Red Seal Prep Flashcards
General overview period 1-4
When cutting on a lathe what are some of the remedies for a built-up edge
Use coolant
Increase cutting speed
Increase DOC and feed rate
The ideal characteristics for your cutting tool on a lathe would be
Hard
Tough
Shock resistant
Chemically inert
What are the remedies when working on a lathe for Crater wear on your cutting tool
Use a grade with more wear resistance
Lower cutting speed
Reduce feed rate
What are the advantages and disadvantages of positive rake angles on inserts
Advantages
Easier cutting action for soft metals like aluminum
Less horsepower required to run cutter
Disadvantages
Only have edges on one side of insert
What are some of the advantages and disadvantages of a negative rake angle on cutting inserts
Advantages
Machine harder materials and interrupted cuts
Inserts have twice as many edges
Disadvantages
More horsepower required
The coordinate system that is based on two or more axes perpendicularly intersecting each other at the point of origin is the
Cartesian coordinate system
The resolution of a CNC machine is defined as
The smallest slide movement the machine control can identify and act upon
Which of the following does not contain a computer
NC CNC DNC CAM CAPP
NC
A bit is used to
Turn on or off parameters
An example of a word in word address programming is
G
X 0
3.548
Go To
X 0
During rapid Traverse, the operator and programmer have to
Ensure safe movements to avoid machine crashes
Preparatory codes of the same _____ can’t appear on the same block
Group
How many miscellaneous codes will the Haas machine except in one block
1
What is tolerance
Total permissible variation in size of a dimension, intentional difference in size of mating parts
What can you do if you were cutting hard materials and your cutter keeps breaking
Increase the negative rake which helps protect the tool when Machining hard materials and interrupted cuts
The safest way to remove chips from machine is to use
A brush
A hand hacksaw blade for sawing thin wall tubing should have a pitch of
32 teeth per inch
The hacksaw blade will bind and break when
It is dull
The gauge used to check internal tapers is called
Plug gauge
Checking the pitch of a thread can be done most accurately with the
Pitch gauge
A reamer is used to produce ______ and ______ holes
Smooth, accurate
The amount of metal left for removal by a hand reamer is generally
5 thou
A hand reamer has a taper on the end for the purpose of
Starting it
The most convenient steel rule for sitting inside calipers is the
Hook rule
To have a dimension with a bilateral tolerance you must have
A dimension with both plus something and minus something
If you machine shaft to 1.5” plus .000, minus .004 and a sleeve to 1.502 plus/minus .001 the resulting fit would be
Clearance fit
Adjustable parallels can be used to _____ and to ______
Support work, make measurements
Angles and tapers are most accurately measured with a
Sine bar and gauge blocks
Positive rake cutting:
Allows chips to flow freely away from The Cutting Edge
An American Standard tool holder supports the tool at an angle of _____ and this angle on the tool bit is called ______
15-20 degrees
Back rake
When grinding a turning tools the side relief angle must be greater than what
8 degrees
The term tempering means
heating above lower critical temperature and quenching in proper medium
Reheating hardened steel to desired temperature below lower critical temperature
Heating metal to just above its upper critical point, followed by slow Cooling in furnace
Heating the steel to just above its upper critical point and Cooling in still air
Reheating hardened steel to desire temperature below lower critical temperature
The hardening colour for carbon tool steel is
Cherry red
List three quenching media used in heat treatments
Water, oil, air
When using the tempering colours, a brown colour would indicate an approximate temperature of
450 Fahrenheit
490 Fahrenheit
530 Fahrenheit
590 Fahrenheit
490 Fahrenheit
Drilling machines with more than one drilling head and a single table are called
Gang drills
The advantage of a radial drilling machine is that the _____ can be ______ over the ______
Drilling head, positioned, workpiece
Excessive feed rates on a drilling operation would most likely cause what
Breakage of the drill point
As a Twist drill begins to break through the workpiece you should what
Reduce the feed
The feed rate for reaming as compared to drilling is usually what
Two to three times the feed rate for the drilling
The Cutting speed for reaming as compared to drilling a given material is about what
1/2 to 2/3
The machine reamer that cuts only at the chamfered end is called a
Rose chucking
In general what are the two types of power saws
Vertical and horizontal
A minimum of _____ teeth should be kept in contact with the workpiece at all times
2-3
The most common types of set on a metal cutting bandsaw blade are the _____ set and the _____ set
Straight and raker
List two safety precautions for the power hacksaw
Solidly mounted workpiece, and guards
List three materials from which band saw blades are made from
High speed steel, carbon alloy, tungsten carbide
The most common types of set on a metal cutting bandsaw blade are the _____ set and the _____ set
Straight and raker
The pitch of a bandsaw blade having 10 teeth per inch length is equal to
.1
A newly welded bandsaw blade requires
Annealing of the welded area
Kerf of the saw blade refers to the
Width of cut made by a saw blade
Band velocity on a bandsaw is expressed in
Surface feet per minute
In order to stop the blade on a vertical band saw from running off the upper wheel
Adjust the upper saw blade guide
Adjust the lower saw blade guide
Adjust the tilt handwheel
Adjust the blade tension
Adjust the Tilt handwheel
The Quick Change gearbox on the engine lathe is used to
Change speeds and feeds
The included Point angle of a lathe Center is
60 degrees
Setting a lathe tool above the Centerline of the lathe will reduce the effective what
End clearance
A thread cutting tool is set 90 degrees to the workpiece axis with the help of a what
Centre gauge
The safest way to file in a lathe is Left-Handed. T or F?
True
To align lathe centres for accurate cylindrical turning you
Mount a test bar between centres, adjust tailstock with set over screws, and test with a dial indicator
If when turning work held between centres, the job tapers smaller on the headstock end you would
Adjust the tailstock towards you
When Machining between centres and the work is reverse to machine the opposite end, if the two diameters are not concentric it indicates what
The headstock Center does not run true
Which of the following would give the tightest fitting bolt - nut combination
1A AND 1B 3A AND 1B 3A AND 3B 2A AND 3B 2A AND 2B
3A AND 3B
On which of the following do you normally find two thread angles
Metric thread American pipe thread Buttress thread API thread Multiple start thread
Buttress thread
Identify thread designation
3/4 - 10 UN C - 2 A
Major diameter, pitch, thread Forum, series, fit, external
Because the measurement of the pitch diameter is least affected by an error in the thread angle, the best size wire is one that contacts the thread at
Pitch line
When using the compound rest method of cutting multiple threads, The Machinist moves the compound, for each thread, a distance that is
Equal to the pitch of the thread
A disadvantage of feeding a Threading tool with the cross slide is that
The Cutting pressure is on both sides of the tool
The movement of a compound rest set at 30 degrees to the Cross slide axis for a 3/4 - 10 UNC 2A thread is
.071
The distance a nut advances on a screw in one revolution is the
Lead
Which of the following is not a method or tool for measuring thread for size
Thread snap gauge
Multiple threads are used to give
Speed
The minimum depth of an undercut for unified thread should be equal to
The root diameter
List three types of knee and column Milling machines
Plain horizontal, Universal horizontal, vertical
List three types of manufacturing Milling machines
Plane, plane knee and column, Tracer controlled
Name eight operations which can be performed on a milling machine
Facing, straddle, gang, sawing and slitting, indexing, drilling, rack Milling, rotary table
What Milling cutter is required to produce a blind keyway in the centre of a shaft
End Mill
When Milling a spiral reamer which method of indexing is used
Simple indexing
In order to revolve the spindle one complete Revolution on most dividing or indexing heads, the index crank must be revolved
40 times
The lead of a helix is
Distance required to make one complete turn
One complete revolution of the index crank revolves the work through an angle of
9 degrees
The gear is required for differential indexing are mounted between the ______ and the ______
Spindle and the indexing plate
The best cutter for fluting reamers is a
Double angle cutter
The radial face of the tooth of a reamer is located
1/64 of an inch before the centre
Which of the following Cutters is not suitable for helical Milling
single cutter
side and face cutter
double angle cutter
helical cutter
Side and face cutter
When Milling a helical Groove, at the end of each cut, shut off the feed and
Lower the table
The arbour key should
Be sufficiently long to extend into the bushings
The cutter should be mounted
As close to the column as is practical
When using a helical tooth cutter place it on the arbour so that the work pressure tends to force the cutter towards the machine column. T or F
True
The up feed method of Milling gives a better work finish and the Cutters retain their sharpness. T or F
False
A set of gear Cutters consist of ______ cutters
8
The size of a horizontal boring Mill is judged by the
Diameter of the spindle bore
A boring Mill that has a table that travels in a longitudinal and transverse direction is called
Table type
Which of the following operations is rarely performed on a horizontal boring Mills
end milling
gang milling
face milling
single point cutting tool
Gang Milling
Which of the following operations would be most difficult to perform on a horizontal boring Mill
External threading
Internal threading
External taper turning
Internal taper boring
External threading
The size of a vertical boring Mill is determined by the
The size of the table
In general what kind of wheels are used on hard materials
Soft
Aluminum oxide wheels are used for grinding
Steel
What will cause the work to burn and crack even when speed and coolant are correct
Dull stone, too hard
A grinding wheel is sized in order of what four things
Type, OD, width, ID
Which of the following is a factor that makes grinding an important Machining process
grinding wheels remove metal faster than milling cutters
grinding wheels remove metal from hardened work pieces
grinding machines are simple to operate
grinding machines require less power than milling machines
Grinding wheels remove metal from hardened work pieces
Which of the following machines is a Precision grinder
Bench grinder
Swing frame grinder
Flexible shaft grinder
Internal grinder
Internal grinder
When a pedestal grinding wheel vibrates excessively, it is an indication of what
Out of balance
To ring test a grinding wheel is to what
Check for cracks
When ring tested a usable wheel will give a
Clear ring
Blotters placed on each side of the grinding wheel are made of
Paper
To ensure the safe operation of a grinding machine
The wheels should be sharpened and dressed as often as is needed
What is the chief function of a surface grinder
To produce a flat surface
Which cylindrical grinding machine is best suited for mass production
Centerless grinding
The cylindrical grinder is generally used to
Finish round objects
The part of the cylindrical grinder that supports the grinding wheel is called the
Wheel head
Trip dogs on cylindrical grinding machines are used to
Change the direction of travel
When a grinding wheel leaves chatter marks on the work the only possible reason is that the wheel is out of round. True or false
False
Which of the following machines can be used for internal grinding
Plane grinding machine
Universal grinding machine
Roll grinder
Piston grinder
Universal grinding machine
Which of the following terms does not apply to internal grinding
Blind hole grinding
Through feed grinding
Form grinding
Taper grinding
Through feed grinding
When changing work pieces in a 4 jaw Chuck it is good practice to loosen
Three Jaws
Unbalanced Wheels cause
Chatter
How is a grinding wheel expected for cracks before it is installed on a Surface grinder
Ring testing with a mallet
What kind of flanges should be used to hold the wheel
Recessed
You disconnect the worm and worm wheel for which method of indexing
Direct
A direct index plate has 24 slots, what is the angular distance between each slot
15°
When simple indexing, one complete turn of the index crank rotates the spindle or work piece how many degrees
9°
2 simple index a workpiece 1/8 of a turn using simple indexing, you use an indexing plate with
24 holes
12 holes
21 holes
49 holes
24 holes
The most basic dividing mechanism is the
Direct dividing head
What must a milling machine be equipped with____ when your climb Milling
Backlash Eliminator
When straddle Milling make sure the Cutters are
Spaced a specified distance apart
The first step when cutting a t slot on a dovetail is to
Machine a clearance slot
When using a slitting saw
Keep your hand on the feed lever during the cut
Do not use an Arbor key
Use a feed rate that is 1/8 to 1/4 the normal feed rate
All of the above
All of the above
The type of End Mill to use when milling a key seat right up to the shoulder is a
2 flute End Mill
You perform drilling on a milling machine just before
Precision boring
You swivel the table of a milling machine for
Gashing
When hopping on a milling machine the workpiece rotates freely between centres. T or F
True
You would use a slot Milling attachment to Mill an external keyway
False
You find key seats in
A shaft
A hub
A door knob
An Arbor Milling cutter
A shaft
What process is to heat steel to just above its lower critical temperature, hold for long enough for the structure to change to austenite then quench the steel quickly enough that it turns into martensite instead of perlite
Hardening
What must you always do to hardened steel
Temper it to remove stresses and restore toughness
What process is taking steel and reheating it to a temperature somewhere below its lower critical temperature and then allow it to cool slowly
Tempering
What process do you heat the steel to just above its upper critical temperature, allow it to soak so that the temperature is consistent and then allow it to cool very slowly
Full annealing which makes hardened steel soft again
What process is to heat the steel to above its upper critical temperature and then allowed to cool slowly and still air
Normalizing which improves the grain structure of the steel
What are the processes of heat treatment of Steel
Hardening, tempering, full annealing, normalizing, and I guess case hardening if you want to include that s***
What are the six colour changes for heated Steel
Light straw Dark straw Brown Purple Violet Dark blue
The milling machine attachment that changes rotary to reciprocating motion is the
Slotting attachment
The endmill that can always be used for plunge milling into solid material is the
2 fluted end mill
The thread angle of an ACME thread is
29 degrees
