Metallurgy, shafts, fits, lubrication test from teacher Flashcards
what is the best definition of metallurgy
study of science
study of metal characteristics during welding
study of mining
study of structure, properties, extraction and refining of metals
study of structure , properties extraction and refining of metals
alloy steel has other elements in it to improve its mechanical properties
true
False
true
aluminium is used because it is has a light weight and it resists corrosion
true
False
true
which of the following is not a mechanical property of metals
hardness
toughness
tensile strength
softness
softness
what is the difference between hot and cold rolled steel
hot rolled steel has a scale left on its surface after bing rolled and cooled
hot rolled is harder after cooling
colled rolled steel has a scale left on it after being rolled
cold rolled steel is made oversized to allow for machining
hot rolled steel has a scale left on its surface after bing rolled and cooled
stress relieving high carbon steels to 400 - 600 degrees F and letting it cool down is an action of
tempering
annealing
normalizing
stretching
tempering
when quenching steel, you will use ______ to help cool it
air
oil
water or brine
any of the above, depending on how quickly it needs to be cooled
any of the above, depending on how quickly it needs to be cooled
which of the following is a physical property of metals
color
weight
texture
all the above
all the above
the carbon content range of low carbon steel (mild) is
0.02 %- 0.30 %
0.30 % - 0.45 %
0.45 % - 0.75 %
0.75 % - 1.5 %
0.02%-0.30%
the lower critical temperature of carbon steel is ______________ degrees F
1333
1100
1450
2400
1333
an increase in carbon content of steel will
increase the ductility
increase the hardness
improves the machinability
decreases the brittleness
increase the hardness
annealing is
to make a hardened work piece harder
to make a hardened work piece softer by quenching it at 1450 degrees F
to make a hardened work piece soft again so it can be machined
to relieve the hardening of the steel by machining
to make a hardened work piece soft again so it can be machined
tempering steel is to relieve the amount of hardening______________________
by heating it to the upper critical point and quenching
by machining
and internal stresses by heating above the lower critical point and cooling at any desired rate
and internal stresses by heating the steel to below the lower critical temperature and cooling at any desired rate
and internal stresses by heating the steel to below the lower critical temperature and cooling at any desired rate
pearlite is a
form of steel at high temperatures
hardened form of steel
stucture of soft steel consisting of layers of ferrite and cementite
type of iron carbide
stucture of soft steel consisting of layers of ferrite and cementite
martensite is a
form of steel at high temperature
a structure of hardened steel consisting of angular needle-like crystals
a mixture of ferrite and cementite
a type of iron carbide
a structure of hardened steel consisting of angular needle-like crystals
austenite is a
form of steel at high temperatures, (ferrite and cementite dissolve into each other)
the hardened form of steel
layers of ferrite and cementite
type of carbide
form of steel at high temperatures, (ferrite and cementite dissolve into each other)
cementite means
form of steel at high temperatures
the hardened form of steel
a mixture of ferrite and pearlite
a type of iron carbide
type of iron carbide
toughness means the ability of a metal to
resist penetration
be deformed without breaking
withstand a pull without breaking
withstand shock or impact
withstand shock or impact
hardness means the ability of a metal to
resist penetration
be defomed without breaking
withstand a pull without breaking
withstand shock or impact
resist penetration
ductility means the ability of a metal to
resist penetration
be deformed without breaking
withstand a pull without breaking
withstand shock or impact
be deformed with out breaking
tensile strength means the ability of a metal to
resist penetration
be deformed without breaking
withstand a pull without breaking
withstand shock or impact
with stand a pull with out breaking
pipes and tubes can be produced in 2 ways.______________ and __________
rolled and welded, pierced and formed
rolled and welded, drawn thru a die
rolled and welded, cast
pierced and formed, drawn thru a die
rolled and welded, pierced and formed
cast iron is considered to have a carbon content of____________
0.60 % to 0.80 %
0.80 % to 1.0%
1.0 % to 1.5 %
1.7 % to 4.5 %
1.7%-4.5%
what makes stainless steel corrosion resistant
carbon
tungsten
aluminium
chromium
chromium
brass is a mixture of
copper and tin
copper and zinc
bronze and zinc
bronze and tin
bronze and zinc
which of the following is not a tool steel sub group
high speed
water hardening
shock resistant
quench and temper
quench and temper
a light straw color when heating up steel during tempering and before cooling would be good for what type of tools
cutting tools
screw drivers
wood saws
shear blades
cutting tools
when testing a piece of steel with a file, you find that the file can barely cut the metal. what Rockwell hardness is the steel
20
30
40
50
50
in the classification 1141, what does the 41 stand for
carbon content
sulfur added
carbon steel
chromium steel
carbon content
hardness testing can be done in different ways. which one of the following is not a true test
rockwell
Brinell
file
torch
torch
MTR stands for _________________ (when dealing with steel orders)
miller test results
mill test reports
material thermal resistance
metal treatment reports
mill test reports
the main differences between ferrous and non-ferrous metals are
carbon content and machinability
iron content and magnetism
color and texture
hardness and ductility
iron content and magnetism
when using the spark test to find out the type of material, what spark shape would high speed steel have
long, straight and yellowish
short with branches that burst, dark yellow
has many bursts with red color near the grinder
orange color with little branching, ends up in ball shaped sparks
orange color with little branching, ends up in ball shaped sparks
which shaped beam will use tapered washers to help bolt it to the foundation
standard beam (S)
welded wide flange (WWF)
wide flange (W)
none of the above
wide flange (W)
how do you size a hollow structural section
width and height
width and inside diameter
inside diameter and outside diameter
wall thickness and outside diameter or dimensions
wall thickness and outside diameter or dimensions
only steel with a carbon content of ______ and above can be hardened
0.01%
0.05%
0.1%
0.2%
0.2
beryllium bronze is a health hazard when it is machined. the particles produced are toxic and must not be inhaled or permitted to touch the skin
true
false
true
keys are timing devices are designed to fail before any other part in a gear train, shaft or hub assembly
true
false
true
the width of a square or flat key should be about ____ of the shaft diameter
1/8
1/4
1/3
1/2
1/4
a pratt and whiteny key _______________________
does not require a key seat in the shaft
is a boxed or blind key
can be fixed or sliding
has a taper 1 in 96
can be used on a parallel or tapered shaft
is a boxed or blind key
a woodruff key
does not require a key seat in the shaft
is boxed or a blind key
can be fixed or sliding
has a taper of 1 in 96
can be used on a parallel or tapered shaft
can be used on a parallel or tapered shaft
a tapered gib head key
does not require a key seat in the shaft
can be boxed or a blind key
has a taper of 1 in 96
can be used on a parallel or tapered shaft
has a taper of 1 in 96
a saddle key
does not require a keyseat in the shaft
can be boxed or a blind key
can be fixed or sliding
has a taper of 1 in 96
can be used on a parallel or tapered shaft
does not require a keyseat in the shaft
a feather key
does not require a key seat in the shaft
can be boxed or a blind key
can be fixed or sliding
has a taper of 1 in 96
can be used on a parallel or tapered shaft
can be fixed or sliding
if you had a woodrufr key with a number of 406, the width would be_______ and the diameter would be______
1/16, 1
1/8, 3/4
1/4, 1/2
1/8, 1/2
parallel key seats in shafts can be open or tapered
true
False
false
the accurate, proper depth of a key seat in a shaft is measured from
the bottom of a key seat to the top of the key seat end
the bottom of the key seat to the top of the key seat side
the bottom of the shaft to the bottom of the key seat
none of the above
the bottom of the shaft to the bottom of the key seat
you should not use a_______________key with a cast hub
gib head parallel
feather
pratt and whitney
tapered key
tapered key
key stock is manufactured with low to medium carbon steel (AISI) 1020 to a ___________tolerence
minus (under sized)
plus (over sized)
size on size
plus (over sized)
key seats in hubs and attachments will be cut to a depth equal to
half the key
half the key plus the clearance
half the hub width plus the tolerance
half the key minus the clearance
half the key plus the clearance
you can cut key seats with
portable key seat cutter
hand broaching with an arbor press
milling machines with endmills
all the above
all the above
when installing keys, on shafts and in tapered bushings, you can put anti-seize on the keys and tapers of the bushings to help stop seizing and damage to the bushing, key seats and the key
true
false
false
when fitting keys, a class ______ fit has a tight fit while a class_______ fit has a clearance fit
1, 2
3, 2
2, 1
2, 3
2, 1
there should always be a clearance (0.005”) on the ________ of a key
top
end
bottom
side
top
setscrews are used to lock attachments onto shafts. for positive locking power, you should
use 2 setscrews of a similar width to the key. one on the key and one 90 degrees to the first
lubricate the threads on the setscrew for maximum thrust
use a knurled cup point setscrew for positive positioning
all the above
all the above
to help facilitate removal of hubs and attachments, you should
make sure there are not 2 setscrews in the hole
file a flat where the setscrew fastens to the shaft to eliminate hang-ups from burrs
use fox wedges to help in removal of gib head keys
all the above
all the above
to help facilitate removal of tapered keys, the gib head should be about 1/4” away from the hub to allow for wedges
true
false
true
when removing stubborn parallel keys, you can use
slide hammers welded to the end of the key
a dutchman
locking pliers
all the above
all the above
a journal is the part of the spindle, shaft or axle that rotates in or on a plain friction bearing
true
false
true
finished shafting is manufactured to wide tolerances and uses finishes like cold rolled, machining, grinding and polishing
true
false
false
C 1045 is percision shafting (percision ground and polished from medium carbon steel) and has a carbon content of
1.0 %
0.1 %
4.5 %
0.45 %
0.45 %
hollow shafting is found on shaft mounted reducers
true
false
true
shaft stresses include bending, shear and ________________
axial thrust
radial thrust
torsional shear
bearing pressure
torsional shear
whenever there is a shoulder machined into a shaft, there should be a __________at the base of the should to help strengthen the shaft and reduce the stress in this area. it should also allow the bearing to sit up against the _____________
fillet, shoulder
square corner, shoulder
taper, radius
fillet, radius
fillet, shoulder
when checking for ____________, you should put the shaft in the lathe centres and set up_______________ to measure for it while rotating the shaft 360 degrees.
runout, feeler gauges
continuity, dial indicators
runout, dial indicators
critical speed, dial indicators
runout, dial indicators
if a bearing fit on a shaft is to loose, it will creep
true
false
true
the ________ bushing does not have a key in the taper of the bushing
QD
split
QD
tapered sleeves are used for positive bearing location and fit. they have a locking washer to lock the sleeve onto the shaft
true
false
false
shear pins____________the machine drive in an overload situation
drive
disconnect
position
center
disconnect
when locking eccentric locking collars onto the bearing and shaft, you must rotate the eccentrc locking collar in the direction of the shaft rotation
true
false
true
ine shafting has bearings located at a maximum distance of _____ between bearings and the fixed bearing should be located as close as possible to the ___________
8’, end of the shaft
8’, drive unit
6’, drive unit
6’, end of the shaft
8’, drive unit
tapered dowel pins have a taper of ________ per foot
1/16”
1/8”
1/4”
1/2”
1/4”
tolerances for dimensioning are the total permissible variation in it size and also determines the fit between mating parts
true
false
true
ANSI fits are broken down into 3 groups - running and sliding fits, location fits and force fits.
true
false
true
ISO metric fits have ______ case letters that represent the hole or bore size and _________ case letters that represent the shaft size
upper, lower
lower, upper
in is not letters but numbers
it depends on the size of the shaft
upper , lower
when selecting a puller, the ____________ determines the puller size
reach
spread
force required
all the above
all the above
presses must have proper gaurding in place before putting them to use
true
false
true
basic size is the nominal size
after tolerances are added
before adding tolerances
after adding only one positive tolerance
after adding one negative tolerance
before adding tolerances
if a shaft has a plus tolerance of + 0.004” and a minus tolerance of - 0.000”, this would be a
bilateral tolerance
unilateral tolerance
basic size
all of the above
unilateral tolerance
allowance is
the intentional difference between mating parts at MMC
the minimum clearance (positive allowance) of mating parts
maximum interference (negative allowance) of mating parts
all the above
all the above
MMC is
shaft is as big as allowed and hole is a big as allowed
shaft is as big as allowed and hole is as small as allowed
shaft is as small as allowed and hole is as big as allowed
shaft is as small as allowed and hole is as small as allowed
shaft is as big as allowed and hole is as small as allowed
which type of fit can be both sliding and press
interference
clearance
transition
shrink
transition
freeze fitting is what type of fitting
shrink
expansion
sliding
forced
expansion
if you used a hydraulic press to push a hub onto a shaft, this would be a _____fit
shrink
expansion
sliding
force
force
surface roughness is measured in micro inches or micro meters with roughness grade numbers from N 1 to N 12
true
false
true
lubrications main function is to reduce
friction
wear
heat
power consumption
friction
a revision number to a drawing is enclosed in a _______________ and is located near the revised dimension
triangle
circle
all the above
all the above
sliding friction
has no metal to metal contact. has electromagnetic bonds
has adheasive wear and asperities touching and welding
has a small contact area and is slightly deformed
has adheasive wear and asperities touching and welding
rolling friction
has no metal to metal contact. has electromagnetic bonds
has adheasive wear and asperities touching and welding
has a small contact area and is slighly deformed
has a small contact area and is slighly deformed
fluid friction
has no metal to metal contact. has electromagnetic bonds
has adheasive wear and asperities touching and welding
has a small contact area and is slightly deformed
has no metal to metal contact. has electromagnetic bonds
viscosity is
the resistance to flow in a fluid
the most important property of lubricating oil
measured in centistokes and SUS
all the above
all the above
viscosity index identifies the amount of change in the viscosity of a lubricant over a temperature range ( 40 to 100 degrees C). a high VI number means
a major change in viscosity
a small change in viscosity
a small change in viscosity
an oilwedge is formed by hydrodynamic principles as the shaft rotates
true
false
true
boundary film forms
at low speeds
at high speeds
at low viscosity
both the 1st and 3rd answers are correct
both the 1st and 3rd answers are correct
which is the correct sequence for the formation of the oil wedge
1. the oil wedge drags the oil into the loaded area
2. shaft journal starts to climb the boundary lubricated area on rotation
3. jounal starts to skid as it climbs onto the area of partial lubrication
4. boundary film adhears to the journal beside loaded area
1,2,3,4
2,4,3,1
4,2,3,1
3,4,2,1
4,2,3,1
to have full hydrodynamic lubrication (at running speed) you will need to
have only boundary film
have only partial film
have a RPM and viscosity high enough to form full film lubrication
none of the above
have a RPM and viscosity high enough to form full film lubrication
Naphtha based oils have the highest wax content
true
false
false
petroleum base oils
do not wear out
are stable up to 55 degrees C
cheap compared to all other oils
all the above
all th above
the total additive package added to base oils is about____________of the oil
11 %
22 %
33 %
1 %
22
synthetic oils
eliminate wax problems
made up of at least 10 chemical bases
stable up to 250 degrees C
all the above
all the above
which statement is not true about oxidation
rate of oxidation of petroleum oils doubles with every 8 degrees C temperature rise above 55 degrees C
produces sludge
raises the viscosity of the oil
increases in the presence of anti-oxidants
ncreases in the presence of anti-oxidants
rust and corrosion inhibitors work by forming a protective layer on the metal surfaces
true
false
true
on worm and wheel reducers, the
worm passes oil to the wheel from the oil bath
wheel passes the oil to the top bearings by having scrapers take it off the wheel
flingers on the worm pass oil to the worm bearings
all the above
all the above
load capacity control with additives such as ____________ and ___________________help with reducing wear during boundary lubrication
E.P., anti-foam
anti-foam, anti-wear
anti-wear, E.P.
anti-foam, E.P.
anti-wear, E.P.
E.P. additives with sulphur and phosphorous corrode copper and bronze
true
false
true
when oil and water have been separated, they are said to be
dispersed
emulsified
demulsified
washed
demulsified
once thru systems do not recycle the oil. which of the following is not a once thru system
bottle
wick feed
hand oiler
splash
splash
a lubrication system’s job is to wet the surfaces of rolling elements and maintain the oil level
1/3 to 1/2 the way up the lowest rolling element
1/3 to 1/2 the way up the total bearing
just over the bottom rolling element
just touching the bottom rolling element
1/3 to 1/2 the way up the lowest rolling element
which of the following systems uses capillary action to move the oil
bottle
wick feed
hand oiler
splash
wick feed
the wick feed and drop feed have ways to adjust the amount of oil being delivered
true
false
true
block lubrication systems have advantages. which is not one of them
single point adjustable flow volume with one pump
rupture disc feature
allows easy recycling of the oil to the tank
modular design of divider blocks
allows easy recycling of the oil to the tank
oil mist lubrication
is used for high speed bearings
can be once thru
is used for high speed roller chain
all the above
all the above
in recirculating pressure lubrication systems, the reservoir helps
cool the oil
aerate the oil
settle out contaminants
both the 1st and 3rd answers are correct
both the 1st and 3rd answers are correct
an industrial mechanic can check oil by smell, touch, and sight. when using site, you can check the oil for
oxidation
dissolved water or air
metallic particles
all the above
all the above
oil analysis tells us about the
types of contamintion
viscosity
wear rate and condition of the machine
all the above
all the above
wear metal (in oil samples) is measured in parts per million and identifies the wearing components. this procedure is called spectroscopy
true
false
true
when taking samples of the oil, you should always take it at regular intervals and once the machine has cooled down
true
false
true
partical counts in oil samples tells us the number of particles per million for each of the following particle sizes
2,5,15
2,7,18
3,6,15
5,15,24
2,5,15
on-line flushing is done during machine operation
true
false
false
consistency of a grease is the degree to which it resists deforming under force and is
a measure of its color
measured using a cone penetration test and given a NLGI number
measure of its drop point
all the above
all the above
grease is made up of a liquid lubricant and a thickener that can be
soap
clay
polyurea
all the above
all the above
greases are classified by the type of thickener, NLGI number and
its pumpability
its drop point
its application
its color
its application
the base oil held in the thickener is released by the addition of
soap
fatty acides
pressure
the thickener
pressure
inorganic non-soap thickeners are good in high temperatures and wet conditions
true
false
true
a grease with a 6 NLGI grade will be a ______________ grease
soft
medium
hard
high penatration numbered
hard
low temperature operation of greases would require a NLGI of 0 to 1 with a oil viscosity of _________
about 15 centistokes
between 75 and 200 centistokes
110 centistokes with additives to improve oxidation stability
none of the above
about 15 centistrokes
when dealing with heavy loads with greases, you would want to have a grease with ___________
molybdenum
E.P. additives
water
the 1st and 2nd answers are correct
the 1st and 2nd answers are correct
when packing a bearing with grease, you will pack the housing ________ full for high speeds and _______ full for slow speeds
1/2. 1/3
1/3, 1/2
2/3, 1/2
3/4, 2/3
1/3, 1/2
dry, solid lubricants like graphite, are used in pins and bushings where moisture is present
true
false
true
automatic centralized grease systems can lubricate many areas with a metered amount of grease at a given rate or time
true
false
true
teflon and molybdenum disuphate is used in engine oil to help with foaming issues
true
false
false
