fF
MAE272 Midterm 2 KEY
***USE TALLY SYSTEM
COLOR CODING KEY:
● 100% CORRECT
● 75% CORRECT/GUESS
● FOR SURE WRONG
Fine versus conventional blanking:
● fine blanking requires more
precise, expensive tooling
Flange in sheet metal can
be produced:
● All are correct
Lost-foam casting is:
● using expandable molds
and patterns
cCold forming of metals is done at
● T/Tm just below 0.3 (I)
Magnetic pulse forming:
● can form thin sheets
without noise and heat
The threaded base (socket) of
a light bulb can be
prspringoduced cost-effectively
by:
● None is correct **discord**
Springback in sheet metal
forming is a function of:
● All are correct
In sheet metal forming, springback
can be controlled by:
● All are correct (I)
To produce 2-piece aluminum
beer and soda cans, which
process is
● Welding (I)
●
not required:
High temperature gas
turbine blades can be
produced by:
● Single crystal casting (chegg)
PM distinguishes from
conventional metals because of:
● All correct (II)
●
What is the difference between
AA 6061-T4 and AA 6061-T6?
T6 is naturally aged, T4 is furnace aged
then work-hardened.
Which process is not required
to produce 3-piece welded
cans
● Deep Drawing)
The frame of an off-the-shelf
beach cruiser bicycle is usually
made from:
● Drawn or extruded
Which is investment casting:
● wax pattern is melted out
for recycyling before pouring
(chegg)(III) also book pg 300
Large rings can be produced
by cost-effectively by:
● Ring rolling (II)
Travelers are
● updated cost estimates
after receiving P.O.
Nesting in sheet metal
manufacturing is:supe
● to reduce material
usage, energy and
tooling costs
(chegg)
● can have percent
Superplastic materials:
elongations up to
1000%
**correct answer from
discord**
Minimum bending radius:
● depends on the
hardness and rolling
direction of the
metal before bending
(chegg)
A rectangular keyway in a
round shaft can be produced
by:
● None is correct (chegg)
An open riser helps:
● reduce porosity, thus
should not solidify before the
casting (chegg; III)
Anisotropy in sheet metals ● can cause dog-ears and non-uniform wall
thickness in
deep drawing (Pg 398; II)
Engine blocks for V-6 hybrid
engines can be produced in
large quantity by:
● No answer is correct
(chegg)(I)
Temperature built up during
machining:
● Will shorten tool life (II)
Continuous casting of metals:
● None of the answers is
correct
Knurling performed on a round shaft
● All are correct (I)
Which are traditional
joining processes?
● All but water jet? (II)
Minimum bend radius for
AA 7075-O is:
● 0 (page 403) (I)
Centrifugal forces can be used to
● Cast hollow and solid objects
spin casting uses interia forces
to produce
● Ferrous and non-ferrous
Risers help
● None of the above (I)
Casting can be used to:
● Manufacture high-volume
production parts (Chegg)F
In sheet metal fab, anisotropy can:
● cause variations of
properties in different
directions (chegg; II)
Superalloy and nickel-based alloys...
● vacuum casting using ceramic
molds (chegg)
Cam shafts in a 16-valve
4-cylinder engine can be
turned on:
● High speed CNC machining
centers
Engine hoods, fenders, boot
lids, etc., of mid-size SUVs are
usually:
● Stretched formed and/ or deep
drdrawawn
Progressive dies are
preferred over compound
dies due to:
● Simpler design and low
maintenance cost (I)
toleranc
Tolerances will vary less
during production due to:
● Raw
By agreement, sheet metals
are defined as such:
● Less than 5 in thick plates
● when one dimension is less than
2.5 mm, and much smaller the
other two (chegg) ( i dont think
this is correct. Cause it says
less than 6mm everywhere)
EDM can produce very large
parts with cycle time 60-90
pieces/min that are:
none of the following
too expensive to sand cast
materials consistency
Hardness increase during
machining can:
● All are correct ?(I)
Sand casting of metals is:
● None of the answers is correct
(chegg) idk....
Draw beads used are used
occasionally:
● in deep drawing to control metal
flow and flange forming
Vickers (HV) is:
● None is correct
In sheet metal fabrication,
minimum bending radius for
AA 6061-0 is:
●0
●
In the production of
2-piece aluminum cans,
the lid is
connected to the can body by:
● Seaming and sealing (III)
Rubber forming or hydroforming
of sheet metals can be of cost
advantage due to:
● Low tooling cost (I)
In rolling, spreading should
be avoided by:
● reducing
Cold forming of metals is done at:
Sand casting of metals is:
Hot rolling of metals can produce:
An estimate for job cost as
per customer's RfQ should
include:
Progressive dies are preferred
over compound dies due to:
the reduction
in thickness (bite)
● T/Tm
just below 0.3 (chegg)
● None of the above (I)
● All answers are correct (III)
● All are correct (chegg)
extremely high production rates
(chegg) 2 upvotes on chegg
**also
Friction in manufacturing should
be reduced or eliminated except:
High temperature gas turbine
blades can be produced by
in book pg 391** (II) In rolling or
friction welding (I)
single crystal casting
Tolerances will vary less during
production due to :
Consistent raw material properties (II)
Hot rolling of metals can produce:
All answers are correct (I)
Which of the following
processes is not required to
produce 3-piece welded steel
cans:
Ironing in multiple operations (if
deep drawing isn’t an option) (I)
Flange in sheet metal can
be produced:
All are correct (today’s lecture)
Not a heat treatment process:
furnace brazing (chegg)
Connecting rods in internal
combustion engines are:
designed to convert a linear
motion into angular one
(master sheet)
Hydro and rubber forming can:
Super plastic forming requires
Risers in casting help
Climb milling is:
preferred for slender parts due
to the downward forces (master
sheet)
Router or traveler is
Document which lists sequence of
operations (interned as a tooling
engineer
and am pretty sure this is right)
Which is called the
lost-wax casting:
Casting using a sand mold is:
Grocery and trash bags are
most cost effective when
produced by:
Extrusion and blown-film
Quality products such as
aluminum foils are best
produced by:
MAE272 Midterm 3
***USE TALLY SYSTEM
COLOR CODING KEY:
● 100% CORRECT
● 75% CORRECT/GUESS or YESSSIIIIRRRR
● FOR SURE WRONG
Friction in manufacturing
should be reduced or
eliminated except:
In rolling or friction welding Exam
2 Confirmed on chegg also
Friction welding:
None is correct
Extruded metal rods and
profiles can be straightened
by:
Roll forging
Superalloy and nickel-based
alloys gas turbine blades are
typically made by:
Vacuum casting (exam 2)
A rectangular keyway in a
round shaft can be produced
by:
None is correct (exam 2)
By agreement, sheet metals
are defined as such:
● when one dimension is less than
2.5 mm, and much smaller the
other two (chegg) ( i dont think
this is correct. Cause it says
less than 6mm everywhere)
Exam 2
Continuous casting of metals:
none
For a good TIG/MIG weld joint,
the workpieces should be:
Heat up parts OR compatible
materials (there are two like this)
of compatible materials; and
the filler rod too
Super plastic forming requires:
slow forming process to
ensure recrystallization
(chegg)
In polymer processing:
All I believe
Centrifugal forces can be used to
Cast hollow and solid objects (chegg IV)
ASTM grain size 7 is:
Good for engine hoods and trunk
lids (chegg)
Quality products such as
aluminum foils are best
produced by:
hot rolling without pickling and oiling (chegg)
IC chips on PCBs are:
Connected by soldering or surface
mounting technique
Which parts can be produced on
a turret lathe with a single
set-up:
Cam shafts (chegg)
High temperature gas
turbine blades can be
produced by:
● Single crystal casting (chegg)
Rubber forming or hydroforming
of sheet metals can be of cost
advantage due to:
● Low tooling cost (I) -Exam 2
OR
be cost effective for short-run,
shallow sheet metal parts
Temperature built up
during machining:v
Will shorten tool life
EDM can produce very large
parts with cycle time 60-90
pieces/min that are:
Grocery and trash bags are
most cost effective when
produced by:
none of the following
Exam 2
Extrusion and blow film (IIII-my
guess)(see page 501)(also chegg)
Tolerances will vary less during
production due to :
- high flexibility of machine
frame (chegg)
- consistent raw material
properties (midterm 2 doc)
Annealing is investment casti
thermal
treatment
for
cold-worked metal to restore its
properties and grain structures
(I)
For AA 6061-O the minimum
bend radius is:
0
Round rivet heads can be
formed by:
Heading in the punch (none of the
other answers make sense)
Risers in casting help:
Reduce porosity thus should not
solidify before the casting
Consumable electrodes can be:
Used in tig welding fro quality welds (II,
chegg and book pg 888)
Camshafts for a 16v 4cyl can be turned on
High speed cnc machining centers
Cold forming of metals is done at:
AA 6061-T4 and AA 6061-T6 are:
None of the above
Magnetic pulse forming: is forming by induction (chegg)(I)
Mfg using centrifugal forcCast hollow and solid
The threaded base of a light
bulb can be produced
cost-effectively by:
Progressive dies are
preferred over compound
dies due to:
Break even point is:
None of the above (II)
● Simpler design and low
maintenance cost (I)
Exam 2
The number of parts made by two
potential processes with same unit
cost.(chegg)
Return on investment (I)
Quotation/bid in response
to customer's RfQ should
not
include:
all dimensions and tolerances
A chip breaker is:
used if the cutter geometry does
not warrant short chips (III)
Changes in bending angles
after bending due to
Springback are functions of:
All are correct (I)
Minimum bending radius
● depends on the
hardness and rolling
direction of the
metal before bending
(chegg) exam 2
Anisotropy in sheet metals
● can cause dog-ears and
non-uniform wall thickness
in deep drawing (Pg 398;
II)
-Exam 2
Cafeteria trays can be
produced by:
Thermoforming of reinforced
plastic sheets (pg 555 in
book) (top displayed google
search)
Fine versus conventional blanking: fine blanking requires
more precise, expensive
tooling
Flange in sheet metal can
be produced:
Hot rolling of metals can produce
All but blanking
● All answers are correct
Sand casting of metals is:
None
Risers help:
None is correct (midterm 2)
Which is called the
lost-wax casting:
Connecting rods in internal
combustion engines are:
Which part can be produced on
a turret lathe with a single setup
All of the above (I) ? (chegg)
Not a heat treatment process: furnace brazing (II, chegg)
Hydro and rubber forming can:
be cost effective for short-run,
shallow sheet metal parts
(chegg)
Knurling performed on a
round shaft:
all
Springback in sheet metal forming
is a function of:
Thread for commercial grade steel bolts
is strongest when produced by
Rolling then stress relieving (chegg)
Guidelines for welding
processes include:
Heat up parts before welding to reduce
distortions, and stress relieve
thereafter if necessary
Engine blocks for 4-cylinder
in-line hybrid engines can be
produced in large quantity by:
Advantages of Nesting in sheet metal:
assemble two hollow objects into each
other lower tooling costing minimize
material waste
Minimum bend radius for
AA 7075-O is:
0 (I)
Which is called the
lost-wax casting
Pattern is melted out for recycling
before pouring (retake doc)
Engine blocks for V-6 hybrid engines can
be produced in large quantity by:
None of the above (I)
Likely to cause cracks inside the bend (I)
Die-casting of steels with ceramic molds
(saw this on chegg)
2-piece aluminum beer and
soda cans can be produced
without:
The threaded base (socket) of
a light bulb can be
prspringoduced cost-effectively
by:
Superplastic materials:
welding
● None is correct
Draw beads used are used
occasionally:
The frame of an off-the-shelf
beach cruiser bicycle is
usually made from
Casting using a sand mold is:
● in deep drawing to control metal
flow and flange forming
a. All of the above
appropriate for large and very
high precision castings (pg. 263)
Cold forming of metals is done at:
● T/Tm
just below 0.3
(chegg) II
An estimate for job cost as
per customer's RfQ should
include:
● All are correct (chegg)
Which are traditional
joining processes?
All but water jet
Which of the following
processes is not required to
produce 3-piece welded steel
cans:
Automated inspection (chegg I)
Lost-foam casting is:
● using expandable molds
and patterns
Exam 2
PM has advantages over
conventional metals because of:
All are correct (chegg)
Flanges in sheet metal can be
All but blanking
Advantages of Nesting in
sheet metal:
In sheet metal forming,
springback can be controlled by:
All but assembling hollow objects
● All are correct (I)
The letter T in AA
6061-T6511 means:
Annealed or recrystallized grain
structures (chegg)
Which is investment casting:
wax pattern is melted out for
recycling before pouring
(chegg) not sure
To produce 2-piece
aluminum beer and soda
cans, which process is not
required:
welding
Nesting in sheet metal manufacturing is:
To reduce material usage, energy and
tooling costs (chegg)
The frame of an off-the-shelf
beach cruiser bicycle is
usually made from
Climb milling is:
preferred for slender parts due to
the downward forces
Progressive dies are preferred
over compound dies due to:
Hardness increase during
machining can:
Which is called the
lost-wax casting:
All are correct (chegg)
In rolling, spreading should
be avoided by
reducing the reduction in
thickness (bite) (chegg)
Vickers (HV) is
Resistance to elastic deformation
None is correct (I)-unless “Hardness
is resistance to indentation” is
an option, then that is correct
In the production of
2-piece aluminum cans,
the lid is
connected to the can body by:
Seaming then sealing
Properties of sheet metals affected
by anisotrophy
Can cause dog-ears and non-uniform
wall thickness in deep drawing
MAE272 FINAL KEY
***USE TALLY SYSTEM
COLOR CODING KEY:
●100% CORRECT
●75% CORRECT/GUESS
●FOR SURE WRONG
The threaded base of a light
bulb can be produced
cost-effectively by:
None of the above (II)
Hydro and rubber forming can:
be cost effective for short-run,
shallow sheet metal parts
(chegg)
Super plastic forming requires:
Changes in bending angles
after bending due to
Springback are functions of:
Superplastic materials:
For a good TIG/MIG weld joint,
the workpieces should be:
of compatible materials; and
the filler rod too
(Midterm 3)
For AA 6061-O the minimum
bend radius is:
0
Not a heat treatment process:
Furnace brazing
Vickers (HV) is:
None is correct
An estimate for job cost as per
All are correct
customer's RfQ should include:
Anisotropy in sht6eet metals:
can cause dog-ears and
non-uniform wall thickness in
deep drawing
AA 6061-T4 and AA 6061-T6 are:
None of the above
Spin casting uses inertia forces to produce
Ferrous and non-ferrous solid and
hollow parts
EDM can produce very large
parts with cycle time 60-90
pieces/min that are:
None or not feasible
Advantages of Nesting in
sheet metal:
all but assembling hollow objects
Properties of sheet metals
affected by anisotropy:
can cause dog-ears and
non-uniform wall thickness in
deep drawing
Magnetic pulse forming:
Can form thin sheets without external
force and heat input (I)
Cold forming of metals is done at:
● T/Tm just below 0.3 (I)
Temperature built up
during machining:
Which parts can be produced on
a turret lathe with a single
set-up:
● wWill shorten tool life
(II) ○ Exam II
Rotational symmetric parts (II)
The letter T in AA
6061-T6511 means:
Centrifugal forces can be used to:
Cast hollow and solid object
Quality products such as
aluminum foils are best
produced by:
Continuous casting and rolling? (I)
Fine blanking:
Pg 391 in book for reference
Break even point is:
return of investment
In the production of
2-piece aluminum cans,
the lid is
connected to the can body by:
-seaming and sealing (I)
Engine blocks for V-6 hybrid
engines can be produced in
large quantity by:
● No answer is correct
(chegg)(I)
ASTM grain size 7 is:
good enough for engine
hoods and trunk lids for cars
Hot rolling of metals can produce:
all answers are correct
Round rivet heads can be
formed by:
Heading in the punch (none of the
other answers make sense) (Midterm
3)
A rectangular keyway in a
round shaft can be produced
by:
● None is correct (chegg)
Minimum bend radius for
AA 7075-O is:
Likely to cause cracks Inside the
bend (check?)
I also saw 0 so not sure
Large rings can be produced
by cost-effectively by:
ring rolling (Exam II)
What is the difference between
AA 6061-T4 and AA 6061-T6?
Fine vs conventional blanking:
T6 is naturally aged, T4 is furnace aged
then work-hardened.
fine blanking requires
more precise, expensive
tooling
Midterm 2 doc says “none
is correct”
Tolerances will vary less
during production due to :
consistent raw material properties
PM distinguishes from
conventional metals because of:
All are correct (I)
Engine blocks for V-6 hybrid
engines can be produced in
large quantity by:
Die-casting of steels with ceramic molds (II)
Nesting in sheet metal
manufacturing is:
to reduce material usage,
energy and tooling costs
In sheet metal forming,
springback can be controlled by:
all are correct
Climb milling is:
preferred for slender parts due
to the downward forces (lI)
Thread for commercial grade
steel bolts is the strongest when
produced by:
Friction welding:
None is correct
Engine blocks for 4-cylinder
in-line hybrid engines can be
produced in large quantity by:
Superalloy and nickel-based
alloys gas turbine blades are
typically made by:
die casting of steels with
ceramic molds (chegg 2
upvotes)
● vacuum casting using ceramic
molds (chegg)
By agreement, sheet metals
are defined as such:
Connecting rods in internal
combustion engines are:
Quotation/bid in response
to customer's RfQ should
not
include:
all dimensions and tolerances
Changes in bending angles
after bending due to
Springback are functions of:
All of the above (master sheet pg 18)
Rubber forming or hydroforming
of sheet metals can be of cost
advantage due to:
Low tooling cost (I) -Exam 2
Guidelines for welding processes include:
Heat up parts before welding to reduce
distortions, and stress relieve
thereafter if necessary
Which of the following
processes is not required to
produce 3-piece welded steel
cans:
ironing in multiple operations
Springback in sheet metal forming
is a function of:
All are correct chegg (II)
Cam shafts in a 16-valve
4-cylinder engine can be turned on
High speed CNC machining centers
Thread for commercial grade
steel bolts is the strongest when
produced by
Annealing is
Engine hoods, fenders, boot
lids, etc., of mid-size SUVs are
usually:
stretched formed and/or
deep drawn
In polymer processing:
All are possible
Router or traveler is
IC chips on PCBs are:
connected by soldering or
surface-mounting technique
In the production of 2-piece aluminum
cans, the lid is connected to the can body
by:
Seaming and sealing
Which is called the
lost-wax casting:
Pattern is melted out for recycling before
pouring (retake doc; IIII) chegg approve
also
Mfg using centrifugal forces can:
Cast hollow and solid objects
Temperature built up during machining:
Will shorten tool life
Flanges in sheet metal can be produced:
All but blanking
Casting using a sand mold is:
High temperature gas
turbine blades can be
produced by:
Hardness increase during
machining can:
All are correct
Which process is not required to
produce 3-piece welded steel cans:
Advantages of Nesting in
sheet metal:
Continuous casting of metals:
● Deep Drawing) (Midterm 2)
All but assembling hollow objects (check?)
● None of the answers is
correct(Midterm 2)
Risers in casting help:
Reduce porosity thus should not
solidfy before the casting
The threaded base (socket) of
a light bulb can be produced
cost-effectively by:
None is correct
Friction in manufacturing should
be reduced or eliminated except:
In rolling or friction welding (I)
Extruded metal rods and
profiles can be straightened
by:
Roll forging
Flange in sheet metal can
be produced:
All are correct (Exam II)
Quality products such as aluminum foils
are best produced by:
Continuous casting and rolling
Fine blanking
can produce shear cut
without fracture surface
(master sheet pg42)
Draw beads used are used occasionally
2-piece aluminum beer and
soda cans can be produced
without:
● in deep drawing to control metal
flow and flange forming
welding
F
Cafeteria trays can be produced by:
Travelers are:
Risers help:
Updated cost estimates after receiving P.O.
● None of the above (I)
2-piece aluminum beer and soda cans can be produced without:
A chip breaker is: used if the cutter geometry does not warrant short chips (probably)
A rectangular keyway in a round shaft can be produced by: none are correct... should
be “end milling”
A riser helps none of the following
A round keyway in a round shaft can be produced by: sink EDM
An estimate for job cost as per customer's RfQ should include: all answers except dimensions and
tolerances
An estimate for job cost as per customer's RfQ should include: All are correct
An open riser helps: reduce porosity, thus should not solidify before the casting
Angles such as chamfers can be measured by using: protractors
Anisotropy in sheet metals: can cause dog-ears and non-uniform wall thickness in deep drawing
(from Chegg but idk if true) Annealing is: residual stress OR thermal treatment (both are mentioned
in book) BE CAREFUL ASTM grain size 7 Is: good enaugh for engine hoods and trunk lids for cars
Break even point is: return of investment ?
Brinell is: standard to determine the surface hardness of a metal By agreement, sheet
metals are defined as such: When one dimension is less than 2.5 mm. And much smaller
than the other two Cafeteria trays can be produced by:
Cafeteria trays can be produced by: Transforming of reinforced plastic sheets
Cam shafts in a 16-valve 4-cylinder engine can be turned on: high speed cnc machining center
Casting can be used to: Manufacture high-volume production parts
Casting using a sand mold is: none is correct
Centrifugal forces can be used: cast hollow and solid objects (chegg)
Changes in bending angles after bending due to Springback are functions of: all are
correct (pg. 404) - cross referenced with chegg response climb milling is: preferred
for slender parts due to the downward forces Cold forming of metals is done at: T/Tm
just below 0.3
Connecting rods in internal combustion engines are: all are correct
Consumable electrodes can be: used up during the brazing process (???)
Continuous casting is none of the following
Continuous casting of metals: none of the answers is correct
Draw beads used are used occasionally: in deep drawing to control metal flow and flange forming
During plastic deformation anisotropy in sheet metals can: can cause variations of properties in
different directions EDM can produce very large parts with cycle time 60-90 pieces/min that are:
none of the following or cheaper than the traditionally made parts (2 variations of same question)
Engine blocks for 4-cylinder in-line hybrid engines can be produced in large quantity by: casting of
steels or light alloys
Engine blocks for V-6 hybrid engines can be produced in large quantity by: No answer is correct
Engine hoods, fenders, boot lids, etc., of mid-size SUVs are usually: stretched formed and/or deep
drawn
Extruded metal rods and profiles can be straightened by: roll forging
Fine blanking: is similar to counter blanking with even tighter clearance? (pg 386) Fine
versus conventional blanking: fine blanking requires more precise, expensive tooling
Flange in sheet metal can be produced by: all are correct
Flanges in sheet metal can be: all but blanking
For a good TIG/MIG weld joint, the workpieces should be: constrained to maintain shape and
eliminate residual stresses Friction welding: (non is correct via chegg no likes) (nothing found in
book so leads to none are correct) Grocery and trash bags are most cost effective when
produced by: extrusion and blown-film? (pg. 500 diagram at bottom) Guidelines for welding
processes include: Heat up parts
Hardness increase during machining can: all are correct
High temperature gas turbine blades can be produced by: Single crystal casting
Hot rolling of metals can produce: all are correct (page 323)
Hydro and rubber forming can: be cost effective for short-run, shallow sheet metal parts (from
Chegg but idk if true) IC chips on PCBs are: connected by soldering or surface-mounting
technique In polymer processing: all are possible
In polymer processing: all are possible
In rolling, spreading should be avoided by Reducing the reduction thickes (bite)
In sheet metal fab, anisotropy can: cause variations of properties in different directions
In sheet metal fabrication, minimum bending radius for AA 6061-0 is: 0
In sheet metal forming all are correct
In sheet metal forming, springback can be controlled by: all are correct
In the production of 2-piece aluminum cans, the lid is connected to the can body by: seaming and
sealing
Knurling performed on a round shaft: all are correct
Large rings can be produced by cost-effectively by: Ring rolling (Page 329)
Lost-foam casting is: expandable molds and patterns (page 270-272)
Lost-foam casting is: using expandable molds and patterns
Magnetic pulse forming: can form thin sheets without noise and heat
Mfg using centrifugal forces can: cast hollow and solid objects
Minimum bend radius for AA 6061-0 is: 0
Minimum bend radius for AA 7075-O is: 0
Minimum bending radius: depends on the hardness of the metal before bending Minimum
bending radius: depends on the hardness and rolling direction of the metal before bending (2)
(398-399) Nesting in sheet metal manufacturing is: to reduce material usage, energy and tooling
costs
New Questions start here
Not a heat treatment process: furnace brazing
PM distinguishes from conventional metal because of: all are correct
Progressive dies are preferred over compound dies due to simpler design and lower maintenance
costs
Progressive dies are preferred over compound dies due to: simpler design and lower maintenance
costs
Properties of sheet metals affected by anisotropy: can cause dog-ears and non-uniform wall
thickness in deep drawing (from Chegg but idk if true) s Properties of sheet metals affected by
anisotropy:
Quality products such as aluminum foils are best produced by: continuous
casting and rolling - Chegg 5likes (page 1) Question Definite Answer
Quotation/bid in response to customer's RfQ should not include: all dimensions and
tolerances (common sense answer I think) Risers help: none is correct
Risers in casting help: reduce porosity thus should not solidify before the casting ? (pg
243) Round rivet heads can be formed by: roll forging (page 335)
Router or traveler is: oplimized operation sequences with set-up and run times
Rubber forming or hydroforming of sheet metals can be of cost advantage due to:
low tooling cost? (pg 1156)
Sand casting of metals is: None of the answers are correct
SPC can be used to: predict the completion time of a job order
Spin casting uses inertia forces to produce ferrous and non-ferrous solid and hollow parts
Springback in sheet metal forming can be controlled by: b and c
Super plastic forming requires: slow forming process to ensure
recrystallization Superalloy and nickel-based alloys gas turbine blades are
typically made by: Advantages of Nesting in sheet metal:
Superplastic materials 10000% something
Temperature built up during machining shorten tool life
The frame of an off-the-shelf beach cruiser bicycle is usually made from: drawn or extruded steel or
aluminum..
The threaded base (socket) of a light bulb can be produced cost-effectively by: none
The threaded base of a light bulb can be produced cost-effectively by: all answers are wrong
To produce 2-piece aluminum beer and soda cans, which process is not required: welding
Tolerances will vary less during production due to: consistent operation procedures
among shifts and operators Travelers are: updated cost estimates after receiving
p.o.
Vickers (HV) is None is correct
What is the difference between AA 6061-T4 and AA 6061-T6? T6 is naturally aged, T4 is furnace
aged then work-hardened.
Which are traditional joining processes? All but jet water (1)
Which is investment casting: Wax
Which of the following processes is not required to produce 3-piece welded steel cans: Deep drawing
Which of the following processes is not required to produce 3-piece welded steel cans: ironing in
multiple operations
Which parts can be produced on a turret lathe with a single set-up: rotational-symmetric parts
What is called lost-wax casting?
Friction in manufacturing should be reduced or eliminated except:
PM has advantages over conventional metals because of:
AA 6061-T4 and AA 6061-T6 are:
The letter T in AA 6061-T6511 means: subsequent treatment after fabrication by thermal and/or
mechanical means (google answer) Springback in sheet metal forming is a function of: all is correct
Chills
End milling
Vu Midterm 2 From hell
PUT SUGGESTED ANSWERS TO QUESTIONS IN RED
1. Hardness increase during machining can
Increase energy requirement during subsequent cutting; all are correct; increase tool
wear; be useful against wear due to surface hardness; be reduced by slower feed rate
smaller depth of cut
2. A rectangular keyway in a round shaft can be produced by:
Answers : Magnetic pulse, water-jet milling, e-chem polishing, none, wire edm 3. EDM can
produce very large parts with cycle time 60-90 pieces/min that are: None, Cheaper than the
traditionally made parts, Made of engineering plastics, too expensive to sand cast, too
cost-prohibitive for wire-edm
(he went over this one in our section. The answer is Not feasible at all) 4. Sand casting
of metals is
None of the answers is correct, using non-reusable sand for permanent molds??? (not so
sure), using a wax pattern for the core, appropriate for large and very high precision castings,
using a wooden pattern without shrinkage factor
5. Which process is not required to produce 3-piece welded steel cans: Brazing, roll
forming, deep drawing, blanking, automated inspection (He told us the answer for
this is deep drawing)
I have “roll forming” as the answer
6. Tolerances will vary less during production due to:
Low skill level of the machinist; high flexibility of machine frame; low tool life; consistent raw
material properties; none of the above
7. Friction in manufacturing should be reduced or eliminated except: Hot chamber die casting, in
rolling and friction welding, in powder metallurgy, tube bending, shearing
8. Fine versus conventional blanking:
fine blanking requires more precise, expensive tooling; none is correct; conventional blanking
dictates the generation of 3D state of stress around the shear surface; counter blanking
produces a smooth shear surface albeit burr; a nd c
9. High temperature gas turbine blades can be produced by:
Single crystal casting
10. By agreement, sheet metals are defined as such:
When one dimension is less than 2.5 mm, and much smaller the other two; thin plates are
thicker than 2.5 in.; less than 5 in. thick plates; produced by continuous profile rolling; formed
in compound dies
??? i think this one is 5 in I just saw that as well
Im researching it …….. Hold please (there are 2 answers) i did see on wikipedia it said sheet
metal is 6.0 mm (.25 in) and under while plate metal is > 6.0 mm (.25 in)
I think it’s produced by continuous profile rolling
11. Minimum bend radius for AA 7075-O is:
Likely to cause cracks
(isn’t this one 0?)<--thats what i put
12. To produce 2-piece aluminum beer and soda cans, which process is not required:
Annealing; ironing; welding; trimming and necking; deep drawing 13. Cam shafts
in a 16 valv 4 cylinder engine
High speed cnc machining centers
14. Progressive dies are preferred over compound dies due to Extremely high production rates;
simpler design and lower maintenance costs; simplicity of the parts such as washers; higher
speed of mechanical presses; complexity of injection molded parts
15. Large rings can be produced….
Ring rolling
16. An open riser helps
reduce porosity, thus should not solidify before the casting, remove flow turbulence after the
solidification phase, let trapped air escape from the mold after solidification, raise strength
and porosity of the casting, a must if blind risers are used
17. Draw beads used are ….
In spin casting of non-axis-symmetrical parts, deep drawing of aluminum cans, in deep drawing
to control metal flow and flange forming, wire drawing, none of the above
18. An estimate for job cost as per customer’s RFQ should include: Set up and run times for each
operation; material, tooling and any other engineering cost; overheads and target profits; sales
and G&A; All are correct
19. In the production of 2-piece aluminum cans, the lid is connected to the body of the can by:
Diffusion bonding, seaming, the cantilever, seaming and sealing, EB welding 20. Knurling
performed on a round shaft:
Must be called out before and after, by rolling not machining, in a lathe, using standard tools,
all are correct
21. Which is investment casting:
Die casting without a hot chamber, wax pattern is melted out for recycling before pouring,
centrifugal casting, spin casting, continuous casting 22. Engine hoods, fenders, boot lids, etc, of
mid-size SUVs are usually: Rolled stretch formed backward extruded, made from powders,
stretched form and/or deep drawn, stamped then profile rolled, blanked and pierced and powder
coated?
23. By agreement, sheet metals are defined as such:
When one dimension is less than 2.5 mm & much smaller the other two, thin plates are
thicker than 2.5 in, less than 5 in thick plates, produced by continuous profile rolling, formed
in compound dies
24. In sheet metal fab, anisotropy can:
Produce lueder’s band inside a forgings, cause dog ears in stretch forming of large parts such
as door panels on airplanes, cause variations of properties in different directions, increase
porosity in the sheet, have adverse effect during the recrystallization process
25. Rubber forming and hydroforming of sheet metals can be cost advantage due to:spin cas
Intricate geometry of workpiece, Short production run of limited quantity, low tooling cost,
high production rate, internal vs external setups
26. The frame of an off-the-shelf beach cruiser bicycle is usually made from Spun cast tubing,
turned aluminum pipes on 5-axis lathes, Drawn steel or aluminum pipes, turned composite
pipes on conventional lathes, all of the above
27. What is the difference between AA 6061-T4 and AA 6061-T6? both are stress relieved by
thermal input [Question asks for difference, not what is the similarity. I put None of the above] I
hate Vu | Same tbh 28. Springback in sheet metal forming is a function of:
E-modulus, yield strength, sheet thickness, bending dies used, All are correct 29. Magnetic
pulse forming:
Can form thin sheets without noise and heat
30. Centrifugal forces can be utilized to:
cast hollow and solid objects
31. Superplastic materials:
Are specially designed composites, can have percent elongations up to 1000%, may contain
nano-carbon fibers, are spin cast alloys, super thermoplastics 32. Spin casting uses inertia forces
to produce:
Ferrous and non-ferrous solid and hollow parts, engine blocks, ball bearing, sun sheet metal
parts, axis-symmetrical sheet metal parts
33. Which of the following processes is not required to produce 3-piece welded steel cans
Roll forming; blanking; seaming; ironing in multiple operations; automated inspection
34. Cold forming of metals is done at:
T/Tm just below 0.3
35. Vickers (HV) is:
Hardness is resistance to indentation; resistance to elastic deformation; same as Rpmedm
36. ockwell (HR); average surface roughness; none is correct
37. Which are traditional joining processes?
Fastening, riveting, soldering, all but water jet, water jet polishing 38. PM
distinguishes from conventional metals because of:
Ability to blend incompatible elements or compounds, impregnation and infiltration,
self-lubricating effect, thin and shallow psandarts only, all are correct
39. Flange in sheet metal can be produced:
by piercing to form the flange, without drilling a pilot hole, all are correct, with an increase in
yield strength due to cold working, to hold more thread with the same sheet thickness
40. Superalloy and nickel-based alloys gas turbine blades are typically made by: Turning, milling
then drill; vacuum casting using ceramic molds; precision machining on CNC 3 axis
machining centers; conventional die casting in cold chamber; forming in steel dies at room
temperature.
41. Minimum bending radius:
Depends on surface coating and resilience of the metal; is independent on the thickness of the
sheet; is a non-issue if springback can be controlled; is
independent of the temper of the heat treated blank and operator’s; depends on the hardness
and rolling direction of the metal before bending 42. In rolling, spreading should be avoided by
Reducing the reduction in thickness (bite); increasing friction alone; using unsupported
skinny rolls; using unsupported skinny rolls; cluster rolls 43. Travelers are:
updated cost estimates after receiving P.O, lists of work instructions such as how to set up a
machine, compositions metal alloys, required to set up climb milling if conventional milling is
not feasible, instructions how to go from drawing to a sand cast part
think this is wrong ^, travelers dont explain how to go from drawing to a partI ^ same i put the
cost estimate one
why would you get a P.O. before giving cost estimate though? What it says after It should be list
of work instructions (+1)
I have no idea
lets keep it not highlighted then
Good idea
Bruh
Im pretty sure its the Updated cost one ( thats why i highlighted it) Thats what i put
too but they said otherwise
44. Engine blocks for V-6 hybrid engines can be produces in large quantity by: No answer is
correct; casting of carbon composites in a hot chamber; profile rolling using tungsten carbide
dies; open die forging; die casting of steels with ceramic molds
45. Temperature built up during machining:
Creates chattering and cold welding; has no effect on surface quality; is independent of cutter
materials; will shorten tool life; is bad for global warming 46. Lost-foam casting is
Less accurate than sand casting, capable of producing larger than 5-ton castings, an
investment strategy for mid-sized accurate parts, using expandable molds and patterns,
better in terms of dimensional accuracy and surface quality than die casting.
47. Nesting in sheet metal manufacturing is:
To reduce material usage, energy and tooling costs; useful for bird watching; irrelevant if
progressive dies are used; only advantageous for thick sheets; same as roll forming
48. In sheet metal fabrication, minimum bending radius for AA 6061-0 is: 0
49. Question
Answer
50. Who hates Vu?
Everyone (15 extra points)
51. Casting can be used to:
Cut a workpiece in parts, solder two workpieces of incompatible material together, make a
workpiece from incompatible powders, produce parts made of high-temperature ceramics,
manufacturer high-volume production parts 52. Anisotropy in sheet metals:
Answer : can cause dog-ears and non-uniform wall thickness in deep drawing??? I
think this is it
Final: this is gonna succk dick
53. Question Changes in bending anges after bending due to Springback are functions of
E modulus, yield strength, sheet thickness, bending dies used, all of the above 54. The letter T
in AA 6061-T6511 means:
Supposed to be T6 or T651, not T6511; major alloying elements are magnesium and silicon;
subsequent treatment after fabrication by thermal and/or mechanical means; annealed or
recrustallized grain structures; strain-hardened crystal structures
55. Knurling performed on a round shaft:
Answer : I think this one is all correct.
56. Fine blanking:
Is similar to counter blanking with even tighter clearance; can produce shear cut without fracture
surface; is conventional blanking in a triple-action press; can produce sheet metal blanks without
any burr; is the same like punching or stamping
57. In rolling, spreading should be avoided by:
Reducing the reduction in thicknes (bite); increasing friction alone; using unsupported
skinny rolls; using preload big rolls; cluster rolls
58. Round rivet heads can be formed by:
Cold extrusion, heading in the punch, cross rolling, roll forging, friction welding
59. The threaded base of a light bulb can be produced cost-effectively by: Answer
60. Lost-foam casting is:
Answer
61. Quality products such as aluminum foils are best produced by Continuous
casting and rolling
62. Flanges in sheet metal can be:
All but blanking (i think)
63. Superplastic materials:
Are specially designed composites, can have percent elongations up to 1000%, may contain
nano-carbon fibers, are spin cast alloys, super thermoplastics 64. Cafeteria trays can be produced
by
None, Thermoforming of reinforced plastic sheets, compression molding, calendering,
vacuum-bag forming
65. Extruded metal rods and profiles can be straightened by:
Normalizing, stretching and twisting or in-line roller leveling, roll forging, roller leveling, none is
correct
66. Advantages of Nesting in sheet metal
Answer : minimize material waste, reduce energy requirement, lower tooling cost, assemble
two hollow objects together, all but assemble hollow objects. 67. Grocery and trash bags are
most cost effective when produced by: This one should be extrusion and blown-film
68. Climb milling is:
Prefered for slender parts
69.
70. IC chips on PCBs are:
MIG or TIG welded together; dip brazed together; bonded together by adhesive;
furnace brazed together; connected by soldering or surface-mounting
71. Thread for commercial grade steel bolts is the strongest when produced by: Rolling then
stress relieving, cold rolling between flat or rotary dies, cutting and then surface hardening,
casting and normalizing, cold forging then annealing
72. Hot rolling of metals can produce:
Railroad tracks; recrystallized grain structure; flats sheets and profiles from ingots; all of the
above; none of the above
73. Hydro and rubber forming can
Produce precision performed components, make 2-piece alu cans more competitive than
plastic bottles, be cost effective for short-run shallow sheet metal parts(i think this is correct,
see pg 420 in textbook), advantageous for rubber bellows, replace roto forming
74. Risers help:
Answer : raise the height of a workpiece on a milling machine, none is correct, remove flow
turbulence after the solidification phase, trapped air escape from the mold after solidification,
raise strength and increase shrinkage of the sand casting. Im not entirely sure on this one
75. Consumable electrodes can be:
Used up during the brazing process
76. For a good weld joint, the workpieces should be:
Constrained to maintain shape and eliminate residual stresses, of compatible materials; and the
filler rod too, constrained in a fixture to avoid residual stresses in workpieces and electrodes,
moved around to cool them, free lattice defects
77. Friction welding:
None is correct, utilizes electrical resistance to generate heat, is capable of joining metals
and china, is brazing without melting, requires filler materials which are similar to both
workpieces
I’m pretty sure its none because ⅔ not possible and 4 it isn’t brazing and since its not brazing
can’t be 5 since filler is for brazing
78. Break even point is:
The number of parts made by two potential processes with the same unit cost, when a
specimen is stretched beyond its elastic limit, return of investment, even fracture at UTS, none
is correct ???
Properties of sheet metals influenced by anisotropy:
Answer
79. Guidelines for welding processes include:
Build up as much welds as feasible, then machine it flush; concentrate as many welds as
possible in one area to reduce unwanted property changes; heat up parts before welding to
reduce distortions, and stress relive thereafter if necessary; use TIG first before trying MIG;
avoid welding whenever possible regardless of cost
80. Which parts can be produced on a turret lathe with a single set-up: 1) Connecting
rods for 4-stroke diesel engines
2) 3-piece steel cans for tomatoes
3) gear housing
4) rotational-symmetic parts
5) Cam shaft
Not 100% this is right
81. Mfg using centrifugal forces can produce:
Answer
82. Not a heat treatment process:
Answer : stress relieving, furnace brazing, quenching in oil, induction sintering,
surface hardening
83. Connecting rods in internal combustion engines are:
Designed to convert a linear motion into angular one; moving the vehicles backward in
reverse gears; produced by casting or forging; not required in electrical cars; all are correct
84. Super plastic forming requires a. Specifically designed superplastic material, b. Isothermal
forming c. Slow forming process d. Materials with up to 1000% elongation e. All of the above
84. Whichof the following is not a heat treatment process
Furnace Brazing
85. Question
Answer
86. Question
Answer
87. Question
Answer
88. Question
Answer
89. Question
Answer
90. Question
Answer
91. Question
Answer
92. Question
Answer
93. Question
Answer
94. Question
Answer
95. Question
Answer
96. Question
Answer
97. Question
Answer
98. Question
Answer
99. Question
Answer
100. Question Answer
101. Question Answer
102. Question Answer
103. Question Answer
104. Question Answer
105. Question Answer
106. Question Answer
107. Question Answer
the threaded
MAE 272 First Midterm Q’s and A’s
1. The threaded base of a light bulb can be produced cost-effectively by: A. Laser beam
cutting
B. Turning on CNC lathes
C. Wire EDM
D. All answers are wrong
E. Sping casting
2. A round keyway in a round shaft can be produced by:
a. E-chem polishing
b. Water-jet milling
c. Facing-off on a turret lathe
d. Sink EDM
e. Wire EDM
3. During plastic deformation anisotropy in sheet metals can: a. Can cause variations of
properties in different directions b. Be more cost-effective if subsequent ironing is applied
c. Have adverse effect during the recrystallization process d. Produce
Lueders band inside a forging
e. Increase porosity in the sheet
4. ASTM grain size 7 is:
a. Determined by a certain number of dislocations per cubic mm b. Still considered
coarse grains for all applications
c. Acceptable if there is enough anisotropy present in the metal d. Associated with
low strength, low hardness, and low ductility e. Good enough for engine hoods and trunk lids
for cars 5. A chip breaker is:
a. Used to deburr machined parts
b. Used to bail the long chips for transport
c. Very popular in wire-EDM
d. Used if the cutter geometry does not warrant short chips e. Used to improve
the surface quality of PM parts
6. Centrifugal forces can be utilized to:
a. Roll steels and non-ferrous alloys
b. Cast hollow and solid objects
c. Injection mold of plastics
d. Weld with consumable electrodes
e. None of the above
7. Hot forming of metals is carried out:
a. Using either conventional lathes of CNC mills
b. Around the warm forging temperatures
c. Around 2000 C
d. At recrystallization temperatures
e. Around 2200 F for most aluminum alloys
8. Annealing is:
a. Restoration of TIG welded structure to its original shape
b. Thermal treating a cold-worked metal to restore its properties and grain structures
c. Stress relieving and/or normalizing of heavy castings
d. Stress relieving to reduce/eliminate residual stressed
e. Heat treating to martensite phase
9. Casting is used to:
a. Make a workpiece from incompatible powders
b. Solder two workpieces of incompatible materials together c. Produce parts
madecontin of high-temperature ceramics
d. Manufacture high-volume production parts
e. Cut a workpiece in parts
10. Continuous casting is:
a. None of the following
b. 24-7 casting of ingots in three shifts without interruption
c. Very cost-effective for large production of steel ingots with more consistent
properties
d. Casting and forming ingots in one process without cooling down to room temperature
e. Required very extensive capital investment which rarely makes economic sense
11. Which is called the lost-wax casting:
a. Spin casting
b. Centrifugal casting
c. Continuous casting
d. Pattern is melted out for recycling before pouring
e. Die casting without a hot chamber
12. Brinell is:
a. Resistance to elastic deformation
b. Casting method
c. Average surface roughness
d. Braille system
e. Standard to determine the surface darkness of a metal (surface hardness?)
13. Minimum bend radius for AA 6061-O is:
a. Independent of thickness
b. Same for AISI 1008 of equivalent hardness
c. 0
d. Independent of rolling direction
e. Likely to cause cracks inside the bend
14. Router or traveler is:
a. Document which lists the sequence of operations
b. A road map to becoming a world-class manufacturing operation c. Driving
direction from A to B
d. CNC tool paths
e. Optimized operation sequences with set-up and run times
15. Which of the following processes is not required to produce 3-piece welded steel cans:
a. Roll forming
b. Deep drawing
c. Automated inspection
d. Brazing
e. Blanking
16. An estimate for job cost as per customer’s RFQ should include: a. All answers
except dimensions and tolerances
b. Overheads and target profits
c. Material, tooling and any other engineering costs
d. All dimensions and tolerances
e. Set up and run times for each operation
17. Springback in sheet metal forming can be controlled by:
a. Changing the elastic modulus without changing material
b. Method of bending
c. Overbending to compensate for elastic recovery
d. B and c
e. All of these answers
18. Engine blocks for 4-cylinder in-line hybrid engines can be produced in large quantity by:
a. Casting of steels or light alloys
b. Open die forging
c. Profile rolling using tungsten carbide dies
d. Casting of carbon composites in a hot chamber e. Dies casting
steels with ceramics molds