Mechanical
Which type of deformation is mainly responsible for chip formation during metal cutting?
- Plastic deformation
- Elastic deformation only
- Thermal expansion only
- Brittle fracture only in all materials
Explanation:
- During machining of ductile materials, the material undergoes severe plastic deformation in the primary shear zone, producing a chip.
What is the main function of a cutting tool?
- To remove material from the workpiece by shearing
- To increase the diameter of the workpiece without removing material
- To cool the machine
- To measure workpiece dimensions
Explanation:
- A cutting tool has a wedge-shaped cutting edge that penetrates the workpiece and removes material as chips.
Which of the following is a primary cutting parameter in machining?
- Cutting speed
- Machine colour
- Workpiece weight only
- Tool storage temperature only
Explanation:
- The important machining parameters include cutting speed, feed and depth of cut. These strongly influence cutting force, power, tool life and surface finish.
What is cutting speed in a turning operation?
- The peripheral speed of the workpiece relative to the cutting tool
- The axial movement of the tool per revolution
- The radial depth of tool penetration
- The spindle torque only
Explanation:
- For turning, cutting speed is the surface speed of the workpiece at the cutting zone. It is commonly expressed in m/min.
Which formula gives cutting speed in a turning operation?
- V = πDN/1000
- V = πD/N
- V = DN/π
- V = N/(πD)
Explanation:
- When D is in mm and N is in rpm, cutting speed is V = πDN/1000 m/min.
What is feed in a turning operation?
- The distance moved by the cutting tool relative to the workpiece per revolution
- The diameter of the workpiece
- The depth of the hole
- The spindle speed
Explanation:
- Feed in turning is commonly specified in mm/revolution. It represents the axial distance advanced by the tool during one revolution of the workpiece.
What is depth of cut in turning?
- Half the difference between the initial and final diameters
- The difference between initial and final lengths
- The feed per revolution
- The spindle speed
Explanation:
- For turning, depth of cut is radial material removed in one pass and is given by d = (D − d)/2, where D and d are initial and final diameters.
Which cutting tool angle mainly affects the clearance between the tool flank and workpiece?
- Clearance angle
- Rake angle
- Helix angle
- Point angle only
Explanation:
- The clearance or relief angle prevents the flank of the cutting tool from rubbing against the machined surface.
What is the main function of rake angle in a cutting tool?
- To facilitate chip flow and influence cutting forces
- To increase machine weight
- To measure cutting speed
- To prevent spindle rotation
Explanation:
- Rake angle influences chip flow, cutting force, power consumption and cutting temperature. Positive rake generally reduces cutting force but can weaken the cutting edge.
A positive rake angle generally results in:
- Lower cutting force
- Higher cutting force in all cases
- No chip formation
- Zero cutting temperature
Explanation:
- A positive rake angle generally makes shearing easier and reduces cutting force and power requirement, although excessive positive rake can weaken the cutting edge.
Which angle prevents rubbing of the tool flank against the machined surface?
- Clearance angle
- Rake angle
- Cutting-edge inclination only
- Helix angle
Explanation:
- The clearance angle provides sufficient space between the tool flank and work surface, reducing rubbing and friction.
Which material is commonly used for high-speed cutting tools?
- High-speed steel (HSS)
- Mild steel only
- Cast iron only
- Pure aluminium only
Explanation:
- HSS retains useful hardness at elevated temperatures and is widely used for drills, milling cutters, taps and various cutting tools.
Which cutting-tool material generally has greater hot hardness than high-speed steel?
- Cemented carbide
- Mild steel
- Copper
- Aluminium
Explanation:
- Cemented carbide retains hardness at much higher temperatures than HSS, allowing substantially higher cutting speeds.
Which property is essential for a cutting tool?
- High hot hardness and wear resistance
- Very low hardness
- Very high ductility only
- Low thermal stability
Explanation:
- A cutting tool must retain adequate hardness at elevated cutting temperatures and resist wear. Toughness is also important to avoid chipping and fracture.
What is tool life?
- The useful cutting time of a tool before it reaches a specified wear criterion
- The total storage time of a tool
- The time required to manufacture the machine
- The time required to cool the workpiece
Explanation:
- Tool life is the period during which a tool performs satisfactorily before reaching a specified limit of wear or failure.
Which relation is commonly associated with tool life and cutting speed?
- VTn = C
- V + T = C
- V/T = C for all tools
- VT = 0
Explanation:
- Taylor’s tool-life equation is VTn = C, where V is cutting speed, T is tool life, n is a tool-dependent exponent and C is a constant for specified conditions.
What generally happens to tool life when cutting speed is increased?
- Tool life generally decreases
- Tool life always increases
- Tool life becomes infinite
- Tool life remains exactly unchanged
Explanation:
- Increasing cutting speed generally raises cutting temperature and wear rate, thereby reducing tool life.
Which type of wear occurs mainly on the tool face in contact with the chip?
- Crater wear
- Flank wear
- Notch wear only
- Corner fracture only
Explanation:
- Crater wear develops on the rake face of the cutting tool due to interaction with the flowing chip, especially at high cutting temperatures.
Which type of wear occurs mainly on the clearance face of a cutting tool?
- Flank wear
- Crater wear
- Crack wear
- Chip wear
Explanation:
- Flank wear develops on the tool’s clearance face due to rubbing against the newly machined surface and is a common criterion for tool-life assessment.
What is built-up edge in machining?
- A layer of workpiece material that adheres to the cutting edge and builds up during cutting
- A crack in the machine bed
- A layer of coolant on the tool
- A permanent part of the cutting tool material
Explanation:
- Built-up edge, or BUE, is formed when work material adheres to the tool near the cutting edge. It is common at certain combinations of material, speed and friction conditions and can affect surface finish and dimensional accuracy.
Which operation is primarily performed on a lathe?
- Turning
- Gear hobbing only
- Surface grinding only
- Broaching only
Explanation:
- A lathe is primarily used for turning cylindrical surfaces, although it can also perform facing, threading, boring, drilling, knurling and other operations.
In a conventional lathe, which component rotates the workpiece?
- Headstock spindle
- Tailstock
- Tool post
- Compound rest
Explanation:
- The headstock contains the spindle and drive mechanism that rotates the workpiece.
Which lathe component supports the free end of a long workpiece?
- Tailstock
- Headstock only
- Tool post
- Apron
Explanation:
- The tailstock supports the free end of long workpieces using a centre and can also hold tools such as drills and reamers.
Which lathe component holds and moves the cutting tool?
- Carriage
- Headstock
- Tailstock only
- Chuck only
Explanation:
- The carriage supports and guides the cutting tool. It includes components such as the saddle, cross-slide, compound rest, tool post and apron.
What is the function of a chuck in a lathe?
- To hold and rotate the workpiece
- To support the tailstock
- To control coolant flow only
- To measure cutting speed
Explanation:
- A chuck grips the workpiece and transfers rotational motion from the spindle to the workpiece.
Which lathe operation reduces the diameter of a cylindrical workpiece?
- Turning
- Facing
- Knurling
- Thread chasing only
Explanation:
- Turning removes material from the external cylindrical surface and reduces its diameter to the required size.
Which lathe operation produces a flat surface at the end of a cylindrical workpiece?
- Facing
- Turning
- Knurling
- Parting
Explanation:
- During facing, the cutting tool moves approximately radially across the end face of a rotating workpiece to produce a flat surface.
Which lathe operation is used to produce a thread?
- Threading
- Facing
- Knurling
- Parting only
Explanation:
- Threading on a lathe involves synchronizing tool movement with spindle rotation to generate the required helical thread profile.
Which lathe operation produces a roughened regular pattern on a cylindrical surface?
- Knurling
- Facing
- Boring
- Drilling
Explanation:
- Knurling is a forming operation in which hardened rollers press a pattern onto the work surface, commonly to improve grip.
Which lathe operation is used to enlarge an existing hole?
- Boring
- Facing
- Knurling
- Parting
Explanation:
- Boring enlarges and improves the accuracy of an existing hole using a single-point cutting tool.
What is the primary motion in a conventional lathe turning operation?
- Rotation of the workpiece
- Rotation of the cutting tool only
- Reciprocation of the workpiece
- Vertical movement of the machine bed only
Explanation:
- In conventional turning, the workpiece rotates while the cutting tool performs the feed motion.
Which machine tool is mainly used for producing flat surfaces, slots and profiles using a rotating multi-point cutter?
- Milling machine
- Lathe
- Shaper
- Drilling machine
Explanation:
- A milling machine uses a rotating multi-point cutting tool to remove material from the workpiece.
What is the cutting tool used in milling called?
- Milling cutter
- Single-point tool only
- Drill bit
- Grinding wheel
Explanation:
- A milling cutter contains multiple cutting teeth and rotates about its axis while machining the workpiece.
Which operation is performed using a face milling cutter?
- Machining a flat surface perpendicular to the cutter axis
- Producing a deep circular hole only
- Producing external threads only
- Grinding a surface
Explanation:
- Face milling is primarily used to produce flat surfaces. The cutter axis is generally perpendicular to the surface being machined.
In peripheral milling, the cutting teeth are mainly located on:
- The circumference of the milling cutter
- The machine bed
- The workholding vice only
- The spindle bearing
Explanation:
- In peripheral or slab milling, the cutting edges are primarily on the circumference of the cutter.
In up milling, the cutter rotation at the cutting point is:
- Opposite to the direction of workpiece feed
- Always in the same direction as feed
- Perpendicular to the feed only
- Independent of feed direction
Explanation:
- In up milling, also called conventional milling, the cutter rotates opposite to the direction of workpiece feed at the point of cutting.
In down milling, the cutter rotation at the cutting point is:
- In the same direction as the workpiece feed
- Opposite to feed in all cases
- Perpendicular to feed
- Zero
Explanation:
- In down or climb milling, the cutter rotates in the same general direction as the workpiece feed at the cutting zone.
Which milling operation is suitable for producing gears using a form cutter?
- Gear milling
- Facing
- Turning
- Grinding only
Explanation:
- Gear milling uses a form cutter or other milling methods to produce gear teeth. Production gears may also be manufactured by hobbing, shaping and other specialized processes.
Which machine tool is primarily used for producing holes?
- Drilling machine
- Lathe only
- Shaper only
- Planer only
Explanation:
- A drilling machine is primarily designed to produce holes using rotating drill bits.
What is the primary cutting tool used in drilling?
- Twist drill
- Single-point turning tool
- Milling cutter
- Grinding wheel
Explanation:
- The twist drill is the most common cutting tool used for producing cylindrical holes in drilling machines.
Which operation is used to enlarge an existing drilled hole accurately?
- Reaming
- Knurling
- Facing
- Parting
Explanation:
- Reaming removes a small amount of material from an existing hole to improve its dimensional accuracy and surface finish.
Which operation produces an internal cylindrical surface using a single-point cutting tool?
- Boring
- Knurling
- Facing
- External turning
Explanation:
- Boring uses a single-point tool to enlarge or finish an existing hole and improve its dimensional accuracy.
Which operation produces a conical recess at the mouth of a hole?
- Countersinking
- Counterboring
- Reaming
- Knurling
Explanation:
- Countersinking produces a conical recess, commonly used to accommodate the conical head of a countersunk screw.
Which operation produces a cylindrical recess at the top of a hole?
- Counterboring
- Countersinking
- Knurling
- Facing
Explanation:
- Counterboring enlarges the upper portion of an existing hole to form a cylindrical recess, commonly for accommodating a socket-head or similar fastener head.
What is the main cutting motion in a shaping machine?
- Reciprocating motion of the cutting tool
- Continuous rotation of the workpiece
- Continuous rotation of the table only
- Rotary motion of a grinding wheel
Explanation:
- In a shaper, the single-point cutting tool is mounted on the reciprocating ram. Material is removed during the cutting stroke.
Which machine tool uses a reciprocating ram carrying a single-point cutting tool?
- Shaper
- Milling machine
- Drilling machine
- Grinding machine
Explanation:
- A shaper has a reciprocating ram that carries a single-point cutting tool. It is mainly used for machining flat surfaces, slots and similar features.
In a shaper, material is normally removed during:
- The cutting stroke
- The return stroke only
- Both strokes equally in a conventional shaper
- The stationary period only
Explanation:
- In a conventional shaper, cutting occurs during the forward cutting stroke. The return stroke is idle, although quick-return mechanisms reduce its duration.
What is the purpose of the quick-return mechanism in a shaper?
- To reduce the time of the return stroke
- To increase the cutting time of the return stroke
- To stop the ram permanently
- To rotate the workpiece continuously
Explanation:
- The quick-return mechanism makes the return stroke faster than the cutting stroke, increasing the proportion of time available for useful cutting.
Which machine tool is mainly used for producing flat surfaces using a reciprocating single-point tool?
- Shaper
- Lathe
- Drilling machine
- Grinding machine
Explanation:
- A shaper is especially suitable for machining flat surfaces, slots, keyways and other relatively small or medium-sized surfaces.
What is the basic function of a grinding machine?
- To remove small amounts of material using abrasive grains
- To produce chips only with a single-point tool
- To join two workpieces
- To cast molten metal
Explanation:
- Grinding is an abrasive machining process. Numerous hard abrasive grains act as small cutting edges and remove very small amounts of material.
Which of the following is used as a cutting tool in grinding?
- Abrasive grains
- Single-point HSS tool only
- Twist drill only
- Milling cutter only
Explanation:
- Each abrasive grain on a grinding wheel acts approximately like a small cutting tool.
Which abrasive is commonly used for grinding steel and other ferrous materials?
- Aluminium oxide
- Silicon carbide only
- Diamond only
- Glass only
Explanation:
- Aluminium oxide is widely used for grinding steels and other ferrous materials. Silicon carbide is commonly used for cast iron, non-ferrous metals and other applications where its sharper, more friable characteristics are beneficial.
Which abrasive is commonly used for grinding cast iron and non-ferrous materials?
- Silicon carbide
- Aluminium oxide only
- Mild steel
- Copper
Explanation:
- Silicon carbide is commonly selected for cast iron, non-ferrous metals and certain non-metallic materials because of its hardness and sharp cutting action.
What is dressing of a grinding wheel?
- Removal of dull or loaded abrasive material to restore the cutting action of the wheel
- Increasing the diameter of the workpiece
- Lubricating the spindle
- Changing the machine foundation
Explanation:
- Dressing removes loaded or dull abrasive grains and exposes fresh sharp grains, restoring the wheel’s cutting ability and correcting the wheel surface.
What is truing of a grinding wheel?
- Restoring the required geometric shape and concentricity of the wheel
- Increasing the workpiece hardness
- Reducing coolant flow
- Changing the workpiece material
Explanation:
- Truing restores the wheel to its required geometric form and corrects eccentricity or distortion.
Which grinding operation is commonly used for producing a flat surface?
- Surface grinding
- Cylindrical turning
- Drilling
- Knurling
Explanation:
- Surface grinding is used to produce accurate flat surfaces with good dimensional control and surface finish.
Which grinding operation is suitable for external cylindrical surfaces?
- Cylindrical grinding
- Surface grinding only
- Drilling
- Shaping
Explanation:
- Cylindrical grinding is used to finish external cylindrical surfaces accurately.
Which manufacturing process involves shaping molten metal and allowing it to solidify in a mould?
- Casting
- Machining
- Grinding
- Forging
Explanation:
- In casting, molten material is poured into a mould cavity having the desired shape and then allowed to solidify.
Which manufacturing process produces components by plastically deforming metal under compressive forces?
- Forging
- Casting
- Drilling
- Grinding
Explanation:
- Forging shapes metal through plastic deformation using compressive forces, usually with dies, hammers or presses.
Which manufacturing process reduces the thickness of metal by passing it between rotating rolls?
- Rolling
- Forging
- Drilling
- Grinding
Explanation:
- Rolling passes metal between rotating rolls to reduce thickness or change cross-sectional shape.
Which manufacturing process produces long products by forcing metal through a die?
- Extrusion
- Casting
- Grinding
- Drilling
Explanation:
- Extrusion forces a billet through a die opening, producing a continuous product with a cross-section corresponding to the die profile.
Which manufacturing process pulls metal through a die to reduce its cross-sectional area?
- Drawing
- Extrusion
- Casting
- Shaping
Explanation:
- In drawing, a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length.
Which process joins two metal pieces by heating them and using a filler metal whose melting temperature is below that of the base metals?
- Brazing
- Forging
- Rolling
- Grinding
Explanation:
- In brazing, the filler metal melts and flows into the joint, while the base metals do not melt under normal brazing conditions.
Which process uses a filler metal with a relatively low melting point and is commonly used for electronic and light-duty joints?
- Soldering
- Forging
- Rolling
- Turning
Explanation:
- Soldering uses a low-melting-point filler metal to join components. The base metals remain below their melting temperatures.
Which machining process uses a single-point cutting tool and rotating workpiece?
- Turning
- Milling
- Grinding
- Broaching
Explanation:
- In conventional turning, the workpiece rotates while a single-point cutting tool removes material from its surface.
Which machining process uses a rotating multi-point cutting tool?
- Milling
- Turning
- Shaping
- Planing
Explanation:
- Milling uses a rotating cutter having multiple cutting edges. The workpiece is generally fed against the rotating cutter.
Which machining process uses a rotating multi-point tool to produce a hole?
- Drilling
- Turning
- Shaping
- Planing
Explanation:
- Drilling uses a rotating drill, normally a multi-point cutting tool, to produce a new hole in a workpiece.
Which machining process generally provides the best surface finish among turning, drilling and grinding?
- Grinding
- Drilling
- Rough turning
- Shaping
Explanation:
- Grinding is a finishing process capable of achieving high dimensional accuracy and fine surface finish because material is removed by very small abrasive cutting edges.
What is machining allowance?
- The extra material intentionally provided for subsequent machining
- The amount of coolant supplied
- The tool clearance angle
- The spindle speed allowance only
Explanation:
- Machining allowance is extra material left on a component after processes such as casting or forging so that it can later be removed by machining to obtain accurate dimensions and surface finish.
Which factor generally increases cutting temperature significantly?
- Increase in cutting speed
- Reduction in cutting speed in every case
- Elimination of friction
- Reduction of material removal rate to zero
Explanation:
- Higher cutting speed generally increases the rate of energy dissipation and cutting temperature. Feed, depth of cut, tool geometry, work material and coolant also affect temperature.
What is the main purpose of cutting fluid in machining?
- To provide cooling and lubrication and help remove chips
- To increase tool friction
- To increase cutting temperature
- To replace the cutting tool
Explanation:
- Cutting fluids can reduce cutting temperature and friction, improve tool life and surface finish, and help carry chips away from the cutting zone.
Which machining parameter has a strong effect on material removal rate?
- Cutting speed, feed and depth of cut
- Machine colour only
- Tool storage time only
- Workpiece name only
Explanation:
- Material removal rate depends on machining conditions such as cutting speed, feed and depth of cut. Their exact relationship depends on the machining process.
What is orthogonal cutting?
- Cutting in which the cutting edge is perpendicular to the direction of cutting velocity
- Cutting with no tool movement
- Cutting using only abrasive grains
- Cutting in which the workpiece does not move
Explanation:
- In ideal orthogonal cutting, the cutting edge is perpendicular to the direction of cutting velocity and the chip flows approximately normal to the cutting edge.
What is oblique cutting?
- Cutting in which the cutting edge is inclined to the direction of cutting velocity
- Cutting with zero rake and zero clearance only
- Cutting without chip formation
- Cutting using only a grinding wheel
Explanation:
- In oblique cutting, the cutting edge is inclined to the direction of cutting velocity, so the chip generally flows sideways relative to the cutting edge.
Which force component acts in the direction of cutting velocity?
- Cutting force
- Feed force only
- Radial force only
- Clamping force
Explanation:
- The cutting force is the principal component acting approximately in the direction of cutting velocity. Its magnitude strongly affects cutting power.
Machining power is approximately equal to:
- Cutting force × cutting velocity
- Cutting force ÷ cutting velocity
- Feed × depth of cut only
- Tool life × clearance angle
Explanation:
- Machining power associated with the cutting force is approximately P = FcV, with suitable unit conversion when force and velocity are not in SI-compatible units.
Which factor generally improves surface finish in turning?
- Reducing feed, within appropriate machining limits
- Increasing feed without limit
- Increasing tool wear
- Using a damaged cutting edge
Explanation:
- For a given tool geometry, reducing feed generally reduces theoretical surface roughness. Tool nose radius, cutting speed, vibration, tool wear and work material also influence the final finish.
Which machine tool is commonly used for machining large flat surfaces by reciprocating the workpiece?
- Planer
- Drilling machine
- Lathe
- Grinding wheel
Explanation:
- In a planer, the workpiece is mounted on a reciprocating table and the cutting tools are mounted on the tool heads. It is suitable for large workpieces and large flat surfaces.
What is the main difference between a shaper and a planer?
- In a shaper the tool reciprocates, while in a planer the workpiece/table reciprocates
- In both, the workpiece always rotates
- In both, the tool is a grinding wheel
- A planer cannot machine flat surfaces
Explanation:
- The principal distinction is the reciprocating member. A shaper reciprocates the cutting tool, whereas a planer reciprocates the workpiece table.
Which process is classified as a non-traditional machining process?
- Electrical discharge machining (EDM)
- Turning
- Drilling with twist drill
- Conventional milling
Explanation:
- EDM removes material by controlled electrical discharges rather than conventional mechanical cutting. It is suitable for electrically conductive materials.
Which machining process is particularly suitable for hard materials and complex cavities when the material is electrically conductive?
- Electrical discharge machining (EDM)
- Conventional turning only
- Knurling
- Hand filing only
Explanation:
- EDM can machine hard electrically conductive materials using electrical sparks between the tool electrode and workpiece.
Which manufacturing process generally produces the highest dimensional accuracy among the following?
- Precision grinding
- Sand casting
- Hot forging without finishing
- Rough rolling
Explanation:
- Precision grinding is a finishing process capable of producing very close dimensional tolerances and fine surface finishes compared with rough primary manufacturing processes.
Which process is generally considered a finishing operation rather than a bulk material-removal operation?
- Grinding
- Rough turning
- Rough milling
- Rough boring
Explanation:
- Grinding generally removes small quantities of material and is widely used for achieving high dimensional accuracy and good surface finish.
Which operation separates a finished component from the remaining bar stock on a lathe?
- Parting-off
- Facing
- Knurling
- Threading
Explanation:
- Parting-off uses a narrow cutting tool fed radially into the rotating workpiece until the component is separated from the bar.
Which operation is used to produce a small chamfer or angled surface on a workpiece?
- Chamfering
- Knurling
- Drilling
- Reaming
Explanation:
- Chamfering removes material from an edge to create an angled surface, commonly for deburring or facilitating assembly.
Which operation is used to produce an internal thread?
- Tapping
- Knurling
- Facing
- Grinding
Explanation:
- Tapping uses a tap to produce an internal screw thread in a previously drilled or prepared hole.
Which operation is used to produce an external thread using a die?
- Die threading
- Reaming
- Counterboring
- Facing
Explanation:
- A die can be used to cut or form external threads on cylindrical workpieces such as rods and bolts.
Which cutting tool is generally used for drilling a hole larger than the original drilled hole while improving accuracy?
- Reamer
- Knurling tool
- Parting tool
- Facing tool
Explanation:
- A reamer removes a small amount of material from an existing hole and provides improved size accuracy and surface finish.
Which factor has a major influence on tool wear?
- Cutting speed and cutting temperature
- Machine paint colour
- Workpiece storage time only
- Toolbox size
Explanation:
- Cutting speed, temperature, cutting force, work material, tool material, tool geometry and cutting fluid all affect tool wear. Cutting speed is particularly important because it strongly affects temperature.
Which type of chip is generally associated with ductile materials machined at suitable high speeds?
- Continuous chip
- Discontinuous chip only
- No chip
- Powder chip only
Explanation:
- Ductile materials often produce continuous chips under suitable cutting conditions, especially with appropriate positive rake and cutting speed.
Which type of chip is commonly associated with brittle materials?
- Discontinuous chip
- Continuous chip in all conditions
- Helical chip only
- No chip formation
Explanation:
- Brittle materials tend to fracture during machining, producing discontinuous or segmented chips.
What is the main purpose of chip breakers?
- To control and break long continuous chips
- To increase workpiece diameter
- To reduce spindle speed to zero
- To increase tool clearance to infinity
Explanation:
- Chip breakers control long chips by causing them to curl and fracture into smaller pieces, improving operator safety, chip evacuation and machining reliability.
Which machining process is best suited for producing a cylindrical external surface with high accuracy and finish after turning?
- Cylindrical grinding
- Drilling
- Shaping
- Knurling
Explanation:
- Cylindrical grinding is commonly used as a finishing operation after turning to achieve close dimensional tolerances and improved surface finish.
Which machine tool is most versatile for producing cylindrical components, threads, tapers and flat end faces?
- Lathe
- Drilling machine
- Shaper
- Surface grinder
Explanation:
- The lathe is one of the most versatile machine tools and can perform turning, facing, threading, taper turning, boring, drilling, knurling and parting operations.
Which machine tool is most suitable for producing slots and keyways using a rotating multi-point cutter?
- Milling machine
- Lathe
- Shaper only
- Drilling machine
Explanation:
- Milling machines can produce slots, keyways, pockets, flats, profiles and many other features using suitable multi-point cutters.
Which machine tool is most suitable for producing a series of holes using a rotating drill?
- Drilling machine
- Shaper
- Planer
- Surface grinder
Explanation:
- Drilling machines are designed primarily for hole-making operations and can also perform reaming, tapping, counterboring and countersinking with suitable tools.
Which manufacturing process changes the shape of a metal blank without removing material in the form of chips?
- Forging
- Turning
- Milling
- Drilling
Explanation:
- Forging is a metal-forming process in which plastic deformation changes the shape of the workpiece without conventional chip removal.
Which manufacturing process is most suitable for producing complex shapes directly from molten metal?
- Casting
- Turning
- Grinding
- Drilling
Explanation:
- Casting can produce complex geometries by pouring molten material into a mould cavity and allowing it to solidify.
What is the main difference between machining and forming processes?
- Machining removes material, whereas forming generally changes shape by plastic deformation
- Both always remove material as chips
- Forming always melts the workpiece
- Machining never uses cutting tools
Explanation:
- Machining removes unwanted material as chips. Forming processes such as forging and rolling change the shape through plastic deformation, usually without conventional chip formation.
Which parameter is directly related to the rate at which the tool advances in turning?
- Feed
- Cutting speed only
- Depth of cut only
- Rake angle only
Explanation:
- Feed specifies how far the tool advances relative to the workpiece for each revolution, usually in mm/rev in turning.
What happens to material removal rate when feed and cutting speed are increased, with other factors appropriately held constant?
- It generally increases
- It always becomes zero
- It always decreases
- It remains exactly unchanged
Explanation:
- Higher feed and cutting speed generally increase the amount of material removed per unit time, although practical limits such as machine power, tool strength and surface finish must be considered.
Which cutting condition generally produces higher tool temperature?
- Higher cutting speed
- Very low cutting speed in every case
- Zero feed
- No contact between tool and workpiece
Explanation:
- Higher cutting speed generally increases the rate of plastic deformation and frictional energy conversion, leading to higher cutting temperatures.
What is the main purpose of a machine tool?
- To accurately shape or finish a workpiece using controlled relative motion between tool and workpiece
- To store raw materials only
- To measure atmospheric pressure
- To transport finished products only
Explanation:
- Machine tools provide controlled motion, rigidity and power so that cutting or forming operations can be carried out accurately and repeatedly.
Which of the following is a cutting process?
- Milling
- Forging
- Rolling
- Extrusion
Explanation:
- Milling is a machining/cutting process in which material is removed from the workpiece in the form of chips.
Which of the following is a metal-forming process?
- Rolling
- Turning
- Drilling
- Grinding
Explanation:
- Rolling is a metal-forming process in which the workpiece is plastically deformed between rotating rolls.
Which process is used to remove burrs and produce a fine surface finish on a machined component?
- Grinding
- Rough casting
- Forging
- Rolling
Explanation:
- Grinding can be used for precision finishing and removal of small amounts of material, including burrs and surface irregularities.
Which factor is most important when selecting a cutting-tool material for high-speed machining?
- Hot hardness and resistance to wear at elevated temperature
- Low hardness at high temperature
- High melting point of the workpiece only
- Low strength of the tool
Explanation:
- High-speed machining generates substantial heat. Therefore, the cutting tool must retain hardness and wear resistance at elevated temperatures while also having adequate toughness.