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ENME221 > Exam Prep > Flashcards

Exam Prep Flashcards

1
Q

A shaft is to be rough machined on a lathe and then cylindrically ground on two surfaces. What feature should be added to allow concentricity of the machined and ground surfaces when swapping between machines?

A

Centre drilled holes

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2
Q

A high strength cap screw typically has what type of head?

A

Cylindrical with internal hex

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3
Q

MIG welding is often used for manufacturing steel frames like trailer chassis. What does the ‘M’ stand for?

A

Metal (MIG = Metal inert gas)

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4
Q

You are required to lap joint two pieces of sheet metal with a mechanical fastener but access to the rear side is not possible. Which of the following is a likely option?

A

Pop rivet

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5
Q

You are designing a large part that has a flat face and an irregular shape outer surface. A spigot on it must be turned on a lathe. Which of the following is the most likely option for holding the part in the lathe?

A

Four jaw chuck

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6
Q

Optical scanners for measuring irregular shapes typically come in two technologies. The department just purchased two. Which technology do they use?

A

White/Blue light

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7
Q

You have been sent to the hardware store to purchase a set of drills. One option appears to be polished steel and the other gold colour coated. What is the significance of the gold colour?

A

The surface is harder and more wear resistant

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8
Q

You have chemically machined a Lear jet body panel to reduce its weight but the sideways dimension is larger than the chief engineer designed and the dimensions of the masking hole. What is your most likely mistake?

A

To allow for sideways undercut under the masking

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9
Q

Your company is purchasing a new EDM machine. The ‘D’ stands for?

A

Dick Discharge (Electrical discharge machining)

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10
Q 
Which of the following is NOT a typical drilling operation?
Counter boring  
Reaming  
Countersinking  
Lapping
A

Lapping

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11
Q

You went to the gas store to get a gas bottle for TIG welding and brought back a bottle of oxygen. Why did the foreman laugh at you and send you back to the store?

A

The gas is used to remove oxygen

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12
Q

The swarf coming off a CNC lathe is tangling in the tool holder and machine time is being wasted removing it. What is NOT a likely solution?
Use a chip breaking tool
Increase the feed rate
Increase the rotating speed
Move the part further away from the tool holder

A

Move the part further away from the tool holder

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13
Q

The head of an engine exhaust valve must be welded to its stem.
Which of the following is the most likely method for mass production?
Manual stick welding
MIG
Spot welding
Friction welding

A

Friction welding

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14
Q

A turn buckle is needed to stretch a shade cloth. What is the special feature of the threads?

A

Right and left hand thread

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15
Q 
Your company has just bought a production line for manufacturing HEX head bolts. What process is used for making the thread?
CNC machining  
Drop forging  
Rolling  
Drawing
A

Rolling

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16
Q 
Two halves of an engine housing are bolted together. Which of the following are special features to aid assembly?  
Dowels and spigots  
Neat fitting bolt holes and gaskets  
Rivets and splines  
Cast ribs
A

Dowels and spigots

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17
Q 
You work for an aircraft manufacturer and the wings are held on by three bolts. Which of the following would you recommend to your boss for ensuring the nuts don’t come undone? 
Wire tied  
Split washer  
Nylock nuts  
Wing nuts 
Deez nuts
A

Wire tied

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18
Q 
Which of the following is NOT an additive manufacturing process?  
FDM (Fused Deposition)  
Polyjet  
SLS (Selective laser)  
MAW (Metal arc)
A

MAW (Metal arc) , it is welding but is a developing concept

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19
Q 
Which of these processes would be considered mass production of small steel gears?  
Powder Metallurgy  
Blanking  
Turning  
Shaping
A

Powder Metallurgy

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20
Q 
Which of the following is a bulk deformation process?  
Milling  
Shaping  
Rolling  
Shearing
A

Rolling

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21
Q 
The camshaft of an engine is normally?  
Mild steel  
Cast iron  
Sintered Brass  
Die cast aluminium
A

Cast iron

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22
Q 
Annealed copper tube is?  
Difficult to bend  
Usually used for house plumbing  
Easy to bend  
Impossible to braze
A

Easy to bend

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23
Q 
You work for a company making welded metal hand rails and  artistic structures. You are required to design stair hand rails for the new University lecture block. What would be your first material choice?
Mild steel  
Silver steel  
Stainless steel  
Commercial bright steel
A

Stainless steel

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24
Q 
What does ‘MS’ stand for in MSDS?  
Manufacturing Systems  
Manufacturing Safety   
Material Safety  
Material Sales
A

Material Safety (data sheet)

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25
Q 
You ordered 6061 aluminium T shaped extrusion. When it arrived the packing slip said Aluminium 6061 T6. What does T6 refer to?  
The shape of the material  
The material composition  
The material heat treatment  
The material surface finish grade
A

The material heat treatment

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26
Q 
Hot rolling steel has what benefit?  
Makes the steel stronger  
Requires less force  
Polishes the outer surface  
Dimensional accuracy
A

Requires less force

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27
Q 
For manufacturing flash less forging is preferred because?  
The material surface finish is better  
The material hardness is better  
Requires less finishing processes  
It is a safer process
A

Requires less finishing processes

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28
Q 
A common use of drop forging is?  
Making thin wall cups  
Extruding fly spray cans  
Making spanners  
Making vices
A

Making spanners

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29
Q 
Center less grinding is used for?  
Grinding cams on shafts  
Grinding gear teeth  
Grinding long rods   
Grinding square bar
A

Grinding long rods

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30
Q 
A dovetail cutter is mainly used for?  
Making slides on machine tools  
Making grooves for keyways  
Making a recess for bolt heads  
Making sheet metal shears
A

Making slides on machine tools

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31
Q 
The frame is to be welded together 50x50x3 RHS mild steel. What type of welding
process should you choose?
a. TIG
b. Submerged metal arc
c. MIG
d. Gas flame brazing
A

MIG

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32
Q

The apprentice welder assembles the first frame and finds it is severely distorted.
What might he/she not allowed for and protected against?
a. Flux shrinkage
b. Choosing the incorrect welding equipment
c. Using the wrong weld filler material
d. Weld shrinkage
e. Cracking of the HAZ

A

weld shrinkage

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33
Q 
The metal panel on the front is required for mounting instruments and has
numerous cutouts. What is the most likely method of cutting the 1.5mm thick mild
steel sheet?
a. CNC machining centre
b. Gas flame cutting
c. CNC turret punch
d. Hardened metal die set
e. Tin snips
A

CNC turret punch

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34
Q 
The equipment is exposed to the outdoor environment which will include rain and
sometimes it will be used near the sea. What type of protection of the metal would
you choose?
a. Acrylic paint applied by brush
b. Galvanising
c. Brazing
d. Laser coating
e. Tin coating
A

Galvanising

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35
Q 
After supplying the equipment the customer storms into the office hurling abuse at
you. He was making a complaint about the LPG gas fitting. What should you have
chosen?
a. ACME thread fitting
b. 30 degree parallel thread fitting
c. Left hand thread fitting
d. Threaded cast iron gas union fitting
e. Parallel taper lock fitting
A

Left hand thread fitting

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36
Q 
The ends of the tank must be formed from 1.5mm stainless steel sheet. What
process would you choose to make them?
a. Spinning
b. Lapping
c. Milling
d. Shaping
e. Extrusion
A

Spinning, (could use press for high numbers but very expensive)

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37
Q 
To enable the frame to be lifted by a fork lift or to allow easy fitting of lifting ropes
the frame will sit on metal skids welded to the frame. What is the most likely
material shown?
a. Hot forged universal section
b. Cold forged universal section
c. Cold rolled channel
d. Hot rolled channel
e. None of the above
A

Hot rolled channel, (cold rolled too expensive)

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38
Q

The front panel is attached with M8 bolts passing through the RHS. There is no
likely danger presented if the bolts come loose but it would not be good for your
reputation it they do. What would you most likely choose to prevent the bolts
loosening?
a. Use nylock nuts
b. Wire tie the nuts
c. Use castle nuts and cotter pins
d. Use flat washers

A

Use nylock nuts

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39
Q 
There are many RHS parts to be cut to length. What machine would you choose to
cut them?
a. Skill saw
b. Cold saw
c. Slitting saw
d. Band saw
e. Reciprocating saw
A

Band saw

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40
Q

The tank is made from 1.5mm thick welded stainless steel sheet. Which of the
following welding methods should be your first choice?
a. Brazing
b. EBW
c. TIG
d. Submerged arc
e. Friction weld

A

TIG

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41
Q

.What technique is used for creating the head on standard Hex head bolts?

a. Rolling
b. Upset forging
c. Milling
d. Coining

A

Upset forging

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42
Q

Cap screws are normally?

a. Low Strength
b. Medium strength with a protective cap
c. High strength with an internal hex
d. High strength with a flat blade screw driver slot
e. Medium strength with an external hex

A

High strength with an internal hex

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43
Q

TIG and MIG welders use inert gas around the weld pool. Why?

a. To keep the weld pool warm
b. To quickly cool the weld to prevent HAZ effects
c. To project the weld pool from the atmosphere
d. To provide a gas to break down the oxide layer

A

To project the weld pool from the atmosphere

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44
Q

Your company makes small engines and it is making a new line for producing
500,000 engines per year. What process would you choose for making the
carburettor body?
a. Hard metal die casting
b. Sand casting
c. Powder metallurgy
d. Additive manufacture

A

Hard metal die casting

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45
Q

Your company mass produces aluminium products. A client requires long lengths of
material that can be cut to length and used for heat sinks for electronic components.
What process would you select?
a. Reverse extrusion
b. Rolling
c. Forging
d. None of the above and you lose the contract

A

None of the above and you lose the contract because ben cartwright is a cunt
(you would want forward extrusion)

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46
Q

You work in a general design shop that specialises in rapid prototyping. Which of
the following are you unlikely to have in your workshop for designing and making
making 3D prototypes?
a. FDM additive manufacture machine
b. SLA additive manufacture machine
c. Polyjet printer
d. Ink jet printer

A

d. Ink jet printer

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47
Q

Which of the following is a bulk forming process?

a. Drop forging
b. Rolling
c. Extrusion
d. All of the above

A

d. All of the above

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48
Q

Which of the following is a method of brazing?

a. Vacuum
b. MIG
c. TIG
d. FDM

A

a. Vacuum (cleaner)

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49
Q 
An internal keyway is required in the bore of a cast iron gear. What process would
be the best to use?
a. Featuring
b. Broaching
c. Milling
d. Turning
e. Sawing
A

b. Broaching

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50
Q
  1. What is NOT a correct name for a process?
    a. Milling
    b. Lathing
    c. Spinning
    d. Shaping
    e. Annealing
A

b. Lathing (always turning)

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51
Q

A tool is required to punch a hole through 100 firm material gaskets. Which of the
following materials and processes would a tool room use to make the tool?
a. Annealed commercial bright
b. Hardended and annealed tungsten carbide
c. Annealed silver steel
d. Hardended and annealed silver steel
e. None of the above

A

Hardended and annealed silver steel

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52
Q

In numerical control what process would use point to point systems

A

drilling (each axis moves independently)

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53
Q

In numerical control what process would use continuous path systems

A

milling, turning (axis move synchronized)

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54
Q

What are the different types of additive manufacture machines?

A 
FDM- Fused deposition modelling 
(like hot melt glue, usually cheap if only one nozzle, uni is a big dog and has 2 nozzle one, Support is dissolved)
SLA- Steriolithography 
(material laid down and cured with UV light, requires post curing, one material at a time)
Polyjet-like inkjet printer (droplets of material squirted and cured on with UV light, multiple materials at once, very fine detail, elastomers)
SLS/SLM-Selective Laser Sintering/Selective Laser Melting(Powder spread down in a small thickness, Laser or electron beam fuses the material, Metals and plastics)
3D Printing (Powder (ceramic, plaster) is laid down and an inkjet printer head squirts an ink type fluid to bind it, full colour, low strength)
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55
Q

What machine can be used for reverse engineering or for checking the dimensions and geometry of objects

A 
3D Scanner (also good for recovering old parts with
no drawings)
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56
Q

What is DP Fever

A

When all you can think about is Double Penetration

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57
Q

Whats is The most common form of steel

A

Hot rolled (used Reinforcing steel, I beams, angle, RHS, plate etc) It is black due scale left after hot rolling Paint may not attach well… May need to remove the scale by, for
example, sand blasting
Can be galvanised for corrosion protection
Available in a range of strength grades: Low, Medium and High
tensile steel
Relatively poor dimensional accuracy

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58
Q 
Silver Steel is:
a) Most typically used for shafts on hydraulic
rams
b) Is an alloy of silver
c) Able to be flame hardened
d) Easily cut with standard hand tools
A

C, Able to be flame hardened

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59
Q

Which has better dimensional accuracy, hot or cold rolled steel?

A

cold

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60
Q

Car exhaust are often made from:

a) Thin wall seam welded RHS
b) Thin wall seam welded tube
c) Annealed copper tube for easy bending
d) Hard copper tube for neatness

A

B,Thin wall seam welded tube

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61
Q

What are normal drill bits made from:

a) High speed steel
b) Tungsten carbide
c) Annealed mild steel
d) Flame hardened silver steel

A

A,High speed steel

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62
Q

The most used UOC 3D printer is:

a) SLA
b) FDM
c) SLS
d) SLM

A

B, FDM like hot melt gluie

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63
Q

Cold Rolled Steel is also called

A

“Commercial Bright” (Due to the last roll forming operations being cold the scale
detaches)

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64
Q

Which has better dimensional accuracy, hot or cold rolled steel?

A

cold

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65
Q

What material section would you use to make a roof

A 
Sheet (Black or Bright) Available in cut sheet or coil
 Appliances
 Machine guards
 Often coated, ready for use
 Eg. roofing material
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66
Q

What material section would you use for General flame/laser/water cut parts

A

Flat Plate (Black)
General flame/laser/water cut parts
Plate fabricated machinery
Ship building

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67
Q

What material section would you use for General engineering applications

A

Flat Bar (Black or Bright),Hot and Cold rolled

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68
Q

What are the general types of bar

A 
Round Bar (Black and Bright)
  General machine shop parts
  Shafts
  Available in a range of strengths
Hollow Bar (Mostly Black)
  Much heavier wall than pipe
  Machine shop parts
  Reduces machining time and wastage
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69
Q

What does ERW stand for? (Seam welded thin wall tube)

A 
Electric Resistance Welded
 Used in Exhaust pipe
 Light equipment
 Low pressure plumbing
 Moderate twisting and low bending strength
Note ERW  =  Seam welded pipe
 Heavier wall than tube
 Moderate pressure plumbing
 Galvanised water pipe
 Farm gates
 Good twisting and bending strength
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70
Q

What type of pipe would you use for boilers?

A 
Seamless tube
 High pressure equipment
 Steam boilers
 Chemical equipment
 Good twisting and bending strength
 No seam for particle retention
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71
Q

What is a RHS section?

A 
(Rectangular Hollow Section)
 Generally seam welded
 General machine or frame construction
 Easy to work with and weld cleanly
 Light wall (1.5mm) or heavy wall (6mm)
 Moderate twisting and good bending strength
 High buckling strength
 Consider how to weld together
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72
Q

What is a disadvantage of Angle sectoiin?

A

Poor twisting and bending strength.
Easily buckles.

but it is Easy to work with
Either equal or unequal length flange

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73
Q

What Standard Engineering Material Section is mostly used for construction

A 
I Beam, Universal Beam
 Mostly used for construction
 Occasionally used for machines
 Excellent bending strength
 Poor for twisting
 Variation used for columns

Channel is also used as General structural section
Poor for buckling

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74
Q

What steel is trying to be something else?

A

Silver Steel
Not made from silver!
Centreless ground
Bright and almost polished mirror finish
Very high strength steel
Normally used in tool rooms
Can be hardened by various processes
Often flame hardened in the workshop
Diameter is ground to a moderate tolerance
Sometimes used for low cycle custom made punches, knives,
drills etc

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75
Q

What steel is used for Most drills, taps and dies

Custom ground lathe tools

A

High Speed Steel
Very hard
Can retain hardness at high temperature
Cannot be cut or shaped with conventional cutting tools
Normally ground to shape
Often supplied with a ground finish and in various sections

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76
Q

What material is used for hydraulic and pneumatic rams

A 
Hard Chrome Bar
 Steel bar with hard chrome plating
 Use for hydraulic and pneumatic rams
 Also used with linear bearings
 Precision ground and polished surface
 Sometimes used for non-corrosive propertie
77
Q

What type of copper tube is mostly used for domestic plumbing

A

Hard Copper Tube
Bought as straight tube
Difficult to make tight bends
For tight bends use weld fittings

78
Q

What type of copper tube is Often used in refrigeration equipment

A 
Annealed Copper Tube
 Generally small diameter  Very flexible
 Bought coiled
 Good for custom bending
 Difficult to make look tidy
79
Q 
Which of the following is not a common
thread locking system:
a) Castle nut and cotter pin
b) Tab washer
c) Nylock nut
d) Grub screw
A

Grub screw

80
Q 
A critical machine requires high tensile
bolts, how do you know the bolt
quality?:
a) Numbers stamped into the head
b) Letters stamped into the head
c) Letters forged onto the head
d) Numbers forged onto the head
A

Numbers forged onto the head

81
Q

A torque wrench is used to:

a) Ensure the bolt is not over tightened
b) To reach nuts in difficult locations
c) Activate thread locking nuts
d) Measure the angle of rotation of the nut

A

Ensure the bolt is not over tightened

82
Q 
Which of the following is a reason not to
select a bolted joint?:
a) Non permanent fixture
b) Joint may come slack due to vibration
c) Dowels are required for alignment
d) Use of unskilled labour
A

Joint may come slack due to vibration

83
Q

What are 3 permanent joining methods?

A

Rivet
Weld
Glue

84
Q

What are 3 Temporary (or Permanent) joining methods?

A

Screwed
Bolted
Spring
Magnet

85
Q

Do you know your standard bolt terminology

A

thread, shank head, nominal length is the length without the head

86
Q

Whats the difference between a bolt, thread and stud?

A 
Bolt
 Tightened by turning the nut
Screw
 Tightened by turning the head
Stud
 Permanently screwed into a  body and
tightened by turning the nut
87
Q

How does a bolt work to hold the pieces together

A

Bolt Pre-Load / Stretch Load / Stretch

When the bolt is tightened it stretches
like a spring…A very stiff spring
This puts tension in the bolt and
compression in the joint
Pre-tension (Pre-Load)
Needed to avoid material separation
Movement between the plates is dependant
on the bolt tension and the coefficient of
friction
Bolt/stud/screw stretches to cause pre-tension

Pre- Load Must Always Be > External Load

88
Q

What are some common modes of failure for bolts/screws

A

Stripped Thread…Excess Axial Load
Miss-aligned Thread
Use Dowels to Avoid
Miss-alignment

89
Q

How can you ensure the Correct Pre-Load is applied

A

Measuring Nut Angle Rotation
Measuring Bolt Stretch
Norbar Torque wrenches and equipment

90
Q

Sheet metal for domestic appliances is:
a) Left in a hot rolled state
b) Painted before folding
c) Requires sand blasting before painting
d) An alloy of copper and iron
e) Prone to corrosion and must be handled
with care

A

b) Painted before folding

91
Q

Two places left hand threads are used

A

flammable gas bottles

shade cloth thingy

92
Q

Printng - FDM

UNI OWNED

A

Fused Deposition Modeling
Like a hot glue gun
1 or 2 nozzles

93
Q

Why do some machines use Square ACME Threads

A

Strength, for things like lathes and vices

94
Q

Printing - Polyjet

A 
Similar to inkjet printer 
Droplets squirted from printer head 
UV light cures it 
Fine details 
Elastomer 
Multiple materials at once 
Various types of supports  and removal
95
Q

Printing - SLS/SLM

A

Selective laser sintering
Selective laser melting

Metals and plastics
Powder lay down in small thicknesses
Laser/electron beam fuses material

96
Q

3D Printing

A

Powder is laid down
Inkjet printer head squirts ink type binding fluid
Low Strength
Full colour

97
Q

How do snap fits work?

A

Parts Elastically Deform During Assembly
Can Be Permanent or Not
Typical Application is Joining Wire Connectors

98
Q

Scanner - how do Structured light -White or blue light work

UNI OWNED

A

Project a series of linear patterns
Also uses triangulation to calculate distances
Uses the edge of the each line pattern

99
Q

High resolution scanning is used for

A

Small parts

100
Q

What are the Two Categories of Welding Processes

A

Fusion welding - coalescence is
accomplished by melting the two parts to
be joined, in some cases adding filler
metal to the joint
Examples: arc welding, resistance spot
welding, oxyfuel gas welding
Solid state welding - heat and/or pressure
are used to achieve coalescence, but no
melting of base metals occurs and no filler
metal is added
Examples: Forge welding, diffusion
welding.

101
Q

Turntable scanning works by

A

Fixed scanner

Moving part

102
Q

Why is it important to protect the weld pool

A

The molten weld pool is extremely reactive
with oxygen
The pool must be protected from the
atmosphere until the pool has solidified
Common Methods
Flux… forms a slag over the pool, requires an
extra operation to remove the slag
Gas as cover, extra cost of the inert gas but it is
a clean process

103
Q

What is the 3D Scanning process

A 
Scan the part 
Align scans 
Fusion, smoothing, editing - .STL file 
add texture if needed 
Use an external program to generate feature tree
104
Q

How are overhanging features made with 3D printing

A

Removable support material

105
Q

What is the 3D Scanning process

A 
Scan the part 
Align scans 
Fusion, smoothing, editing - .STL file 
add texture if needed 
Use an external program to generate feature tree
106
Q

How are overhanging features made with 3D printing

A

Removable support material

107
Q

What are the advantages and disadvantages of Rivets

A 
Advantages
High Production Rates
Simple
Reliable
Low Cost
Blind Application (Pop)
Permanent
 Disadvantages
Requires impact or other loading to
perform the application
108
Q

What is a Hot (UpSet) Rivets

A 
Hot rivet shrinks when it
cools and adds extra
compression in the joint
Rivet diameter is
increased to fill hole gap

2.5 million hot formed rivets holding the
Eiffel Tower together

109
Q

What is an eyelet used for?

A

Used to provide strength for connection to a weak
material.
Often used to strengthen fabric for rope connections

110
Q

How do snap fits work?

A

Parts Elastically Deform During Assembly
Can Be Permanent or Not
Typical Application is Joining Wire Connectors

111
Q

Advantages of Powder Metallurgy

A

Specific porosity
Mass produce to near net shape
Favorable to casting
Can be automated

112
Q

Disadvantages of Powder Metallurgy

A 
High tooling and equipment costs 
Metallic powders are expensive 
Variation in density can occur 
Limited geometry 
Can not fill die laterally
113
Q

Why do you blend particles for Powder Metallurgy

A

Particles with the same chemistry and different particle size
Reduces porosity

114
Q

Why do you mix particles for Powder Metallurgy

A

particles with different chemistry

Makes alloys

115
Q

What is the Powder Metallurgy process

A

Blend/mix
compaction
Sintering
deburing

116
Q

Powder Metallurgy - Compaction

A

Punch-and-die
Powder fills die
Pressed at high pressures into shape with an axial punch
High pressure = high density = stronger

In compressed state the component is weak called a ‘Green Compact’

117
Q

Powder Metallurgy - Sintering

A 
Performed below melting temperature 
Increases strength and hardness 
Lubricant is burnt 
Particles fuse /Grain growth  
Metal stabilise

Part is approx 80% of the strength of a metal

118
Q

How are powders created for Powder Metallurgy

A

Atomization
Chemical
Electrolytic

119
Q

what are the Five Types of Welds

A 
Surface
 Groove
 Fillet
 Plug
 Slot
120
Q

How do you increase the strength of a powder metallurgy part?

A

Add a second metal which is absorbed in the furnace

Increases strength by increasing density

121
Q

What are theTwo Categories of Welding Processes

A

Fusion welding - coalescence is
accomplished by melting the two parts to
be joined, in some cases adding filler
metal to the joint
Examples: arc welding, resistance spot
welding, oxyfuel gas welding
Solid state welding - heat and/or pressure
are used to achieve coalescence, but no
melting of base metals occurs and no filler
metal is added
Examples: Forge welding, diffusion
welding.

122
Q

Sheet metal forming

A

Bending
Deep/cup drawing
shearing
miscellaneous

123
Q

Why is it important to protect the weld pool

A

The molten weld pool is extremely reactive
with oxygen
The pool must be protected from the
atmosphere until the pool has solidified
Common Methods
Flux… forms a slag over the pool, requires an
extra operation to remove the slag
Gas as cover, extra cost of the inert gas but it is
a clean process

124
Q

Powder Metallurgy - Powder is composed of

A

Combination of metal powders and lubricants

Metals: Carbon, Steel, etc

125
Q

How do you increase the strength of a powder metallurgy part?

A

Add a second metal which is absorbed in the furnace

Increases strength by increasing density

126
Q

Bulk formatting deformation/forming

A

Rolling
Forging
Extrusion
Wire and bar drawing

127
Q

Sheet metal forming

A

Bending
Deep/cup drawing
shearing
miscellaneous

128
Q

Bulk deformation advantages

A

Significant shape change
Material strength can be increased during cold forming
Near net shape
Sometimes parts don’t require subsequent machining

129
Q

Bulk deformation

A

Deforming parts whose initial form is bulk rather than sheet
Starts with cylindrical/rectangular bars and billets
The process causes plastic deformation
Performed hot or cold

130
Q

Define: Rolling

A

plate is squeezed between rollers to reduce thickness

Rollers oppose each other
Compressive forces
Friction pulls the sheet though

131
Q

Define: Forging

A

The work piece is squeezed between opposing dies or hammered into shape

132
Q

Define: Extrusion

A

The work material is squeezed

through a die

133
Q

Define: Wire and bar drawing

A

the diameter of wire or bar stock is reduced by pulling the material through a die opening

134
Q

Bulk starting shape: Bloom

A

Large square/rectangle bar

135
Q

Bulk starting shape: Slab

A

Thick plate

136
Q

Bulk starting shape: Billet

A

Small bar

137
Q

what is PAW welding

A

Plasma Arc Welding

Special form of fusion welding
in which a constricted plasma
arc is directed at the weld
area. >20,000 deg

Advantages:
 Good arc stability and excellent weld quality
 Better penetration control than other AW
processes
 High travel speeds
 Can be used to weld almost any metals
Disadvantages:
 High equipment cost
 Larger torch size than other AW processes
 Tends to restrict access in some joints
Application of PAW
 Automobile assemblies
 Appliance manufacture
 Metal cabinets
138
Q

Hot rolling

A

‘black’ finish - due to oxidation
Large deformation
Less force required
Grains reform

139
Q

What is the definition of Solid State

Welding Processes

A

Operation done with little/no
melting of the material.

SSW Advantages over Fusion
Welding Processes
If no melting, then no heat affected zone, so metal
around joint, in some cases, retains original
properties
Many SSW processes produce welded joints that
bond the entire contact interface between two
parts rather than at distinct spots or seams
Some SSW processes can be used to bond
dissimilar metals, without concerns about relative
melting points, thermal expansions, and other
problems that arise in Fusion Welding

140
Q

Can Friction Welding (FRW) be used to join dissimilar metals

A

fuck yeah

141
Q 
What joining technique would you use for
making 20 boat trailers?
a) Stick
b) MIG (Metal Inert Gas)
c) TIG (Tungsten Inert Gas)
d) Bolts and Rivets
A

b) MIG (Metal Inert Gas)

142
Q 
Riveted joints offer the following
advantages
a) Fast
b) Reliable
c) Non skilled labour
d) Tight joint
e) All of the above
A

e, All of the above

143
Q

Left hand threads are identified by?

a) Stamp on the nut
b) Forging on the bolt head
c) Groove around the nut or bolt head
d) Tapered thread

A

c) Groove around the nut or bolt head

144
Q 
Left hand threads are most commonly
used for?
a) Oxygen bottle pipe connections
b) Tightening ropes
c) Engine cylinder head studs
d) Cap screws
A

b) Tightening ropes (turn buckle)

145
Q

Cold rolling

A

‘bright’ finish
produces better surface finish and more accurate size than cold rolling
Grain elongate - better material properties

146
Q

Hot rolling

A

‘black’ finish - due to oxidation
Large deformation
Less force required
Grains reform

147
Q

Roller configuration: Two

A

High velocity

148
Q

What is the purpose of support rollers

A

Heavy backing gives support

Less unwanted deformation

149
Q

Reflow Soldering is primarily used for?

a) Plumbing… spouting
b) Plumbing… house water pipes
c) Surface mounted electronic boards
d) Through hole electronics boards

A

c) Surface mounted electronic boards

150
Q

Rolling configuration: Tandom

A

Each set performs further deformation

Rotational speed of each roller set much be higher than the previous

151
Q

Thread rolling

A

Rolled against a die
Generally done cold
Better thread strength and surface than machining

152
Q

Brazing filler can be supplied as?

a) Foil
b) Paste
c) Rod
d) All of the above

A

d) All of the above

153
Q 
For using adhesives on a production line
which of the following is an important
consideration:
a) Curing time
b) Clamping method
c) Materials to bond
d) Surface roughness
e) All of the above
A

e) All of the above

154
Q

Tolerance…

A

The difference between the maximum and minimum limits of size is the tolerance

155
Q

Fits…

A

When two parts are assembled the relation resulting from the difference between their sizes before assembly is called a fit. (fitting - the ability to be assembled)

156
Q

35H7 What does 35, H and the 7 refer to?

A

35 - Basic size
H - Fundamental deviation for hole
7 - IT grade for hole

157
Q 
A sheet metal part is to be permanently
attached to a metal RHS frame with a
fastener. There is no rear access.
Which of the following could work?
a) Hex head nut and bolt
b) Pop rivet
c) Upset rivet
d) Pressed clinch
A

b) Pop rivet

158
Q 
Which of the following should you
consider when welding together two
parts?
a) Distortion
b) HAZ
c) Filler rod compatibility
d) Potential damage to local parts
e) All of the above
A

e) All of the above

remember HAZ means heat affected zone

159
Q 
You need to make a special shaped form
tool for turning low strength metal.
What material would you use?
a) Commercial bright
b) Hard chrome rod
c) Silver steel
d) High speed steel
e) All of the above
A

d) High speed steel

160
Q 
A bolted joint is required that must be
easy to undo without tools. What
could you use?
a) Castle nut
b) Flange nut
c) Nylock nut
d) Wing nut
e) Cap nut
A

d) Wing nut

161
Q 
A sheet metal part is to be permanently
attached to a metal RHS frame with a
fastener. There is no rear access.
Which of the following could work?
a) Hex head nut and bolt
b) Pop rivet
c) Upset rivet
d) Pressed clinch
A

b) Pop rivet

162
Q

Rolling configuration: Cluster

A

Allows for small rolls
Less force and power

Multiple support rollers

163
Q

Thread rolling

A

Forging - Generally done cold

Better thread strength and surface than machining

164
Q

Rolling configuration: Tandom

A

Each set performs further deformation

Rotational speed of each roller set much be higher than the previous

165
Q

What is ring rolling used for

A

Ball bearing races
Heavy rotating machinery
Pressure vessels

166
Q

What is the minimum clearance if George’s penis had a diameter of 20: 18 - 22 mm and the poor girls
hole is 23: 22 - 24? What type of fit is this?

A

Allowance: 1 mm

Clearance fit. Praise the lord. It’s a good thing this George has a small penis

167
Q

why are Lubricants needed for Hot Forging/sex

A

Lubricant is required to stop sticking, should be

sliding motion.

168
Q

Applications of forging

A

Crankshafts for engines
Connecting rods for engines
Aircraft structural parts
Spanners

169
Q

What is the difference between forward and backward extrusion

A

Direct (Forward) Extrusion - Starting billet round; final shape determined by the die (like toothpaste)

Indirect (Backward/Reverse) Extrusion, you basically ram it in

170
Q

Forge hammer

A

applies impact load. Hammer is lifted then dropped

171
Q

Upset forging (heading)

A

Open die - between two dies

Used to form heads on screw, bolts, etc

172
Q

Impression-die Forming

A

The die has a cavity. The metal is constrained but a
flash is formed.

Flash cools quicker

173
Q

Flash is removed by

A

Trimming
grinding
sawing

174
Q

What does ANSI (ASME) stand for

A

American National Standards Institute

175
Q

GD&T

A

Geometric dimensioning and tolerancing.

176
Q

Maximum material condition MMC explain for shaft and hole

A

The MMC is the size of the part when it consists of the most material. For a shaft the is the largest diameter. For a hole this is the smallest diameter

177
Q

Clearance fit

A

There is always space: Min clearance > 0

178
Q

Interference fit

A

There is never a space: Min Clearance =

179
Q

Transition fit

A

Could be clearance or interference.
Max clearance > 0
Min clearance

180
Q

Define the type of fit that a mattress wank creates

A

Interference

181
Q

What is the minimum clearance if George’s penis had a diameter of 20: 18 - 22 mm and the poor girls
hole is 23: 22 - 24? What type of fit is this?

A

Allowance: 1 mm

Clearance fit. Praise the lord. It’s a good thing this George has a small penis

182
Q

What is the definition of Extrusion

A

Compression forming process in which the work
metal is forced to flow through a die opening to produce a
desired cross-sectional shape
Like squeezing toothpaste

183
Q

What is the difference between forward and backward extrusion

A

Direct (Forward) Extrusion - Starting billet round; final shape determined by the die (like toothpaste)

Indirect (Backward/Reverse) Extrusion, you basically ram it in

184
Q

Importance of machining

A

Variety of work materials can be machined
Most frequently used to cut metals
Rapid material removal
Variety of part shapes and special geometric
features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good? dimensional accuracy and surface finish

185
Q

Disadvantages of machining

A

Wasteful of material
-Chips generated in machining are wasted material
Time consuming
-A machining operation sometimes takes more time
to shape a given part than alternative shaping
processes, such as casting, powder metallurgy, or
forming

186
Q

Types of machining chips

A
  1. Discontinuous chip
  2. Continuous chip
  3. Continuous chip with Built-up Edge (BUE)
  4. Serrated chip
187
Q

Do Extrusions leave the die straight?

A

no (rarely) to do this you should Stretch or Roll piece

188
Q

What are 3 Defects in Extruded Products

A

Centre burst (chevron cracking)
· internal crack develops from tensile stresses along
centreline
b)Piping (fishtailing)
· sink hole that develops during direct extrusion
c)Surface cracking
· caused by high work part surface temperatures and
high extrusion speeds

189
Q

What is the Wire and Bar Drawing definition

A

Cross-section of a bar, rod, or wire is
reduced by pulling it through a die opening
ó Tension and compression stress applied to
squeeze metal

ENME221 (1 decks)

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