and the surge tank is commonly called the high line conduit, pipe line, or flow line. From the surge tank to the turbines, it is called the _______
Penstock
349
A well designed and fabricated __________ job is the lightest and produces a finished job of lower hydraulic loss than a riveted pipe of equal size
Welded
350
To prevent negative pressures from collapsing the line, ______ _______ are installed along the line where the danger points are located.. generally where a great change in the slope occurs
Air vents
