Cold Working

Cold-working metal forming is performed at a temperature above the recrystallization

True
False
Score: 10/10 Correct Solution

Which are the main advantages of cold-working compared to hot-working?

No heating required
Lower forces required for deformation
No undesirable residual stresses
Better surface finish obtained
New Answer Improved strength properties
New Answer Lighter and less powerful equipment required
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Which are the main categories of cold-working processes?

Squeezing
Coating
Swaging
Forging
Bending
Shearing
Drawing
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In which form are the workpieces that will undergo a bending process?
Flat metal sheet
Metal strip
Metal bars with section diameter more than 40 mm
Brass bars of any size
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The most important factor when designing a part that has to be manufactured by bending is the
minimum radius that can be bent successfully without metal cracking.
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Shearing is the mechanical cutting of materials in sheet or plate form without the formation of
chips or use of burning or melting
True
False
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How can be calculated the necessary force to perform a shearing operation?

Multiplying the area of the cross section by the shear strength of the work material
Multiplying the area of the cross section by the shear strength of the work material and dividing by
the friction coefficient
Multiplying the area of the cross section by the friction coefficient and dividing by the shear
strength of the work material
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Blanking and piercing are two names for the same process
True
False
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Cold drawing can only be performed with metallic tools
True
False
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When is advisable to perform high-energy-rate forming (HERF)?

When the workpiece is considerably large
When the workpiece is made of a difficult to form metal
When the workpiece is considerably small
It does not exist such a process
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Hot Working

Select the hot-working metal forming processes among the following

Rolling
Forging
Shearing
Pearcing
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Hot-working metal forming processes are performed at a temperature just below the
recrystallization
True
False
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The necessary power for a rolling process to happen decreases for longer rolling strip contact
length
True
False
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Which of the following processes is not a type of forging

Open-die hammer
Swaging
Shearing
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Metals with lower yield strength are easier to extrude

True
False
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Which of the following assertions is/are correct

To extrude high yield strength metal no lubricant is needed
Aluminum is easier to extrude than steel
Steel is easier to extrude than Aluminum
The most common lubricant for extruding Aluminum is liquid nitrogen
Phosphate-based and molten glass lubricants are used to extrude steel
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In open-die forging, what is called the geometrical defect (in the finished workpiece) caused by
the friction between the dies and the workpiece? Barreling
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Sometimes it is necessary to use isothermal rolling. When?
When the material to be rolled is an thicker than 3.8 mm
When the material to be rolled is a high-strength metal thinner than 3.8 mm
It does not exist such a process
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Metal Casting
What are the names of the main casting processes?
Sand casting
Centrifugal casting
Permanent casting
Die casting
Film casting
Plaster-mold casting
Investment casting
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The cores for casting hollow workpieces are made of sand because it is more firm and resistant
to collapse than green sand.
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Which are the advantages for centrifugal casting?

Fine grain size
Tendency for the lighter nonmetallic inclusion, slag particles, and dross to segregate
toward the inner radius of the castings
High resistance to atmospheric corrosion of centrifugally cast pipes
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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 500 pieces
When custom made products (one of its kind) have to be produced
It is never profitable to use permanent-mold casting, it is a process that no longer is used in
modern industries
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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?
Up to 100,000 parts
Up to 5 part
Up to 50 parts
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In die casting the molten metal is forced into the mold.

True
False
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What is the factor that limits the size of the parts in die casting?
The capacity of the machine.
The material the mold is made of
There is no limitation for the size of the parts.
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Which are the advantages for die casting?

Large quantities of parts with close tolerances and smooth surface
Parts with small thickness
Impossible for gases to be entrapped
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Which are the other two names for investment casting?

Lost-wax casting
Film casting
Precision casting
Line casting
Grape casting
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Other Processes
Which of the following are plastic molding processes?
Injection molding
Extruding
Coinjection molding
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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.
True
False
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Powder metallurgy normally consists of four basic steps, name them in the right order.
1. Producing a fine metallic powder
2. Mixing and preparing the for powder use
3. pressing the powder into the desired shape
4. heating the shape at an elevated temperature
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Which are the three main categories of surface treatment?

Cleaning, coating and chemical conversion
Cleaning, coating and hardening
Coating, hardening and chemical conversion
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Traditional Machining

Material removal processes, also known as machining, remove material by mechanical, electrical,
laser, or chemical means to generate the desired shape and/or surface characteristic. Which of
the following assertions is/are true:
Machining is precise. It is capable of creating geometric configurations, tolerances, and
surface finishes that are often unobtainable by other methods.
Machining is not flexible. It is very difficult for one machine to make differently shaped parts.
Machining can be economical. Small lots and large quantities of parts can be relatively
inexpensively produced if matched to the proper machining process.
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Commonly used metal-cutting machine tools can be divided into three groups, depending on the
basic type of cutter used:
Single-point tools, multipoint tools and abrasive grits.
Single-point tools, rotating tools and abrasive grits.
Cutting tools, forming tools and abrasive grits.
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A big advantage with recirculating ballscrew is the effective stiffness ensured by the large contact
area between the balls and the thread.
True
False
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Industrial diamonds are now available in the form of polycrystalline compacts for the machining of
metals and plastics with greatly reduced cutting force, high hardness, good thermal conductivity,
small cutting-edge radius, and low friction. Which of the following assertions is/are true:
It is advisable to use diamond tools when machining carbon steel, titanium and nickel .
Shortcomings with diamond tools are brittleness, cost, and the tendency to interact
chemically with workpiece materials that form carbides.
Industrial diamond tools are still a science fiction feature, the technology to reproduce diamond
artificially does not exist yet.
Score: 10/10 Correct Solution

Which are the two important issues in selecting a cutting material?

Hardness and stiffness
Toughness and hardness
Toughness and stiffness
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A thin layer of TiC, TiN, or Al2O3 can be applied to HSS or carbide substrate. Why?
to improve resistance to abrasion, temperature
to improve tool toughness and hardness
to improve resistance to friction and chemical attacks
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Optimum speed and feed rate do not depend on tool and workpiece material, therefore there are
three sets of parameters recommended for any type of machining process: 120 m/min and 0,1
mm/rev (for fine machining); 210 m/min and 0,3 mm/rev (for hard machining); 150 m/min and 0,2
mm/rev (for average machining).
True
False
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The most widely used drill is the general-purpose twist drill, which has many variations. The flutes
on a twist drill are helical and are not designed for cutting but for removing chips from the hole.
True
False
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The optimal speed and feed for drilling depend on:

workpiece material
tool material
design of drill
tolerance
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In turning, how can the net horsepower required to remove material be estimated?
By multiplying the tangential force by the surface speed of the workpiece
By multiplying the radial force by the surface speed of the workpiece
By multiplying the tangential force by the feed rate and the length of the workpiece.
Score: 10/10 Correct Solution

Feed rate for most applications falls:

Between 0.13 and 0.51 mm/rev
Up to 0.013 mm/rev
Between 1.3 and 5.1 mm/rev
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Pair the right definition with the right name

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Sensors and computer control

A good taxonomy for sensors is provided by the requirements for different degrees of process
control, This taxonomy contains three classes:
Sensors used in regulatory feedback control loops.
Force sensors
Process analyzers.
Piezoelectric accelerometers
Product quality analyzers
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CNC systems consist of two functional types:

point to point
parallel path
contouring, or continuous path
orthogonal path
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Thermal deformation of the machine structure is a source of error in CNC systems. Which error
category does it belong to?
Cutting process effects
Controller and drive dynamics
Mechanical hardware deficiencies
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Stability
What does FRF stays for?
Frequently Referred Feed
Frequency Response Function
Frequency Referred Force
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In all of the material removal processes just described, the achievable material removal rate may
be limited by dynamic interactions between the cutting process and the structure of the machine-
tool-workpiece system (Tlusty 1985).The resulting vibrations between the tool and workpiece
cause excessive variations of the cutting force, resulting in poor surface quality and reduced life
of the cutting tool (Welboum 1970). The vibrations encountered can be classified in three broad
categories:
Free, Forced and self-excited vibrations
Free, Dependent and self-extracted vibrations
Forced, Dependent and self-excited vibrations
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Stability in cutting processes does not depend on cutting speed

True
False
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Structure change and consolidation

What is meant with Normalizing?
Normalizing is a heat-treating process that results in a relatively uniform steel
microstructure.
Normalizing is a casting process used to produce a special steel (so called Normalized steel)
Normalizing is a hot-working metal forming process used to produce a special steel (so called
normalized steel)
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Normalization treatments are performed for a variety of reasons:

Refines the dendritic grain structure remaining from casting
Eliminates severe texture (and hence anisotropic properties) that results from forging and
rolling operations
Reduces residual stresses
Improves the response of a steel to further processing, such as machining or surface
hardening
Improves mechanical properties by precipitating desirable phases
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What kind of diagram is usually useful when performing a normalization?

TTT curve (Time–temperature-transformation curve)
NT curve (Normalization Time curve)
NTT curve (Normalization-Temperature-Time curve)
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Laser surface hardening is used as an alternative to flame hardening and induction hardening
ferrous materials. Which of the following assumptions is/are true?
The rapid heating rate achievable by the laser minimizes part distortion and can impart
surface hardness to low-carbon steels.
The entire operation cannot be performed in air.
This process is used to harden selected areas of machine components, such as gears,
cylinders, bearings, and shafts.
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In shielded-metal arc welding, an arc is struck between the workpiece and a covered (or coated)
metal electrode. Which of the following assumptions is/are true?
Filler metal is provided by the consumable electrode.
Welds by this method are not very often of very high quality
The metallurgical properties of a weld depend greatly on the type of electrode and its
covering.
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What kind of power supplies are used for shielded-metal arc welding?
AC
DC
Combination AC/DC
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Where should the welds be located?

Away from areas of maximum stress.
Nearby areas of maximum stress.
Exactly on areas of maximum stress.
Score: 10/10 Correct Solution
Grinding
Grinding is often preferred to milling when the amount of metal to be removed is small and the
dimensional accuracy and surface finish are critical.
True
False
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Milling and grinding are frequently used in combination.

True
False
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Broaching is usually used for removing large amounts of material

True
False
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Which are the variants for external grinding?

Plain grinding
Traverse grinding
Centrifugal grinding
Plunge grinding
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Excessive heat is not a problem when grinding, therefore no lubricant is needed.

True
False
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Assambly
Generally, automatic assembly systems consist of three major components:
Chain system, Feed rating device and Parts handling/placing mechanisms.
Transfer system, Parts feeding device and Parts handling/placing mechanisms.
Belt device, Parts feeding device and Manual assembly benches.
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Approximately 80% of manufacturing cost is determined at the conceptual design stage. Design
for assembly (DFA) is crucial during early design.
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The basic activities associated with material handling are:

Moving, storing and counting material.
Moving, assembling and controlling material.
Moving, storing, and controlling material.
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CAD-introduction
What does the acronym DFM stays for?
Design for Modeling
Design for Manufacturing
Design for Maintenance
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Machining - introduction
What does the acronym CAD stays for?
Computer-Aided Design
Computational Animated Design
Computer-Aided Drawing
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What does the acronym CAM stays for?

Computational Animated Motion
Computer-Aided Manufacturing
Computer Accuracy Manufacturing
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At the factory level, machining operations employing two or more numerically controlled (NC)
machine tools may use a separate mainframe computer that controls several machine tools or an
entire shop. The system is often referred to as distributed numerical control.
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Today many factories are implementing flexible manufacturing systems (FMS). Which of the
following assertions is/are correct:
FMS is an evolution of DNC
FMS is an evolution of CAM
FMS consists of several NC unit processes
FMS stays for Flexibility Manufactured System
FMS stays for Flexible Manufacturing System
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Metrology & precision

What is a telescopic ball-bar test?
test for CNC machining center evaluations
test for NC lathe evaluation
test for CAM reliability
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What does the acronym CMM stays for?

Computerized Machining Module
Coordinate Measuring Machine
Coordinate Measuring Module
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Non-traditional machining
What does the acronym EDM means?
Electrical Discharge Machining
Electronic Device Manufacturing
Electronic Discharge Machining
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Which are the most used materials for die-sinking EDM tool materials?
Ceramic
Graphite
Diamond
High speed steel (HSS)
Copper
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ECM (Electrical Chemical Machining) can produce very sharp corners (less than 0.02 mm,
radius)
True
False
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Planning and simulation

Simulation models are typically classified into three types:
discrete event
continuous
combined
systematic
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Which are the three techniques used for intelligent manufacturing processes?
Neural network, Fuzzy logic and expert system
Natural network, Funky logic and export system
Neutral network, Fuzzy logic and expert system
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Quality systems
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In contrast to quality engineering, the total quality management embraces the entire product
realization process. Its objective should be to maximize the net value of the product to society,
which includes buyer, seller, and the rest of society
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Rapid prototype
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With Rapid prototype shapes of machine parts are created by building up layers and layers of
materials, unlike the material-removal technique which shapes by gradual machining using a
cutting tool
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For rapid prototyping to be carried out, three-dimensional CAD data is not necessary.
True
False
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