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TDPT 280 FINAL EXAM (Spring, 2017)

Name: Date: Score:

Instructions: Respond to each of the following on this exam, using extra sheets as
necessary. Make sure you fully answer each test item. Write legibly and use correct
grammar. You may use a calculator, rule, straightedge and graph paper. There may not
be exactly 100 raw points possible on this exam; your score (percentage) will be
determined by dividing the number correct by total possible. Relax. Be confident.

Part A: Learning From Decisions

1. List and briefly describe each of the demonstration and contract lab activities you
conducted in this class. Tell us what you made. (If you did several laser cutting projects,
for example, name each major project rather than the individual parts that made up the
project.) (4)

2. One of the wonderful aspects of prototyping is that it provides quick feedback about
design decisions weve made. Several times while working on your projects this semester,
you had to make some decisions. But the results of your work likely illustrated how some
of these decisions could have been improved, and maybe how your decision making
process could have improved. For each of the four areas listed below (A through D), think
about a good example of your decision making process from the above list of projects.
Then write a paragraph where you mention the activity and describe, in detail the extent to
which you engaged in the behaviors listed by that item. (16)

A. For one activity, give a good description of the decision making strategy you
used in this activity.
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B. For one activity, explain the extent to which you used multiple sources of
information and knowledge in forming judgments.

C. For one activity, identify how your own strengths and limitations impacted your
decisions.

D. For one activity, describe how you took an experimental or inquiry approach and
the degree to which this was informed by what others have learned and written.
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Part B: Reverse Engineering

3. Define reverse engineering as it pertains to manufactured products. (1)

4. List 3 physical limitations of using any laser scanner to capture the surface geometry of
a product. (3)

5. After laser scanning a part, we could smooth features during editing. What are two
drawbacks to this smoothing? (2)

6. List two common applications of reverse engineering that do not result in rapid
prototyping. (2)

7. In addition to laser scanning, what is another common method that can be used to
recreate a physical model into a 3D file? (1)

8. Write an ethical principle to guide us with reverse engineering. (1)

Part C: 3D Prototyping
9. What do the letters in FDM stand for? (1)

10. What are two materials we can use to build in the FDM and what are two advantages
of each material? (4)

11. Explain why the FDM requires building a support structure but the Z-Corp solid object
printer does not. (1)

12. Which rapid prototyping technology is most commonly used by large manufacturers?
(no abbreviations) (1)
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13. In typical 3D printing software, what does the software do to the models geometry
before sending it to the 3D-printer to be made? (hint - think thin!)

14. Describe the typical way a rapid prototyping company would produce 20 polyurethane
products if they own an SLA or FDM system. (3)

15. Give an example of how supports work in 3D printing. Extra Credit: Name the solution
used to dissolve support materials (HIPS) in the Waterworks system used with a uPrint
FDM - OR - describe the process of dissolving Polyvinyl Acetate (PVA) supports. (1+1)

16. Describe two ways that a part created on the form 2 (SLA Machine) can be
strengthened and why those approached increase strength. (2)

Part D: Laser Machining

17. Laser is an acronym. What words does it stand for? (1)

18. Laser light is coherent. List three other properties that distinguish all laser light from
the light in this room. (3)

19. A 150-watt laser just cuts through thick Marmalite at a power setting of 25% and a
speed setting of 10%; what equivalent setting would work to minimize cutting time? (2)

20. During the demonstration on laser cutting, it was pointed out that dangerous hydrogen
chloride gas can be emitted if a certain polymer is cut, and therefore there is a ban on
laser cutting that polymer. Name that polymer or give its abbreviation. (1)

21. There are two basic types of images we send to the laser cutter, and only one of these
is used for point-to-point cutting. What are the names of these two basic image types? (2)

22. Our laser cutter requires focusing. We typically use a 2 focal length lens, which has a
focal range of + .1. If you intend to cut completely through a piece of quarter-inch thick
acrylic, then theoretically, how far should the lens be from the top of the acrylic to
maximize laser power-to-speed efficiency? (1)
Part E: CAD/CAM CNC
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23. List 2 advantages and 2 disadvantages of CNC machining in terms of production

efficiency. (4)
Advantages:

Disadvantages:

24. Distinguish between a "cut" and a "feed" on the NC lathe by indicating the primary axis
involved in each (i.e., X, Y or Z). (2)

25. A machinist is standing in front of a typical CNC mill (similar to the one in our lab).
Standard axis orientation (the "right hand rule") is used. While the cutter remains
stationary, the stock begins to move toward the operator and to the operator's right,
simultaneously; meanwhile, the mill cutter moves down toward the stock. For each of the
three major axes listed below, circle the term corresponding to the whether the relative
movement of the cutter is in a positive direction or a negative direction. (3) {Beware!}

X: Positive, Negative, Neither, Both, Cannot Determine

Y: Positive, Negative, Neither, Both, Cannot Determine

Z: Positive, Negative, Neither, Both, Cannot Determine

Some Common NC Codes:

G0 Rapid traverse; point-to-point M2 End of program
G1 Linear interpolation M3 Spindle on CW
G2 Circular interpolation arc CW M5 Spindle off
G3 Circular interpolation arc CCW M6 Tool change
G4 Dwell N Block number
G5 Pause F Feed rate
G90 Absolute dimension input S Spindle Speed
G91 Incremental dimension input R Radius
M1 Program stop T Tool Selection
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NOTE: Test items 26 through 32 refer to the following NC mill program. A 3" cube of wax
is machined using the following NC code with tool initialization at 0, 0, 0, on the top,
front, left corner of the workpiece. There is no cutting tool offset. An 1/8" end mill is
used. Refer to the list of common NC codes, above, for help.

N0G90G0X0Y0Z0.1
N1M03S2000
N2G0X1Y1
N3G1Z-0.1F4
N4X1.5Y2.5
N5G0Z0.1
N6X2.5Y1.5
N7G1Z-0.07
N8G3X1Y1.5I1.75J1.5
N10X2I1.5
N11G1Y2.5Z0.1
N12X0Y0
N13M02

26. In the grid above, make an accurate, realistic drawing of the top of the machined
workpiece. Show the edges of the cut and properly indicate intersections. (7)

27. Rewrite block N4 so that it begins N4G91G1. and performs the same function it did
prior to this change. (1)
N4G91G1

28. Block N8 causes a semicircular contour to be cut. You are to insert a new line after
Block N8 so that the other half of the circle is cut. Write that new line. (2)

29. What is the feed rate for linear interpolation cuts in this program (be sure to include the
unit)? (1)

30. What is the depth of cut for the circular interpolation? (1)

31. Assuming no tool offset, what is the distance between the edge of the block and the
outside edge of the cut produced in Block N8? Answer in decimal inches. Check your
answer. (1) {Beware!}

32. What are the final X, Y and Z coordinates of the cutter? (3)
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NOTE: Test item 33 refers to the following NC mill program. A 3" cube of wax is machined
using the following NC code with tool initialization at 0, 0, 0, on the top, front, left corner of
the workpiece. There is no cutting tool offset. An 1/8" end mill is used. Refer to the list of
common NC codes for help.

N0G90G0X0Y0Z0.1
N1M03S1500
N2G91
N3G0X1Y2
N4G1Z-.2F6
N5X1.5
N6Y.5Z-.1
N7X-1Y-2
N8G2X0Y2I0J1
N9X.5I.25J0
N10G0Z0.1
N11X0Y0
N12M02

33. In the grid above, make an accurate, realistic drawing of the top of the machined
workpiece. Show the edges of the cut and properly indicate intersections. (7)
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NOTE: Items 34 through 36 refer to the following part to be machined on a CNC lathe.
After cut off, the finished part is shown in the perspective below with a length of 2.5 and
an overall diameter of 1. The leftmost 1 is a cylinder with a diameter of 1. The section
immediately to the right of that is a cylinder with a diameter of .8 and a length of .5. The
section to the right of that flares out over the length of .5 to a diameter of 1. To the right
of that there is a concave curve with a radius of .25, and then a convex curve with a
radius of .25.

34. In the drawing below that shows the hatched collet, label the values of the X and Z
coordinates for all 12 key points listed. (12)
X Z

X Z

X Z

SP=X Z

X Z

X Z X Z X Z X Z X Z X Z X Z
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35. On the back of this page or on a sheet to be attached, write an efficient Numerical
Control lathe program to machine this part including the cutoff operation using absolute
dimensioning. The original cylinder measures 1 in diameter and 3.5 in length, with 3
sticking out of the collet. The maximum depth of cut is 0.25", the spindle speed is to be
2500 RPM, and the feed is to be 5 inches per minute. You are using the same cutting
tools used in class (Tool 1 removes material while moving right to left and Tool 3 is the
cutoff tool.) The program is to start with Tool 1 even with the surface of the cylinder and
0.1" to the right of its end at the Start Point (SP), and end with Tool 1 in the same place.
Use the chuckface and the center of the cylinder as the origin. Because your time is
limited, include two lines of introductory remarks that indicate the diameter and amount
exposed and the cutting tools starting position only. (15)

36. On an attached sheet, write an nc lathe control program using relative or incremental
dimensioning to machine the same part as in Problem 35 using the same parameters
and cutting logic. Each line (block number) must correspond between these two programs.
No code remarks or annotations are needed, but please provide a dynamic listing of the
absolute coordinates on a separate table. (15)
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