ME 324 Jeopardy

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1 Mat. Prop
A

2 Surfaces

3 Machining

4 Adv. Mach

100 200 300 400 500

100 200 300 400 500

100 200 300 400 500

100 200 300 400 500

D - Casting Which process starts with a material that is in a fluid or semi-fluid state and solidifies the material in a cavity:
A. B. C. D.

Forging Machining Turning Casting

A,1

TRUE Is this statement TRUE OR FALSE? Surface roughness is defined as the average value of the vertical deviations from the nominal surface over a specified surface length

A,2

TRUE Is this statement TRUE OR FALSE? Costs tend to increase when better surface finish is required because finishing processes must be included in the manufacturing sequence.

A,3

D All of the above

Which of the following is true about the importance of nontraditional material removal processes?
A.

B. C.

D.

The need to shape new metal alloys and nonmetals that are difficult to machine by conventional processes The requirement of unusual and complex workpart geometries The need to avoid surface damage which is often associated with conventional machining All of the above

A,4

A Screw Dislocation

Which is not a point defect in a crystal lattice structure:

A. B. C. D.

Screw dislocation Interstitialcy Schottky defect Vacancy

B,1

C - Total permissible variation from a specified dimension

Which statement is the best description of tolerance?

A. B. C. D.

Clearance between a shaft and a mating hole Measurement error Total permissible variation from a specified dimension Variation in manufacturing

B,2

B - Cubic boron nitride

Which of the following materials has the highest hardness:

A. B. C. D.

Aluminum oxide Cubic boron nitride High-speed steel Titanium carbide

B,3

D - Superfinishing

Which one of the following abrasive processes achieves the best surface finish:
A. B. C. D.

Centerless grinding Honing Lapping Superfinishing

B,4

C - Maximum load divided by the original area of the specimen

Which one of the following is the correct definition of ultimate tensile strength
A.

B. C. D.

Stress encountered when the stressstrain curve transforms from elastic to plastic behavior Maximum load divided by the final area of the specimen Maximum load divided by the original area of the specimen Stress observed when the specimen finally fails

C,1

A - Cracks

Thermal energy is NOT normally associated with one of these changes in the altered layer.
A. B. C. D.

Cracks Hardness variations Heat affected zone Recrystallization

C,2

D Tool life

Which one of the following is the most important method for testing machinability :
A. B. C. D.

Cutting forces Cutting temperature Horsepower consumed in the operation Tool life

C,3

B Etch Factor = d/u

Etch factor is equal to which of the following in chemical machining A = Area of electrode, C = specific removal rate, d = depth of cut, I = current, t = time, and u = undercut :
A. B. C. D.

CIt d/u u/d CI/A

C,4

B - Mechanism of plastic deformation

Twinning is which of the following

A. B. C. D.

Elastic deformation Mechanism of plastic deformation Slip mechanism Type of dislocation

D,1

A 100% (if PCI =1, then T = 6 = 99.73%)

If the product tolerance is set so that the process capability index = 1.0, then the percentage of parts that are within tolerance will be closest to which one of the following when the process is operating in statistical control:
A. B. C. D.

100% 65% 95% 99%

D,2

Chip thickness ratio r = to/tc = 0.30/0.65 = 0.4615

In an orthogonal cutting operation, the tool has a rake angle = 15. The chip thickness before the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate the chip thickness ratio.

D,3

C - Electric Discharge Machining

Which one of the following processes would be appropriate to drill a hole with a square cross section, 0.25 inch on a side and 1inch deep in a steel workpiece:
A. B. C. D.

Abrasive jet machining Chemical milling Electric Discharge Machining Electric Discharge Wire Cutting

D,4

The flow curve equation is: = 492.7 0.28

In a tensile test a metal begins to neck at a true strain = 0.28 with a corresponding true stress = 345.0 MPa. Without knowing any more about the test, estimate the strength coefficient and the strainhardening exponent in the flow curve equation.

E,1

PC = 3 = 6.255 3(0.004) = 6.255 0.012 cm

An automatic turning process is set up to produce parts with a mean diameter = 6.255 cm. The process is in statistical control and the output is normally distributed with a standard deviation = 0.004 cm. Determine the process capability.

E,2

Cutting time, Tm = L/fr = 700/1.17 = 598 s = 9.96 min

A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an engine lathe. Cutting speed = 2.30 m/s, feed rate = 1.17 mm/s, and depth of cut = 1.80 mm. Determine the cutting time.

E,3

TRUE Is this statement TRUE OR FALSE? In a certain grinding operation, the grade of the grinding wheel should be M (medium), but the only available wheel is grade T (hard). The wheel can be made to appear softer by increasing the force on the individual grits.

E,4