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MACHINE DESIGN

MANUFACTURING
PROCESSES AND METALS
PART 5
ES MECHANICAL ENGINEERING REVIEW

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


1
MEMBERS
1. A third type of primary bond is the:
A. Metallic bond
B. Covalent bond
C. lonic bond
D. Wooden bond

The answer is: A

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2
MEMBERS
2. The appearance of more than one type of cystal
structure is known as:
A. Allotropism
B. Polymorphism
C. A and B
D. None of these

The answer is: C


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3
MEMBERS
3. Metal structures that are not single crystals is
known as:
A. Grain boundaries
B. Edge and screw
C. Work hardening or strain hardening
D. Polycrystals

The answer is: D

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4
MEMBERS
4. Recrystallization is a function of time because it
involves which is the movement and exchange of atoms
across grain boundaries.
A. Recrystallization
B. Grain growth
C. Diffusion
D. Orange peel

The answer is: C

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5
MEMBERS
5. As the load is further increased, the engineering stress
eventually reaches a maximum and then begins to
decrease. The maximum engineering stress is called:
A. Ultimate tensile strength
B. Engineering stress or nominal stress
C. Yield stress
D. Proportional limit

The answer is: A

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6
MEMBERS
6. For brittle materials such as ceramics and glasses, a
______ has been developed, in which the disk is
subjected to compression between two hardened flat
platens.
A. Śtrain softening or work softening
B. Disk test
C. Seamless tubing
D. Torsion test
The answer is: B

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7
MEMBERS
7. The part fails at a stress level below that at which
failure would occur under static loading.
A. Hot hardness
B. Cyclic stress
C. Fatigue failure
D. Stress amplitude

The answer is: C

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8
MEMBERS
8. An example of accelerated strain aging in steels is:
A. Strain aging
B. Mechanical fibering
C. Strain aging
D. Blue brittleness

The answer is: D

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9
MEMBERS
9. Residual stress can be reduced or eliminated by
A. Oxygen
B. Warping of parts
C. Temperature gradient
D. Stress-relief annealing

The answer is: D

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10
MEMBERS
10. Thermal stresses may be caused both by
temperature gradient and by______
A. Shrink fits
B. Thermal fatigue
C. Thermal shock
D. Anisotropy of thermal expansion

The answer is: D

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11
MEMBERS
11. Two dissimilar metals may form a galvanic cell that is,
two electrodes in an electrolyte in a corrosive
environment including moisture.
A. Intergranular corrosion
B. Crevice corrosion
C. Galvanic corrosion
D. Stress-corrosion cracking

The answer is: C

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12
MEMBERS
12. Is relatively soft and ductile; it is magnetic from room
temperature to 768°C, this temperature is known as:
A. Alpha ferrite
B. Curie temperature
C. Hypoeutictoid
D. Delta ferrite

The answer is: B

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13
MEMBERS
13. Is obtained by annealing white cast iron in an
atmosphere of carbon monoxide and carbon at between
800°C and 900°C, for up to several hours, depending on
the size of the part.
A. Nodular Iron
B. White Cast Iron
C. Malleable Iron
D. Ferritic malleable iron
The answer is: C

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14
MEMBERS
14. Martensite is tempered in order to improve its:
A. Retained austenite
B. Mechanical properties
C. Tempering
D. Hardenability

The answer is: B

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15
MEMBERS
15. If carried out above room temperature, the process is
called:
A. Artificial aging
B. Natural aging
C. Cryogenic treatment
D. Maraging

The answer is: A

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16
MEMBERS
16. Metal part is placed in copper induction coils and is
heated by high frequency current, then quenches.
A. Flame hardening
B. . Induction hardening
C. Decarburization
D. Annealing

The answer is: B

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17
MEMBERS
17. Dry, fine, and loose solid particles, usually aluminum
oxide, are heated and suspended in a chamber by an
upward flow of hot gas at various speeds. The parts to be
heat treated are then placed within the floating particles.
A. Continuous furnaces
B. Salt-bath furnace
C. Fluidized beds
D. Induction heating
The answer is: C

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18
MEMBERS
18. The limestone reacts chemically with impurities,
acting like a
A. Flux
B. To flow as fluid
C. Fuel for plant operations
D. Slag

The answer is: A

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19
MEMBERS
19. For smaller quantities, electric furnaces can be of the
A. Open-heart
B. Electric
C. Basic oxygen
D. Induction type

The answer is: D

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20
MEMBERS
20. Deoxidizes steels, improves toughness, and may
improve formability and machinability.
A. Boron
B. Calcium
C. Carbon
D. Cerium

The answer is: B

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21
MEMBERS
21. Improvos stronath, hardness, and machinability: in
aluminum-dooxidized stools, it controls the size of
Inclusions and improvos strength and toughness; it
decreases ductility and toughness.
A. Hydrogen
B. Nitrogen
C. Oxygon
D. Tin
The answer is: B

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22
MEMBERS
22. The minimum chromium content of stainless stoor
should be:
A. 10 to 11 % by weight
B. 10 to 12% by weight
C. 10 to 13% by weight
D. 10 to 14% by weight

The answer is: B

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23
MEMBERS
23. Have higher resistance to both corrosion and stress
corrosion cracking than do the 300 series of austenitic
steels.
A. Austenitic stainless steels
B. Ferritic stainless steel
C. Martensitic stainless steels
D. Duplex structure stainless steels

The answer is: D

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24
MEMBERS
24. High strength to weight ratio; high thermal and
electrical conductivity; good corrosion resistance; good
manufacturing properties.
A. Nonferrous metals and alloys
B. Aluminum
C. Magnesium
D. Copper

The answer is: B

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25
MEMBERS
25. Metal comes from sea water.
A. Porous Aluminum
B. Magnesium
C. Copper
D. Brass

The answer is: B

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26
MEMBERS
26. A more recent technique for processing copper is a
process involving chemical and electrolytic reactions.
A. Pyrometallurgy
B. Hydrometallurgy
C. Technometallurgy
D. Evaporametallurgy

The answer is: B

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27
MEMBERS
27. An alloy of nickel, chromium and iron.
A. Nichrome
B. Sulfide and Oxide ores
C. Supperalloys
D. Monel K-500

The answer is: A

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28
MEMBERS
28. Typical applications of molybdenum are in:
A. Solid-propellant rockets
B. jet engines
C. honeycomb structures
D. All of these

The answer is: D

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29
MEMBERS
29. Is silvery in appearance, it has good strength and
ductility at elevated temperatures, and it has good
corrosion resistance because of an adherent oxide film.
A. Unalloyed Berylium x
B. Zirconium
C. Lead
D. Zina

The answer is: B

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30
MEMBERS
30. The most important tin mineral is;
A. Cassiterite
B. Pewter
C. Gold, silver and platinum
D. Gold

The answer is: A

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31
MEMBERS
31. The earliest synthetic polymer was
phenolformaldehyde, a thermoset develop in 1906 and
called
A. Plastics
B. Polymer
C. Cellulose
D. Bakelite

The answer is: D

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32
MEMBERS
32. The brittle behaviour of amorphous polymers below
their glass-transition temperature can be reduced by
blending them, usually with small quantities of an:
A. Amorphous
B. Crystallites
C. Crystallization shrinkage
D. Elastomer

The answer is: D

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33
MEMBERS
33. Has a wide range properties, is inexpensive and
water-resistant, and can be made rigid or flexible.
A. Polypropylenes
B. Polystyrenes
C. Polysulfones
D. Polyvinyl chloride

The answer is: D

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34
MEMBERS
34. Alumina is also called:
A. Corundum or emery
B. Flint
C. Feldspar
D. Alumina

The answer is: A

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35
MEMBERS
35. Crystalline form of carbon; high electrical and thermal
conductivity, good thermal shock resistance.
A. Silica
B. Glasses
C. Glass ceramics
D. Graphite

The answer is: D

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36
MEMBERS
36. We define a glass as an inorganic product of fusion
that has cooled to a rigid condition without crystallizing.
A. Glass
B. Silica
C. Lampback
D. Bukyballs

The answer is: A

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37
MEMBERS
37. Is a vertical distance channel through which the
molten metal flows downward in the mold.
A. Pyrolysis
B. Kelvar
C. Gating system
D. Sprue

The answer is: D

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38
MEMBERS
38. The temperatures for graphitizing:
A. 1300°C
B. 1400°C
C. 1500°C
D. 1600°C

The answer is: C

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39
MEMBERS
39. Are typically used in military and commercial aircraft
and in rocket components, helicopter blades. automobile
bodies, leaf springs, drive shaft.
A. Formica
B. Epoxies
C. Reinforced plastics
D. Ceramic matrix

The answer is: C

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40
MEMBERS
40. Serve as reservoirs to supply the molten metal
necessary to prevent shrinkage during solidification.
A. Sprue
B. runners
C. gates
D. risers

The answer is: D

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41
MEMBERS
41. Most sand casting operations use:
A. Silica sand
B. Collapsibility
C. Mulling machine
D. Bentonite

The answer is: D

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42
MEMBERS
42. Patterns are usually coated with a
A. Parting agent
B. Split patterns
C. One-piece pattern
D. Match-plate patterns

The answer is: A

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43
MEMBERS
43. The mold is made of plaster of paris, with the addition
of talc and silica flour to improve strength and to control
the time required for the plaster to set.
A. Shell-mold casting
B. Composite molds
C. Rammed graphite molding
D. Plaster-mold casting

The answer is: D


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44
MEMBERS
44. Hot rolled round rods are used as the starting
material for rod and wire drawing called:
A. Wire rods
B. Cold rolling
C. Pack rolling
D. Skin pass

The answer is: A


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45
MEMBERS
45. Internal thread rolling can be carried out with a
fluteless.
A. Ring-rolling
B. Thread rolling
C. Forming tap
D. Rotary tube piercing

The answer is: C


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46
MEMBERS
46. It is gathered into a localized area.
A. Impression-die forging
B. Flash
C. Fullering
D. Edging

The answer is: D


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47
MEMBERS
47. The internal diameter and/or the thickness of
the tube can be controlled with or without the use
of internal mandrels.
A. Tube swaging
B. Parting line
C. Draft angles
D. Forgeability
The answer is: A
EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
48
MEMBERS
48. The billet is smaller in diameter than the chamber,
which is filled with a fluid, and the pressure is transmitted
to the billet by a ram.
A. Drawing
B. Indirect extrusion
C. Hydrostatic extrusion
D. Lateral or side extrusion

The answer is: C


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49
MEMBERS
49. Is the mechanical cutting of materials without the
formation of chips or the use of burning or melting.
A. Burr
B. Punching
C. Shearing
D. Blanking

The answer is: C


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50
MEMBERS
50. Is a punch and die operation used to separate
a stamping or other product from a strip of stock.
A. Nibbling
B. Shaving
C. Cutoff
D. Dinking

The answer is: C


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51
MEMBERS
51. is the length of the neutral axis in the
bend and is used to determine the blank
length for the bent part.
A. Stretch forming
B. Anisotropy
C. Forming-limit diagram
D. Bend allowance
The answer is: D
EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
52
MEMBERS
52. Containers or shells that are too difficult to draw in
one operation generally undergo
A. Drawbeads
B. Ironing
C. Redrawing
D. Embossing

The answer is: C


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53
MEMBERS
53. The source of energy is a spark between electrodes
connected by a thin wire.
A. Laser-assisted forming
B. Electrohydraulic forming
C. Honeycomb structure
D. Dents

The answer is: B


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54
MEMBERS
54. The die is filled with metal powder by gravity,
and the powder is sintered directly in the die.
A. Pressureless compaction
B. Sintering
C. Coining and sizing
D. Impact forging

The answer is: A


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55
MEMBERS
55. Is use to make hollow thin-walled glass iterns.
such as bottles and flasks.
A. Blowing
B. Pressing
C. Spinning
D. Sagging

The answer is: A


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56
MEMBERS
56. Cutting processes remove material from the
surface of a workpiece by producing
A. Chips
B. Cutting-off
C. Slab-milling
D. Chip compression ratio

The answer is: A


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57
MEMBERS
57. Temperatures and their distribution in the
cutting zone may be determine from
A. Shaving
B. Dynamometers or force transducers
C. Mean temperature
D. Thermocouples

The answer is: D


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58
MEMBERS
58. A disposable or throwaway inserts.
A. Tool steels
B. Diamond grinding
C. Chip groove
D. Carbide inserts

The answer is: D


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59
MEMBERS
58. A disposable or throwaway inserts.
A. Tool steels
B. Diamond grinding
C. Chip groove
D. Carbide inserts

The answer is: D


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60
MEMBERS
59. High hardness over a wide range of
temperatures high elastic modulus of and thermal
conductivity, and low thermal expansion.
A. Carbide
B. cemented of sintered carbide
C. A and B
D. NONE of these

The answer is: C


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61
MEMBERS
60. Means that the part is rotating while it is being
machined.
A. Turning
B. Facing
C. Form tools
D. Boring

The answer is: A


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62
MEMBERS
61. Affects chip formation, tool strength, and
cutting forces to various degrees.
A. Rake angles
B. Back rake angle
C. Relief angles
D. Cutting-edge angles

The answer is: D


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63
MEMBERS
62. Generally have geared-scroll design that makes the
jaws self-centering; they are used for round workpieces,
such as bar stock, pipes and tubing which can be
centered to within 0.025 mm.
A. Three-jaw chuck
B. Four-jaw chuck
C. Power chucks
D. Collet chuck

The answer is: A


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
64
MEMBERS
63. May be defined as a ridge of uniform crosssection
that follows a helical or spiral path on the outside or
inside of the cylindrical surfaces.
A. Screw thread
B. Tapered threads
C. Tapping
D. Solid threading dies

The answer is: A


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65
MEMBERS
64. Provides an enlarged cylindrical hole with a flat
bottom so that a bolt head, or a nut, will have a
smooth bearing surface that is normal to the axis of
the hole.
A. Counterboring
B. Countersinking
C. Spot facing
D. Reaming
The answer is: D
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66
MEMBERS
65. Has smooth cutting edges.
A. Finishing reamers
В. Тар
C. Tapered taps
D. Bottoming taps

The answer is: A


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67
MEMBERS
66. The cutter is mounted on a spindle having an
axis of rotation perpendicular to the workpiece
surface.
A. Slab milling or peripheral milling
B. Conventional milling or up milling
C. Climb milling or down milling
D. Face milling

The answer is: D


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
68
MEMBERS
67. Cutting speed of planners can range up with
capacitios up to 110 KW.
A 120m/min
B.130 m/min
C. 140 m/min
D. 150 m/min

The answer is: A


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69
MEMBERS
68. Have straight blades and reciprocating motions
A. Tooth set
B. Smagging
C. Hacksaws
D. Circular saw

The answer is: C


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70
MEMBERS
69. Components are being used in advanced
machine tools for their strength, stiffness, corrosion
resistance, surface finish, and good thermal
stability.
A. Gray iron
B. Polymer concrete
C. Ceramic
D. Composites
The answer is: B
EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
71
MEMBERS
70. Vitrified bond is also known as ______.
A. Grit number
B. Vetrifled, resinoid, rubber and metal
C. Ceramic bond
D. Resineid

The answer is: C


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72
MEMBERS
71. Is when the porosities on the grinding surface of the
wheel becomes filled or clogged with chips.
A. Grinding wheel
B. Attritious wear
C. Dressing
D. Loading

The answer is: D


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73
MEMBERS
72. Centerless grinders are now capable of wheel
surface speeds on the order of ______ using cubic
boron nitride abrasive wheels.
A. 8,000 m/min
B. 9,000 m/min
C. 10,000 m/min
D. 11,000 m/min
The answer is: C
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74
MEMBERS
73. Typical examples of coated abrasives are:
A. Sandpaper and emery cloth
B. Belt grinding
C. Wire brushing process
D. Honing

The answer is: A


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75
MEMBERS
74. Chemical milling has been used on a wide variety of
metals, with depths of metal removal as large as:
A. 10 mm
B. 11 mm
C. 12 mm
D. 13 mm

The answer is: C


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76
MEMBERS
75. Are used to rapidly cut ferrous and Mion-ferrous
sheets and plates.
A. Plasma-arc cutting
B. Abrasive water-jet machining
C. Abrasive-jet machining
D. Nanofabrication

The answer is: A


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77
MEMBERS
76. The process involves olther a consumable or non-
consumable electrodo.
A. Filler materials
B. Pressure gas welding
C. Arc welding
D. Sheilded metal-arc welding

The answer is: C


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78
MEMBERS
77. Electrodes are coated with claylike materials that
include silicate binders and powdered materials such as.
A. Oxides
B. carbonates
C. fluorides, metal alloys and cellulose
D. All of these

The answer is: D


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79
MEMBERS
78. This is a new process originally intended for welding
of aerospace alloys, especially aluminum extrusions,
although current research is being directed at extending
this process towards polymers and composite materials.
A. Friction Stir welding
B. Resistance welding
C. Resistance spot welding
D. Spot welding
The answer is: A
EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
80
MEMBERS
79. Is a surface discontinuity usually caused by poor
welding practice are longitudinal and by the selection of
improper materials.
A. Weld profile
B. Undercutting
C. Overlap
D. Cracks

The answer is: C


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81
MEMBERS
80. The source of heat in in Induction heating by high-
frequency AC current
A. Furnace brazing
B. Induction brazing
C. Resistance brazing
D. Dip brazing

The answer is: B


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82
MEMBERS
81. Has been a common method of joining and assembly
in such applications as labeling, packaging, book-binding,
homo furnishing and footwear.
A. Copper and gold
B. Aluminum and stainless steels
C. Adhesive bonding
D. Natural adhesive

The answer is: C


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83
MEMBERS
82. Is based on a difference between the thermal
contractions of two components.
A. Crimping
B. Snap-In fasteners
C. Shrink and Press Fits
D. Ultrasonic welding

The answer is: C


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84
MEMBERS
83. A test that has gained wide acceptance, particularly
for bulk deformation processes is:
A. Ultrasonic vibrations
B. Forces or dimensional changes
C. Ring compression test
D. Wear

The answer is: C


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85
MEMBERS
84. The workpiece surface is hit repeatedly with a large
number of cast steel, glass, or ceramic shot, which make
overlapping indentions on the surface.
A. Molybdenum Disulfide
B. Oxalate
C. Shot peening
D. Laser peening

The answer is: C


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86
MEMBERS
85. Is a process in which an alloying element is diffused
into the surface of the substrate, thus altering its process.
A. Chemical vapour deposition
B. Ion implant
C. Diffusion coating
D. Electroplating

The answer is: C


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87
MEMBERS
86. Is a commonly-used separation technique and results
in very straight edges, with minimal chipping and cracking
damage.
A. Etching
B. Planarization
D. Diamond sawing
D. All of these

The answer is: D


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88
MEMBERS
87. In steel are usually considered to be the metallic
elements added for the purpose of modifying the
properties.
A. Age hardening
B. Artificial aging
C. Alloy
D. Alloying element

The answer is: D


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89
MEMBERS
88. Have the same structure at all points.
A. Free Carbon
B. Hard Drawn
C. Homogeneous Material
D. Izod test

The answer is: C


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90
MEMBERS
89. Is incompletely deoxidized steel.
A. Red Shortness
B. Relaxation
C. Residual Stress
D. Rimmed Steel

The answer is: D


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91
MEMBERS
90. Is the heating of an iron-base alloy to some 100°F
above the transformation range with subsequent cooling
to below that range in still air at room temperature.
A. Graphitizing
B. Hardening
C. Malleabilizing
D. Normalizing

The answer is: D


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92
MEMBERS
91. Load of 100 kg with 1/8 inch ball for soft metals such
as bearing metals and magnesium.
A. Rockwell B
B. Rockwell C
C. Rockwell A
D. Rockwell E

The answer is: D


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93
MEMBERS
92. Chromium steels with Low Chromium
A. 51XX
B. 52XX
C. 53XX
D. 54XX

The answer is: A


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
94
MEMBERS
93. Nickel 1.65% - molybdenum 0.25%
A. 46XX
B. 48XX
C. 50XX
D. 51XX

The answer is: A


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
95
MEMBERS
94. Medium Carbon Alloy Steels
A. 0.10 - 0.25%C
B. 0.25 -0.50%C
C. 250 and 400 Brinell
D. 0.50 - 0.70%C or more

The answer is: B


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
96
MEMBERS
95. Strengthens low-alloy steels and improve resistance
to high temperature oxidation.
A. Nickel
B. Selenium
C. Silicon
D. Tantalum

The answer is: C


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
97
MEMBERS
96. For gears, splinted shafts, and tools, miscellaneous
heavy duty machine parts.
A. AISI4063
B. AISI 4130,4140 *
C. AISI 4340
D. AISI 4640

The answer is: CD

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98
MEMBERS
97. Is a process of case hardening steel by the
simultaneous absorption of carbon and nitrogen from a
surrounding hot gaseous atmosphere, followed by either
quenching or slow cooling, as required.
A. Carbonitriding
B. Induction Hardening
C. Flame Hardening
D. Work Hardening

The answer is: A


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99
MEMBERS
98. Is also called ductile iron, has the cast ability of gray
iron, but higher strength and ductility,
A. Nodular cast iron
B. Malleable iron
C. Wrought Iron
D. Chilled iron

The answer is: A

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


100
MEMBERS
99. An alloy of copper and zinc
A. Brass
B. Bronze
C. Manganese. Bronze.
D. Lead

The answer is: A

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


101
MEMBERS
100. Has a tin base and is a general purpose beaning
material, also used for die-castings.
A. Titanium
B. Babbit B23-46T
C. Babbit23-49
D. Hastelloy B

The answer is: C

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


102
MEMBERS

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