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Intro to Machining 1210
Exam 1
151
Engineering
Undergraduate 2
02/21/2012
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Term
Compressed air
 Definition
Can injure ears, injure skin, cause metal chips to fly
Term
To protect hands
 Definition
Keep them out of danger by thinking about safety, clear chips with a brush instead of hands
Term
First step in lifting
 Definition
Bend knees and squat down
Term
When clearing a machine tool after use:
 Definition
use a brush to remove the chips from the machine
Term
Oil soaked rags
 Definition
Should be stored in approved safety cans, can be a fire hazard
Term
You are going to do maintenance on a permanently wired machine tool. You should first:
 Definition
Switch off the circuit breaker to the machine and tag with an appropriate warning
Term
Grinding dust can:
 Definition
Be a hazard to health, be controlled by a vacuum dust collector, cause damage to other machines
Term
Proper dress includes:
 Definition
Solid shoes, shop apron or shop sleeve shop coat, short or secured hair, and a short sleeve shirt
Term
Safety is:
 Definition
An attitude that should be considered in everything you do
Term
The difference between a screw and a bolt is:
 Definition
Application
Term
Set screws are used:
 Definition
To secure pulleys to shafts
Term
A regular nut is:
 Definition
Thicker than a jam nut
Term
A bearing is often held on a shaft with:
 Definition
Retaining Ring
Term
An external tooth lock washer:
 Definition
Provides more friction than an internal tooth lock washer
Term
Thread forming screws are used because:
 Definition
They are convenient in sheet metal assemblies
Term
Cap screws
 Definition
Precision screws
Term
An arbor press designed with a rack and pinion like the one in the WSU lab is what type?
 Definition
Mechanical
Term
The amount of pressure you should apply to a bushing in an arbor press would be:
 Definition
Just the amount needed to push it through the bore and when slight additional resistance is felt, stop pressing
Term
What 2 important things should be done before pressing in a bushing?
 Definition
Chamber and lubricate the bore
Term
A mandrel will slip into a bore on one of its ends. Why then does it press tightly in the bore?
 Definition
it is made very slightly tapered so that is is somewhat larger at one end
Term
To avoid failures from seizing when pressing a shaft or mandrel, you should:
 Definition
Apply high pressure lubricant to the bore and shaft
Term
2 basic principles always taken into consideration by persons familiar with the proper use of shop presses are:
 Definition
Personal safety and care of the workpiece to keep it from being damaged
Term
C-clamps are mostly used by machinists for:
 Definition
Clamping workpieces on the bench for filing and sawing
Term
Type of tool is least likely to slip when holding small parts.
 Definition
Lever jawed wrench aka vise grip
Term
An advantage of the adjustable wrench is that one tool can be used for many sizes. What are its disadvantages?
 Definition
If is adjusted too loosely it will slip and round of the nut or bolt head. It is bulkier than end wrenches and will not fit in some places.
Term
Standard screwdrivers will slip and damage the slot if:
 Definition
The blade is too narrow or too wide. The hardness or temper has been drawn out by overheating. The point is misshapen.
Term
When clamping parts with finished surfaces in a bench vise:
 Definition
Soft jaws should be used
Term
pipe wrenches can used on:
 Definition
pipe and pipe fittings, NOT nuts, bolt heads, ground and polished shafts, cold finished round stock
Term
When disassembling a machine a few light blows are needed on the end of the shaft to remove it. Which is the proper tool to use?
 Definition
Plastic or rawhide mallet
Term
Large water pump pliers can be used:
 Definition
For unfinished packing nuts, pipe and pipe fittings
Term
Parallel clamps are mostly used for:
 Definition
Holding work for delicate measuring and layout setups
Term
The pitch of a hacksaw is the same as:
 Definition
number of teeth per inch
Term
The speed for sawing is generally how many strokes per minute?
 Definition
50 strokes per minute
Term
2 reasons a hacksaw blade will break
 Definition
If it is too loose in the frame. If the workpiece slips in the vice
Term
A new hacksaw blade should be use to finish a cut started with an old hacksaw blade because?
 Definition
The set would wear rapidly
Term
A general rule when selecting a hacksaw blade is use a:
 Definition
Blade with at least 3 teeth in contact with the cutting area
Term
Will cause a hacksaw blade to dull quickly
 Definition
Too fast of sawing speed
Term
Set on a hacksaw blade can be:
 Definition
Wavy
Term
To start a hacksaw cut easily:
 Definition
Mark the starting point with a file
Term
A mill file is:
 Definition
single cut
Term
Files are cleaned with a;
 Definition
File card
Term
File coarseness is designated by numbers on which files?
 Definition
Needle(Swiss pattern)
Term
A file cuts:
 Definition
only on the forward stroke
Term
File handles are used to:
 Definition
protect the file user
Term
Files do not make good pry bars because they are:
 Definition
Too brittle
Term
The life of a file is shortened by:
 Definition
Too much pressure on the file while filing, filing too fast, letting one file lay on top of another
Term
Soft materials should be filed with which kind of file?
 Definition
Coarse
Term
The edge on a file without teeth is called a:
 Definition
Safe edge
Term
A hole with a slot in it should be reamed with a
 Definition
spiral flute reamer
Term
Coolant is used when reaming:
 Definition
To obtain a good hole surface finish
Term
Stock allowances in inches for hand reaming should be between:
 Definition
.001 to .005 inches
Term
Which reamer should you select to reduce chatter while reaming a hole?
 Definition
Spiral Flute
Term
The full diameter(actual size) of a hand reamer is determined by:
 Definition
Measuring over the margins with a micrometer where the starting taper ends and the margin of the land appears
Term
When a reamser is rotated in reverse it will:
 Definition
Becomes dull very quickly
Term
To ream a hole .002 inch larger than a nominal size:
 Definition
Ream with an expansion reamer
Term
Hand reamers can be readily identified by the:
 Definition
square on the shank
Term
Fluteless spiral pointed taps are used to tap:
 Definition
Holes in sheet metal
Term
Thread forming taps:
 Definition
Produce no chips
Term
The size of a tap is marked on the:
 Definition
shank
Term
Taps are surface treated to:
 Definition
Improve their wear resistance
Term
Taps can be surface treated by;
 Definition
Nitriding
Term
The rake angel of the cutting edge of a tap varies:
 Definition
for different materials (taps)
Term
The difference between the taps in a standard(not serial) set is found on the:
 Definition
Number of chamfered threads(tapered, plug, bottoming)
Term
Serial taps of the same nominal size:
 Definition
have different pitch diameters
Term
Spiral fluted tapes are used:
 Definition
to tap deep blind holes
Term
Spiral pointed taps are used:
 Definition
to tap through holes
Term
The alignment of a tap is checked with a:
 Definition
Square
Term
To thread to the bottom of a blind hole, which tap should you use?
 Definition
Bottoming
Term
Taps may break while tapping:
 Definition
If chips clog the flute
Term
Rough threads in tapped holes can be caused by:
 Definition
Insufficient lubrication, dull taps, chips clogging the flutes
Term
The strength of a tapped hole is determind by:
 Definition
The percentage of thread cut, the material being tapped, the depth of thread engagement
Term
Dull taps:
 Definition
Produce oversize threads
Term
The length of a tapped hole should be how many times the diamater of a screw?
 Definition
1.5 times
Term
The diameter of the tap drill is important because it:
 Definition
Regulates the percentage of thread depth
Term
A tap is driven with
 Definition
A tap wrench
Term
A die is turned with a:
 Definition
Die stock
Term
The chamfer on the cutting end of a die:
 Definition
Distributes the cutting action over a number of threads
Term
A rod should be chamfered before threading to:
 Definition
Make the die start easier
Term
While cutting threads with a hand die, the die is frequently reversed or backed off to:
 Definition
break the chips into small pieces to fall out of the die
Term
Cutting fluids are use when threading to obtain:
 Definition
a good surface finish, a long tool life, close tolerance
Term
A round split adjustable die is expanded and contracted by a:
 Definition
Screw
Term
Some heavy-duty off-hand grinders are used exclusively for:
 Definition
rough grinding
Term
When is it permissible to use tool grinders for rough grinding?
 Definition
Never
Term
tools can be damaged on a pedestal grinder if they are:
 Definition
overheated
Term
Grinding wheels on a pedestal grinder are usually sharpened and dressed with a:
 Definition
Desmond dresser
Term
Pedestal grinders in a machine shop are mostly used for:
 Definition
Tool grinding
Term
A certain machined part has a length of 1257 mm. Expressed in terms of meters, the part would be how long?
 Definition
1.257m
Term
1 inch
 Definition
2.54 centimeters
Term
The distance between the graduations on the sleeve of a micrometer
 Definition
.025 inch
Term
How many threads per inch are on a micrometer spindle?
 Definition
40
Term
In order to be certain of the dimension when measuring with a micrometer?
 Definition
Take at least 2 readings
Term
When measuring a workpiece still hot from machining:
 Definition
Cool off the workpiece
Term
A 2-inch micrometer measures:
 Definition
1 to 2 inches
Term
The part of the micrometer which carries the .001 inch graduations is called:
 Definition
Thimble
Term
A standard micrometer has a discrimination of what part of an inch?
 Definition
.001 inch
Term
To measure a 5/16 inch inside rounded corner, you would use a:
 Definition
Radius gage
Term
An electronic digital height gage with a finger indicator attachment:
 Definition
Can be used for both direct and comparison readings.
Term
You have just drilled and reamed a 1/4 in diameter hole. In order to check the size you could use a:
 Definition
small hole gage and micrometer
Term
When transferring height measurements using a precision height gage micrometer, what should always be used?
 Definition
Optical Comparator
Term
You wish to check the outline of a form lathe cutter to determine whether it has been properly ground. This could be done on:
 Definition
An optical comparator or profile projector
Term
A common comparison measuring system for holes ranging from approximately 1/2 to 6 inches would be a:
 Definition
telescoping gage and micrometer
Term
An AA set of gage blocks has a size tolerance of +- .000002 inch. This set is:
 Definition
A laboratory grade set
Term
Wear block are used:
 Definition
To protect the gage blocks on the end of the stack from damage by direct contact.
Term
A heat sink, in regard to gage glocks is:
 Definition
Used to restore gage block temperature to the surrounding temparature
Term
A good wringing interval is what part of an inch per interval?
 Definition
.000002
Term
Corrosion mainly is a problem with gage blocks and is caused from:
 Definition
Leaving blocks wrung for extended periods of time, handling gage blocks, using incorrect preservatives
Term
As gage blocks are disassembled and replaced they are:
 Definition
Thoroughly cleaned, handled only with cloth or tissue, coated with preservative
Term
The spindle speed range is changed from high to low with;
 Definition
The spindle stopped
Term
The quill lock is used to:
 Definition
provide rigidity when milling
Term
The ram:
 Definition
Can be moved, holds the toolhead, gives added machine capacity
Term
The clamping devices on the machine slides:
 Definition
Should be tightened expect for the moving slide
Term
The saddle supports:
 Definition
the table
Term
On a variable speed spindle drive:
 Definition
speed changes are done with the spindle running
Term
Loose machine slides:
 Definition
Are tightened with gib adjustment screws
Term
The spindle brake is used:
 Definition
when changing tools
Term
a major component of the vertical milling machine is:
 Definition
the toolhead
Term
End mills capable of making their own starting holes are called:
 Definition
center cutting end mills
Term
Carbide tipped indexable end mils should be used to machine:
 Definition
highly abrasive materials, steel, cast iron
Term
To remove a considerable amount of material, you should use which kind of an end mill?
 Definition
Roughing
Term
Fast helix end mills are used to machine:
 Definition
Aluminum
Term
Milling cutters with carbide inserts are used to:
 Definition
Avoid resharpening, remove material efficiently, machine most materials
Term
The best method of holding and driving and end mill is:
 Definition
a solid collet or end mill driver
Term
Frequently changed cutting tools should be held:
 Definition
In quick-change tool holders
Term
Dovetails are milled with:
 Definition
single angle milling cutters
Term
A workpiece that is to be clamped to the machine table can be aligned with the table axis by:
 Definition
Placing it against stops in the T-slots, measuring from the edge of the table to the side of the work, indicating the side of the workpiece
Term
When an edge finder is used to align the spindle cneterline with a workpiece edge, the spindle RPM should be:
 Definition
700 RPM
Term
The machine spindle is centered over an existing hole in the workpiece with aid of:
 Definition
a dial indicator
Term
While aligning a workhead, the head clamping bolts should be:
 Definition
exerting a slight drag
Term
When a aligning a workhead, how much preload should be set into the indicator?
 Definition
.015 in
Term
When the tip moves sideways on a .200 inch diameter edge finder, how far is the spindle centerline from the workpiece edge?
 Definition
.100 in
Term
To align a vise on a machine table:
 Definition
Indicate the solid vise jaw
Term
high cutting speeds are used with:
 Definition
light cuts
Term
cutting fluids:
 Definition
Prolong tool life, act as lubricants, increase production
Term
The longest tool life can be obtained when using:
 Definition
The right cutting speed, a feed rate that is not too low, the correct coolant
Term
What is the feed rate in IPM for a 1/2 diameter, 2 flute end mill with a cutting speed of 100 SFM and feed per tooth of .003 inch?
 Definition
IPM = F*N*rpm
Term
Circular slots are best machined with:
 Definition
the aid of a rotary table, the workpiece clamped to the table, circular slot cutters
Term
Angular cuts on workpieces can be made?
 Definition
with the peripheral teeth on an end mill, by tilting the workhead, by tilting the workpiece
Term
How many thousandths of an inch of material should be left for a finishing cut when roughing out a cavity?
 Definition
.030
Term
Holes can be drilled on a vertical milling machine by:
 Definition
using the quill power feed, raising the knee of the machine, using the sensitive quill feed
Term
When milling a keyseat into a shaft:
 Definition
The cutter needs to be centered over the shaft, the cutter should be sharp, the cutter has to be the correct size
Term
When milling a cavity:
 Definition
The cutting pressure should be against the cutter rotation
Term
What is the RPM for a 1/4 inch diameter, four flute end mill at a cutting speed of 200 SFM?
 Definition
rpm = CS*4/D
Term
Under normal cutting conditions, the depth of cut for an end mill should be no more than _______ in steel.
 Definition
1/2 the cutter diamater
Term
Cutting fluids should be used when machining:
 Definition
Steel(not brass or cast iron)
Term
Lower cutting speeds used when machining:
 Definition
Hard materials, tough materials, abrasive materials
Term
An adjustable boring head is used to machine:
 Definition
Nonstandard size holes, true cylindrical holes, holes in specific locations
Term
accurate round holes can be machined with the use of the:
 Definition
Offset boring head
Term
The hole size obtained by boring is affected by:
 Definition
The length of the boring tool, the depth of cut, the diameter of the boring tool
Term
Hole size variations can be caused by:
 Definition
tool wear, changes in depth of cut, feed rate changes
Term
When the depth of cut in a boring operation is increased the:
 Definition
tool deflection will increase also
Term
The cutting edge of the boring tool:
 Definition
Must be in line with the axis of the tool slide
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