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Manufacturing Process > Final Exam > Flashcards

Final Exam Flashcards

1
Q

Which one of the following statements is true about turning?

a. The vibration of cutting is proportional to the machine weight.
b. The frequency of noise is independent from the type of material.
c. The cutting tool may crack if the vibration is violent.
d. None of the above.

A

c. The cutting tool may crack if the vibration is violent.

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2
Q

Which one of the following statements is true about the end milling machining?

a. The end mill tool is tapered to a point at the tip
b. The cutting edge of the end mill tool is only located at the center of the tool.
c. Both end mill tool and drilling tool can be used for cutting grooves.
d. The end mill machine can be used for producing inclined surfaces

A

d. The end mill machine can be used for producing inclined surfaces.

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3
Q

Which one of the following statements is true about the band saw machine?

a. It is single degree of freedom system.
b. The band saw process is a precise process.
c. The machine can be stopped only by the push of a button.
d. The cut face is always perpendicular to the centerline

A

a. It is single degree of freedom system.

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4
Q

Which one of the following processes is best for manufacturing rails for railways?

a. Forging
b. Rolling
c. swaging
d. Milling

A

b. Rolling

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5
Q

Which one of the following statements is true about the bulk deformation process?

a. The process is to create minor deformations.
b. The work piece is usually heated in order to decrease the yield strength.
c. The deformation force is only created by the die and not the tool.
d. Options (a) and (c).

A

b. The work piece is usually heated in order to decrease the yield strength.

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6
Q

Which one of the following statements is true about forging?

a. The metal flow direction remains consistent during forging.
b. Some finishing operations are typically necessary after forging.
c. The friction decreases during the process compared to the start of the process.
d. Options (b) and (c).

A

b. Some finishing operations are typically necessary after forging.

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7
Q

Which one of the following statements is true about forgeability?

a. Super alloys are more forgeable that aluminum.
b. The material ductility has an inverse relation with forgeability.
c. Lubrication can affect forgeability.
d. None of above.

A

d. None of above

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8
Q

Which one of the following statements is true about lubrication in forging?

a. It decreases the temperature gradient.
b. It increases the chance of sticking between the die and the work piece.
c. It hinders the metal flow within the die.
d. It pressurizes the die.

A

a. It decreases the temperature gradient.

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9
Q

Which one of the following statements is true about forging die design?
a. The smaller the radii of the internal features, the easier it is for the material to
fill those features in.
b. The fewer the forging steps the larger the power it requires.
c. Extra flash means the more forging load is required.
d. Options (b) and (c).

A

b. The fewer the forging steps the larger the power it requires.

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10
Q

Which one of the following statements is not true about the forging process?

a. The die material should not be resistant to mechanical and thermal socks.
b. Hydraulic presses cause more dynamic loads than hammers.
c. The die size influences the die material.
d. Number of pieces required influences the choice of die material.

A

b. Hydraulic presses cause more dynamic loads than hammers.

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11
Q

What is a defect that is seen in drawing?

a. Center cracking
b. Seams
c. Options (a) and (b)
d. None of the above

A

c. Options (a) and (b)

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12
Q

What is the name of the only cold forming tool used in the type of machining
process called turning and what is its function?
a. Parting tool- to create a partition between parts of a shaft
b. Filleting tool- to create an almost circular fillet at the shaft steps
c. Knurling tool- used to press a pattern into a round section often used to
increase friction as a grip for handles
d. Threading tool- to create a thread at the outer surface of the work piece

A

c. Knurling tool- used to press a pattern into a round section often used to
increase friction as a grip for handles

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13
Q

Which one of the following is not true about the live center that can be used in the
type of machining process called turning?
a. It is for supporting the work piece end
b. It can be used to create co-axial centric drill holes
c. It can be used to stabilize a pipe
d. While drilling, the drill tool remains stationary and the work piece moves
instead.

A

c. It can be used to stabilize a pipe

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14
Q

File format for 3D model data used by machines to build physical parts. Standard
interface for additive manufacturing systems.
a. STEP
b. STL
c. IGES
d. CAM

A

b. STL

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15
Q 
Creating objects with specific geometries through the removal of material (cutting,
drilling, milling, grinding, carving)
a. direct metal laser sintering (DMLS)
b. subtractive manufacturing
c. selective laser sintering (S
A

b. subtractive manufacturing

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16
Q

What material is not yet available in 3D printing?

a. The plastic ABS
b. Ceramic
c. Titanium
d. Diamond

A

d. Diamond

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17
Q

Which of these is true about additive manufacturing?

a. It creates parts by taking material away
b. It creates parts by adding up layers of material
c. It creates parts by subtracting layers of material
d. It creates parts by rearranging the shape of objects to new shapes.

A

b. It creates parts by adding up layers of material

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18
Q

3D printed food is a regular source of sustenance for some populations in the
world.
a. True
b. False

A

b. False

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19
Q

Match the definition with the AM technology
21) Fused Deposition Modeling
22) Stereolithography
23) Polyjet
24) Binderjetting
25) Selective laser sintering
a. A printer head deposits an inorganic binder onto a layer of powdered
material.
b. Similar to inkjet printing, where multiple print heads deposit the
photopolymer on ta build tray.
c. A material extrusion process used to make thermoplastic parts through
heated extrusion and deposition of materials layer by layer.
d. A laser beam guided by a computer melts a particular cross section of
polymeric or metallic powders layer by layer until a 3D part has been
produced.
e. Uses photopolymerization

A

21) Fused Deposition Modeling (c)
22) Stereolithography (e)
23) Polyjet (b)
24) Binderjetting (a)
25) Selective laser sintering (d)

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20
Q 
Which one of these is not one of the 4 primary considerations for choosing the
appropriate AM technology for a project?
a. Standards and requirements
b. Aesthetics
c. Support material
d. Application
A

Support material

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21
Q

What is the order of the 3D printing process pipeline:

a. Construct CAD model -> print model -> pre-processing -> post-processing
b. Pre-processing -> Construct CAD model -> print model -> post-processing
c. Construct CAD model -> pre-processing -> print model -> post-processing
d. Construct CAD model -> pre-processing -> post-processing -> print model

A

c. Construct CAD model -> pre-processing -> print model -> post-processing

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22
Q

In Additive manufacturing which is true about the raft: it is used to…

a. Re-orient the part in order to print without support
b. Assess biocompatibility
c. Ensures the bed of the machine is level
d. To get the part off of the build plate easier.

A

d. To get the part off of the build plate easier

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23
Q

When 3D printing parts that need to be assembled or connected and threads and
holes are part of the model, the supports should always be arranged to print on
the threads since the supports get removed afterwards.
a. True
b. False

A

b. False

24
Q

Cybersecurity is an emerging field of research in additive manufacturing.

a. True
b. False

A

a. True

25
Q

Which of these categories is not a category that machining can be divided into?

a. Cutting
b. Abrasive processes
c. Advanced/non-traditional
d. Bulk deformation

A

d. Bulk deformation

26
Q

Which of the following is not an advantage of machining?

a. Removing volume generally takes less time than other processes
b. Closer dimensional accuracy and surface finish than other processes
c. More economical if the number of parts are low
d. Can produce sharp corners

A

a. Removing volume generally takes less time than other processes

27
Q

Which of these is not an independent variable of machining?

a. Type of chip produced
b. Workpiece material properties
c. Characteristics of machine tool
d. Type of cutting tool

A

a. Type of chip produced

28
Q

Matching:

34) Direct (Forward) extrusion
35) Impact Extrusion
36) Indirect (Backward) extrusion
37) Hydrostatic Extrusion

a. Avoids friction of billet against container walls, therefore ram force is
lower, but the ram is also less rigid.
b. This method increases material ductility suppressing cracks and pores.
c. Involves forcing metal billet through die operation using a ram which must
overcome the friction of the billet against the container walls, as well as
mechanical deformation forces.
d. A rapid process for producing thin-walled hollow shapes, but limited to
small parts.

A

34) Direct (Forward) extrusion Answer: (C)
35) Impact Extrusion Answer: (D)
36) Indirect (Backward) extrusion Answer:(A)
37) Hydrostatic Extrusion Answer: (B)

29
Q

What are two trade-offs of metal forming

a. High forces required and machinery and tooling required are expensive
b. High forces required and wasted material
c. Expensive machinery and tooling and wasted material
d. None of these

A

a. High forces required and machinery and tooling required are expensive

30
Q

What are three independent variables in metal forming
a. Starting material, tool or die geometry and starting temperatures
b. Force or power requirements, starting temperature and lubrication
c. Material properties of the product, exit temperature and starting
temperature
d. Exit temperature, surface finish and force or power requirements

A

a. Starting material, tool or die geometry and starting temperatures

31
Q

What are three dependent variables of metal forming
a. Starting material, tool or die geometry and starting temperatures
b. Force or power requirements, starting temperature and lubrication
c. Material properties of the product, exit temperature and starting
temperature
d. Exit temperature, surface finish and force or power requirements

A

d. Exit temperature, surface finish and force or power requirements

32
Q

What is swaging?
a. Process of forcing a billet through the opening of a die, and it is capable of
producing finite lengths of solid or hollow cross sections
b. Continuously reducing the thickness or changing the cross section of long
stock by compressive forces applied through a set of rolls
c. A solid rod or tube is reduced in diameter by the reciprocating radial
movement of two or four dies
d. None of the above

A

c. A solid rod or tube is reduced in diameter by the reciprocating radial
movement of two or four dies

33
Q

Which of the following describes open-die forging
a. The workpieces acquires the shape of the die cavities while it is being
upset between the closing dies
b. Take a cylindrical workpiece and place it between two flat dies and
press to reduce its height
c. The workpiece is completely surrounded by the die and no flash is formed
d. None of the above

A

b. Take a cylindrical workpiece and place it between two flat dies and
press to reduce its height

34
Q

Which describes ideal homogenous deformation during upsetting?

a. Reduction in height < increase in diameter
b. Reduction in height > increase in diameter
c. No reduction in height
d. None of the above

A

d. None of the above

35
Q

What are possible reasons for barreling?

a. Friction
b. Upsetting the workpiece too quickly
c. cooling of hot workpieces between cool dies
d. a & c

A

d. a & c

36
Q

Why is the flash gap important during impression-die forging?
a. Because the release of pressure encourage the filling of the internal
cavities
b. Because the high pressure developed encourages the filling of the
internal cavities
c. The flash cools slower, deforming quicker, and further assisting in filling
the internal cavities
d. None of the above

A

b. Because the high pressure developed encourages the filling of the
internal cavities

37
Q

What types of materials are good candidates for precision forging
a. Materials requiring high forging loads and low temperatures
b. Materials requiring high forging loads and temperatures
c. Materials requiring low forging loads and temperatures
d. None of the above, material preference for precision forging is not
dictated by temperatures or loads required.

A

c. Materials requiring low forging loads and temperatures

38
Q

In closed-die forging, what is one reason for proper control of master volume?

a. To ensure flash formation
b. Undersized blanks will completely fill the die cavity
c. Oversized blanks cause premature die failure or jamming
d. All of the above

A

c. Oversized blanks cause premature die failure or jamming

39
Q

Compared to conventional forging, incremental forging

a. Requires much lower forces
b. Quieter operation
c. Family of similar parts can be forged using the same dies
d. All of the above

A

d. All of the above

40
Q

What are possible causes of cracking (internal and surface) in forging

a. Poorly designed die
b. Excess material in workpiece
c. Disproportionate temperature distribution or high thermal gradient
d. All of the above

A

d. All of the above

41
Q

Which of these are examples of defects?

a. Laps
b. Cold shuts
c. Cogging
d. a and b

A

d. a and b

42
Q

After using a two-high roller configuration to reduce the thickness of a slab of
metal, we notice that the middle of the slab has greater thickness than the edges.
To increase uniformity of the slab thickness, what is a possible course of action?
a. Add reversing functionality to the roller
b. Increase the draft
c. Convert to a four-high configuration
d. Reduce the roller size

A

c. Convert to a four-high configuration

43
Q

Which of the following definitions describes Impression-die forging process?
a. The workpiece is completely surrounded by the die and no flash is formed.
b. Take a cylindrical workpiece and place it between two flat dies and press to reduce its
height.
c. The workpieces acquires the shape of the die cavities while it is being upset
between the closing dies.
d. Blank is formed into final shape in several small steps.

A

c. The workpieces acquires the shape of the die cavities while it is being upset
between the closing dies.

44
Q

Which one of the following is not true about rolling process?

a. It must only be performed hot
b. It is often the first in creating row metal forms
c. It creates useful geometric forms
d. It create parts with desired material properties

A

a. It must only be performed hot

45
Q

Which of the following is specific to Metal drawing but not to Extrusion process?

a. Amount of area reduction
b. Die angle
c. Friction and its effects on metal flow
d. Formation of seams

A

d. Formation of seams

46
Q

In Extrusion process, oxidation impurities collected from the dead zone can be reduced by
the following ways, except:
a. Reducing friction and minimize temperature gradient
b. Using a dummy block
c. Changing die angle
d. Machining billet prior to extrusion

A

c. Changing die angle

47
Q

Which one is not a cause of internal cracking in Extrusion process?

a. Longitudinal stretches or folds in the material
b. Extrusion ratio
c. Friction
d. Die angle

A

a. Longitudinal stretches or folds in the material

48
Q

Which one is not an advantage of AM process?

a. Complex and arbitrary geometry possible
b. Cost profitable for small series
c. Raw material and process cost lower with respect mass production target
d. Very thin wall and lattice structure possible

A

c. Raw material and process cost lower with respect mass production target

49
Q

To minimize turbulence fluid flow

a) Avoid sudden changes in flow direction
b) Pour the molten metal really fast
c) Avoid the use of gates and runners
d) Increase the Reynold’s number

A

a) Avoid sudden changes in flow direction

50
Q

Risers must be designed in casting to solidify

a) After the casting solidifies
b) Before the casting solidifies
c) Same time as the casting solidifies
d) None of the above

A

a) After the casting solidifies

51
Q

Once the mold cavity is filled, the solidification time is a function of:

a) Ratio of volume to surface area
b) Ratio of pouring rate to surface roughness
c) Surface roughness
d) Pouring rate and fluidity

A

a) Ratio of volume to surface area

52
Q

Which of the following is a Permanent mold casting

a) Sand Casting
b) Die Casting
c) Investment Casting
d) Ceramic-mold Casting

A

b) Die Casting

53
Q

Which one of the following statements is not true?
a) Bolts are discrete products while pipes are continuous products.
b) Nations with large Gross Domestic Product (GDP) concentrate on manufacturing of laborintensive
products.
c) Honing is a Finishing Process
d) The basic goals of concurrent engineering are to minimize time, cost and product design
changes.

A

b) Nations with large Gross Domestic Product (GDP) concentrate on manufacturing of laborintensive
products.

54
Q

What is the correct order of Technology Readiness Level (TRL) of the followings?

  1. Basic principles observed and reported
  2. System prototype demonstration in an operational environment
  3. Analytical critical function proof of concept
  4. Component validation in a laboratory environment
    a) 1-2-3-4
    b) 3-1-4-2
    c) 2-4-3-1
    d) 1-3-4-2
A

d) 1-3-4-2

55
Q

Which one of the following statements is true?

a) LIGA is an appropriate manufacturing method for very large parts.
b) Casting is an appropriate manufacturing method for very small parts with tiny features.
c) Threads can be manufactured by injection molding.
d) Small holes cannot be manufactured by chemical processes at all

A

c) Threads can be manufactured by injection molding.

56
Q

Which one of the following statements is true?
a) Assembly is not an important phase of the overall manufacturing operations
b) Design and manufacturing should never be viewed as separate disciplines
c) Manufacturing processes are always started after the design process is
completed.
d) None of the above.

A

b) Design and manufacturing should never be viewed as separate disciplines

57
Q

Which one of the following statements is true?

a) The riser needs to be designed straight.
b) The faster the casting occurs the higher the quality of final product would be.
c) Sharp internal features can be accurately casted using conventional casting.
d) The final product needs finishing after casting.

A

d) The final product needs finishing after casting.

Manufacturing Process (8 decks)

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