What are the three cutting conditions that a machinist must consider before operating?
Speed (RPM), feed, depth of cut
100
What is the difference between a thermoset and a thermoplastic?
TS = cannot be reheated and reshaped... TP = can be reheated and reshaped
100
What are the three modes by which a cutting tool can fail?
Temperature failure, fracture failure, gradual wear
100
What are the four bulk deformation processes that we discussed in class?
Forging, Drawing, Rolling, Extrusion
200
Name all the necessary PPE/safety equipment that a foundry-man must have before performing a metal casting operation.
Full PPE gear includes: safety glasses, face shield, protective leggings, gloves, jacket, and apron... Ventilation and brick flooring
200
What are rough cuts and finish cuts used for?
Roughing is used to machine off a significant amount of material very quickly... Finishing is used to finish the part and achieve the desired dimensions with a smooth surface finish
200
What is the primary source of silica in glassworking?
Silica is most commonly derived from natural quartz in sand
200
What are the three most important properties that a tool material must have?
Toughness, hot hardness, wear resistance
200
List at least three types of rolling processes that we discussed in class.
Thread rolling, gear rolling, ring rolling, roll piercing
300
What does it mean if an alloy is eutectic?
A eutectic alloy is an alloy composition that has one single melting/freezing temperature... Eutectic alloys are much easier to cast with than non-eutectic alloys
300
What is the difference between up milling and down milling?
Up milling = against the feed (up river)... down milling = with the feed (down river)
300
List at least two shaping processes in glassworking piece ware that we discussed in class.
Extrusion is a compression process in which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape.
400
What are chills used for in the casting process?
Chills are used for directional solidification (which helps reduce damage caused by inconsistent solidification)
400
What is the difference between forming shape and generating shape?
Forming = shape of part is created by geometry of tool.... Generating = shape of part is created by trajectory of tool
400
Describe the injection molding process for plastics.
Injection molding is a process in which a polymer is heated to a highly plastic state and forced to flow under high pressure into a mold cavity, where it solidifies.
400
List and explain at least two reasons why cutting fluids are used in a machining operation?
Heat reduction, friction reduction, washing away chips, reducing work part temperature for handling, reducing cutting forces and power requirements, improving dimensional stability, improving surface finish
400
What is the difference between the drawing process of bulk deformation and the drawing process of sheet metalworking?
Sheet-metalworking drawing = used to make cup-shaped, box-shaped, or other complex-curved and concave parts...
Bulk deformation drawing = the cross section of a bar, rod, or wire is reduced by pulling it through a die opening
500
List and explain two ways in which a foundry-man can combat against metal shrinkage
Oversized pattern, riser, chills
500
List at least 5 turning operations that we discussed in class.