ISE exam 1: 1-4.3

Question 1

Product engineering process

Answer 1

1. Product idea
2. design and prototyping
3. Specifications and process engineering
4. Manufacturing and automation
5. production and monitoring

Question 2

Tolerance

Answer 2

Allowable range of dimensional variation on all features

Question 3

Unilateral

Answer 3

always unbalanced
0.95 +0.10 - 0 1.05 + 0 - 0.10

Question 4

Bilateral unbalanced

Answer 4

0.98 + 0.07 - 0.03

Question 5

Bilateral balanced

Answer 5

1.00 +/- 0.05

Question 6

Always specify the _____ tolerance that satisfies the functional requirement

Answer 6

loosest

Question 7

Over-specification

Answer 7

Closed loops in tolerance graph

Question 8

under-specification

Answer 8

loosely hanging loops in tolerance graph

Question 9

Least material conditions for hole

Answer 9

Larger hole

Question 10

Least material conditions for shaft

Answer 10

smaller shaft

Question 11

Most material conditions for hole

Answer 11

smaller hole

Question 12

most material conditions for shaft

Answer 12

larger shaft

Question 13

When LMC assign the true position tolerance for a hole to the ____

Answer 13

largest diameter

Question 14

When MMC assign the trust position tolerance for a hole to the _____

Answer 14

smallest diameter

Question 15

When LMC assign the true position tolerance for a shaft to the ____-

Answer 15

smallest diameter

Question 16

When MMC assign the true position tolerance for a shaft to the _____

Answer 16

largest diameter

Question 17

Virtual hole size =

Answer 17

Produced hole - TPT MMC

Question 18

Virtual shaft size =

Answer 18

Produced hole + TPT MMC

Question 19

3 types of fits

Answer 19

Clearance, interference, Transition

Question 20

Clearance fit

Answer 20

room to move, largest allowable shaft is always smaller than the smallest allowable hole

Question 21

Interference fit

Answer 21

Needs “brute force” to move, think of a train wheel on tracks
Smallest allowable shaft is always larger than the largest allowable hole

Question 22

Transition fit

Answer 22

Large enough to fit but small enough to hold

Question 23

ANSI fits are always

Answer 23

thousandths of an inch

Question 24

clearance equation

Answer 24

Hole max - shaft min

Question 25

interference equation

Answer 25

Hole min - shaft max

Question 26

as tolerance value goes ____, cost goes ____, but is ____ functional

Answer 26

down, down, less

Question 27

as tolerance value goes ____, cost goes ____, but is ____ functional

Answer 27

up, up, more

Question 28

4 types of materials

Answer 28

Metals, ceramics, polymers, composites

Question 29

2 classifications of metals

Answer 29

Ferrous (based on iron) and non-ferrous

Question 30

Steel with carbon content > ____% are classified as cast iron

Answer 30

2.1

Question 31

Stainless steel

Answer 31

Highly alloyed sheets made of chromium. Provide high corrosion resistance

Question 32

3 classifications of polymers

Answer 32

Thermoplastics, elastomers, thermosets

Question 33

Thermoplastics

Answer 33

melt when heated and solidify when cooled

Question 34

Thermosets

Answer 34

Cannot be remelted. More rigid and brittle than thermoplastics

Question 35

Elastomers (rubber)

Answer 35

property to be stretch.

Question 36

Ceramics

Answer 36

Generally very hard and rigid, but brittle and limited tensile strength

Question 37

Composites

Answer 37

Two or more material phases are combined to achieve desired properties

Question 38

The primary phase of composites is the

Answer 38

matrix

Question 39

the embedded phase is the

Answer 39

reinforcing agent

Question 40

3 types of chip formation

Answer 40

continuous, discontinuous, continuous with build up edge

Question 41

continuous chip formaiton

Answer 41

ductile work material, high cutting speeds, low tool chip friction, small feeds and depths

Question 42

discontinuous chip formation

Answer 42

brittle work materials, low cutting speeds, large feed and depth of cut, high tool chip friction

Question 43

continuous with built up edge formation

Answer 43

ductile work materials, low to medium cutting speeds, friction causes portions of chips to adhere to rake face

Question 44

shear force

Answer 44

due to the workpiece90

Question 45

friction force

Answer 45

due to the tool

Question 46

Approximately ____% of the energy in machining is converted into heat

Answer 46

98

Question 47

High cutting temperatures

Answer 47

reduce tool life produce hoot chips cause inaccuracies in part dimensions/tolerances