Gold-working rm Ap phurecTsane & jorking metal erlarmes af a Temperature above the rectystellization “ ae “|e - ’ e y ch or in nin vane ocak spore a haw? , i No heating required T Lower forces required for deformation 1 No undesirable residual stresses Lo 117 Better surface finish obtalied : 17 New Answer Imp-oved strength properties = [New Answer Lighter and Jess powerful equipment required , » “ciigh are the main cacegories of cold-working processes? a ‘swueering L— Coating : ‘Swaging . va Forging Bending shearing = Drawing p= . msaead which form are the workpieces that will undergo @ bending process? FF Flat metal sheet Metal strip Metal bars with section diameter more than 40 mm r 7 Brass bars of any size > Complete the sentence by typing yeur answers into the textboxe sine most important fictor when designing 9 part that has to be manufactured by bending is the visi | 8 that can be bent successfully without metal cracking. : | | shearing isthe mecharica cutting of materials in set or plate Frm without Ure fuematin of | Show ofuse of boring or mating :ns © Tre to False How can be calculated the necessary force te perforin a shearing operation? Multiplying the area of the cross section by the shedr strangth of the work material : uttipyng the area of the cross section by the Shear strength of the work material and» dividing by the friction coefficient ¢ Hlultipying the area of the cross section BY the friction coefficient and civicing by the sheer Strength of the work materia! . planking and piercing are two names for the same process : ‘Troe ve c © False . « y 4 cold drawing can only be petfarmed yi metals 29s co true yo . © False noe . “ 4 When ig advisable to perform high-aneray te forming (HERF)? \ FF when the workpiece Is considerably large TF when the workpiece I mace of 2 fe 0 form MEN Tr when the workpiece is considerably small Tr tedoes not exist such 9 process elect the hot-working enetal forming processes 2710" the following Rotting Forsing io ‘Shearing aaaa Pearcing Ko & ‘Hot-warking metal forming, processes are performed at a temperature just below the ‘ recrystallizationThe necessary power for a rolling process to happen decreases fer longer rating strip contact sagth Cc true be @ False * awhich of the following processes is not a type of forging T opensdie hammer F swaging Shearing x “a - Metals with lower yield strength are easier to extrude ue © true C False s : Py Which of the following assertions is/are correct, my To extrude high yield strength, metal no lubricant is needed F Aluminum Is easier to extrude than stee! (Baal Ie wawlnr ta extrude than Aluminuna — The most common lubricant for extruding Aluminum Is liquid nitrogen F Phosphate-based end molten glass lubricants are used to extrude steel Complete the sentenee by typing your answers inte the textboxes In open-die forging, what is called the geometrical defect (in the finished workpiece) caused by the friction between the dies and the workpiece? . ne ‘Sometimes it is necessary to use Isothermal rolling. When? When the material to be rolled is an thicker than 3,8 mm x »)se when the materi to be rled ts @ high-strength mital thinner than 3.8 mem it does not exist such a process Complete the sentence by typing your answers Into tre textboxes Ths sr or oto tow wee ay mst «7 pore ene fei mora rien ‘and resistant to collapse than! °°" sand. Which are the advantages for centrifugal casting? FW Fine grain size WW Tendency for the lighter nonmetallic inclusion, slag particies, and dross to segregate toward the inner radlus of the castings High resistance to atmospheric corrosion of centritugally cast pipes ‘When is It more profitable to use permanent-mold casting Instead of sand casting? When large quantities of the same product have.to be produced, rule of thumb $90 pieces When custom made products (orie of its kind) have to be produced It is never profitable to use permanent-mold casting; it fs 2 process that na longer Is used dn modern industries . qo. -~ In permanent-mold casting, how many parts can be produced in the same die before it Is time to ‘change it with a new one? upto 100,000 parts © UptoS part © Up to 50 parts . In die casting the motten metal is forced into the mold. © True © False — a )What Is the factor that 6 the size of the parts in die casting? © tne capoctty of tie machine. : © The material the mold is made of . © there it no tnitstion forthe siz ofthe parts. « Which are the advantages for dle casting? FF Large quantities of parts with close tolerances and smooth surface Parts with small trickness I” Impossibte for gases to be entrapped e : Which are the other two names for Investment casting? FF Lost-wax casting : Flim casting a . % —Pracislon casting . Une casting Grape casting 3 Which of the following are plastic molding processes? FF Injection molding a . extruding : Lo FF Coinjection moiding ra Plastic molding is the process where plastics are heated to a liquid or semifluid state and are formed in a mold under the only pressure given by the material weight, ote © False ‘Complete the sentence by typing your answers into the textboxes © Powder metallurgy normally consists of four basic steps, name them in the right order. m {1. Producing 2 fine!" “: 2. Mixing and preparing the! P™4” for use Pressing 3. the powder Into the desired shape Featng ' 4 the stipe at an elevated temperature i ° « Which are the three main categories of surface treatment? © Cleaning, coating and chemical conversion © Cleaning, coating and hardening : © ~ coating, hardenig and chemical conversion : . . Marit removal presses, lo known s3 machining, remove material ty meshauia, cr arr cheial ‘means o generate he desitd shape aor sure eraser, Which oth lllowing esse es 17 Machining preci. is crblea reg gene ofan rans sas iss hat a aflen unobtainable by ater metho 7 Machining nec Hexine, is very tcl forane machine ok ec hope pans @ Machining en be orca. Sl ft and lrg qonites pts cb eave inenronsivsy roded it inte othe proper maining proves. . v “ Conimony we maal-culing machine olsen be divided ino Sires grou. depending os base ype ater nde | © Singlepoin ots, mito ool snd abive i YO © Single point ols osting ons an ara sts : © Cantino, forming tok ad abrasive gris : : x # a A bigodvaninge with-recirlating baliscrew is the eTective sifiass ensured by de large coat ares between the bali tnd the tread. . eC thue ' - ia ‘Industrial diamonds ae no available i te form ofpolyeqsaline compacts for ihe machcing of meats and plastics | ‘wilh preatly reduced exiting free, hig hardness, good thermal conductivity. ssl euting-edge radius, and low fetion, | Which ofthe fltowing assertions iar ve: this advisable to use diamond looks when rote earn see, ilaniam and nice. FF Shortcomings wit dfomond tools sre bitleness, cst, and the lenecy to intrse ch ‘materials thot form eabides Tr Iinkstraldinenond eats ae sil a science feton fexiwe, the kednalogy to reproduce anos aii doce ot + exist yet. + cally with workpiecea ‘Which are the two important issues in selecting a exiting material? CHaniness and stsiness @ Toughness and hardness © Toughoess and titness Score: 0/0 1 Solute N ‘Athin ayer of TIC, TIN, or ALO, ean be applied to SS oF enride subsea, Why’? FF twimprove resistance to abrasion, emperatire Ttoimprove ol tooghoss 25 hares yo F —toimprove resistance to fston and chil aac M0 Correct Solution Optimsm speed and feed rate do not depend an tool and workpiece material, erefore there ave three sets of parameters ‘recommended for any type of machining process: 120 mvmin ad OF mnrcy (Tor five machining) 210 renin and 03 -monvev (for hard machining; 150 nin ond 0,2 oonveey (Cor avernge ening), ‘Scot Cte © False [Seore: 1040” Correct Solution . ‘The most widely wed hetical and are net the goneral-purpose twist dil, which has many variations. The Mes 1a vst dil are ed for culing but for removing chips from he kote, . © Tne _—— Cc False a ‘The optimal speed and fed fee diling depend on: col alertdesign ot ait WH tolerance . Ir turing. how con the net horsepower requir to remove mstecal be estimated? © By mokiplying the tangential forse by the surface speed ofthe workpiece i“ © ay mutiplying the radial force by Ue surface speed ofthe workpiece e By multiplying the tangential Free bythe Teed rate and te engl the workpivee. Ved ene tr mont appear ls © Detwoen 0,13 ant 0.$1 smo © Upto 0.013 mmtey Between 1.3 and 5.1 ewer ao] Daseaton ap ones + ac aE enh nn a pry AER Sa on TAG TRS tinecatnoteet mowed enn ste hang,” — ing cite sale: tne gatoes hae Kermtsprtalto tne mained ste feo note ages o coins Tigig ahs ERT TET ——Con re gia tag TT cage loeueseengive ceconieerce od _pergere nig Vertu Sty Sink Sen espe cron ee Fetes co aditetigsisrrcee perpen tiesureced beng ed iB operaans ARE] erphery, con beused i face cUs eed periery cuffers; cuters ean have caizuty in cus ingisining dimenslann accuracy dv lo long . Unseppaediengh ABE AGT ORY Te TEE TA BRITT TE Peripheral Mills answer Fae 1 . ‘Special Mls answer ford . Face Mills : sewer or : a ‘A good taxonomy for sensors is provided by he raquirements ler diferent degrees of process ool, Ths taxonomy ‘cotains Shree classes: - .Sensors used in regulate esdbnek contol loops. - Force sensors r r Process analyzers. TF Plewsctesirlensceleroncters [- Fr . Prochct quality analyzers - ‘CNC systems consist two Fonetional types: . point o point R r FF contouring, or coninuois path orthogonal path “Thermal deformation of the machine structure ie w source ofercar it CNC systems. Which efor calegory does icbclong, to? . 7 TF Coting proves ees Controller and drive dynamics 7 Mechanical hardware defences ‘Wht docs FRE sts for? © Frequonily Referred Feed © Frequency Response Fonction io Frequency Referred Farce _ Inall ofthe material removal processes just described, the achivaife materia removal rate maybe led by dynamic interactions between the euttng process and the structure ofthe machine-loal-workpee sysen:(Tiusly 1988)-The resulting vibrations helween th tool and workpiece enuse excessive variations ofthe eulling force, resuling in poor ‘surface quality and reduced life of the elting tool (Welbount (970) The vibrccns encountered can be classified in three broad categories: Free, Forced and setexcited vibrations © mle atostennenviin — L- ‘© "Forced, Dependent and self-excited vibrations - pomi” ‘Stability in ting processes does not depend on euting speed cine “ —" © False ao nazanbidh Normals? _Normaliving |s # heat-ireating process thal rests In a relatively unifor steel microstruc ne © Normaticing ica casting process used to produce a special sos (0 called No‘malizel tec!) © Normalizing is a hot-working metal farming pracess used lo produce a speeal steel (9 cle non « [Normalization treatments are performed fora varity of reasons FF Refine the dendritic gevin structure remainiog feos casting FF Eliminates severe texturs (and lense snisoteupic propetics) that resulis Su Forging snl vlling vperations FF Reduces residual stresses 5% teaproves the response ia ste! la Fer foci, sel pores beg B a ‘What ind of diagram is usually wsefal when performing a nomlization? FF rrTearve (Time-enpertur-tanstonnain cure) a Nr curve (sormatization Tie curve) NTT curve (Normalization: Temperature Score: 10/10 Gorrent Eotution iw {ase surface hardening is wsed 25 on llemative to Name hardening and induction hardening ferrous materials, Whieh of the following assumptions ifs true? Fr Teer eating ate achievable by ts laser minimizes pa sername ares carbon st FThe entre operation cannot be performed in air FF This process is used to harden selected areas of machine components such as gears, cylinders, bearings, and sha, :4010 Correct Solution tp - aInshisdedswetat ae welding on aris suck tween the wee and nxvl (coe) tl esd. Which of the fotlowing assumptions iar true? FF “Titer mettis providec bythe couse lei, TF _ Welds by this metho a0 not very often of very high ality F The metallurgical propertiss afm ld depend greatly onthe iype of eeerde aud is coving. ‘Score: 1010 Correct Solution _ ‘What kind of power supplies are. used for shickiod-melal are welding? Fac F oc . F Combination AC/DC . ‘Where should the welds be Tocated” © Away rom areas of mint ses. Nearby areas of moximam sires. © Banelly én areas of maxims sees. Score: 1040 Correct Solution . Grinding is. often preferred to slling when he amount qfmetal lo be removed is snail ud the cmensionataccuroey ow surface finish ae eriical. © The an . Cc False wot 1010 Gorreet Solution Uy used in combination e The yo c . _ te we « ‘Correct Solution ‘Droaching is usunly used for removing large amounts of material, The - False Ia a4 Score: 1040 Gorrect Solution ‘Wha ar the vera Ces BE Min grinding ‘Traverse pricing a Centrifugal grinding Plunge grinding. c e ‘Score: 10/10 Correct Solution [Bxeussive hen snot problem when grinding, Uverefore mo tubrican is needed, Tue False e « c Score: 1040 Gorrect Solution Generally, automatic assembly :ystems consist of three major eompancnts: (Chain ayeter, ed rating devies and Ports hanaling/placng mectoniams, “Transfer system, Pats (ceding dovico and Ports handting/tacing meetanisins et device, Pars feeding deviee and Manual ssenibly benches. ‘Complete the sentence by iysing your answers ino the textboxes Approximately 89% of manvfacturing cost is determined atthe conceptual desi sige. design | tor | assemby (DPA) s ervtal ducing early design, 19“Tae base activities associated with material handling ae: : Mong, sioring and soaring material. — Movingeassembting nd eto materia. © Movi string, and eontofling material. Score: 19710 Correct Solution ‘What docs the acronym DEM stays for? Desig for Modeling e © Design for Manusactur e Desig for Maintenance "What dogs the aerenyrn CAD stays for? 2 Campuler-Aided Design: © © Computational Animated Design & —Ciagpaer-Ated Praseng —~ (0M0 Correct Solution oF “ ‘What doc the aeronym CAM sys fr? © “compnatinst Anime! Motion © Computse-Aikd Manfactring © Computer Accuraey Manfoetiing i Score: 100 Correct Solution . v Compile the sentence by typing your snswers inl the lextboxes ‘At the fotoryIevel, machining operations employing tw or more nuereallyconalod (NC) racine tools may use a 12 12emi frame computer thet controls several machine loos or an cuir shop. The sysiem is often referred toss ‘Today many Fecovies ae ipiementing exible manuf Gated eve eth Seon: 10rt0 Gonect Salution ~ a a ng systems (FMS), Which atthe fo ‘owing msortions ite FF FMSisancwoution of DNC TF PMsinan evolution of CAM $9 MS comiai of xevers NC ul proces $7 FMS stays for Fesbiliy Monutecturd System FF _ PMS stays for Plexble Manvfactoring System ‘Score: 1010 Gorreet Solution ‘Whatis telescopic balbar test? F-test for CNC machining contr evaluations test fOrNC fathe evalustion © test for CAM reliably Score: 1010 Correct Solution ‘ « ‘What doo the neronym CMM slays foe? © Computerized Machining Module © Coordinate Measuring Machine © Coordinate Measuring Module [Score: 1010 Correct Solut ‘Wat does.he acronysn EDM means? —lectscal Discharge Mechining © ClectrnieDevies Mamufkrng © Blectronie Discharge Machining 14 lAScore: 100 Correct Soliton : " : are ie most used materials for die-sinking EDM tool materials? ” - Ceramic Graphite igh spe see (TSS) . Conger aa413d4d Seore: 10/10 Correct Solution _ : REM (Blcttat €ovent Machtlng) ean papeies very shar carer Cav han 02 nu, ris) Tue © False | Score: 100 Conest Si _Simulvion models are ypically lssificd into Unee type Score: 10/10 to 5 x r . « » ‘Which ere the Uitee techniques used for inttigent manufacturing processes? © Neural network, Fuezy fogie and expert systert © Natural network, Funky Tie end export system © Neutral network, Fuzzy logic and exnert syste ‘Score: 100 Gowreet Selytion Complete the senlence by typing your answers inte the textboxes