Free Bachelor of Mechanical Engineering Advanced Manufacturing Questions and Answers — Questions and Answers

Question 1: Which of the following applications also makes use of the hobbing process?

Sprocket cutting (Correct answer)
Punching
Metal bending
Rust removal

Correct answer: Sprocket cutting

Gears, splines, and sprockets are frequently cut using the machining process known as hobbing. The cutting device is referred to as a hob.

Question 2: Which of the following is a specific instance of hobbling?

Milling (Correct answer)
Drilling
Grinding
Casting

Correct answer: Milling

A unique form of milling called hobing involves making a sequence of cuts with a tool called a hob to create teeth.

Question 3: The angle between the workpiece's spindle axis and the hob's spindle axis should equal ___ while making spur gears.

(helix angle of the hob)2
(helix angle of the hob) (Correct answer)
2*(helix angle of the hob)
(helix angle of the hob)/2

Correct answer: (helix angle of the hob)

Since the hob contains helical threads, it must be angled with the workpiece in accordance with the requirements before being put into the workpiece. That angle for spur gears should match the hob's helix angle.

Question 4: As the helix angle of the helical gear, the angle between the spindle axes of the hob and the workpiece must be .

decreased by the half amount
decreased by the same amount
increased by the half amount
increased by the same amount (Correct answer)

Correct answer: increased by the same amount

One must take the gear's helix angle into account when producing the helical gear. The angle between the hob spindle axis and the workpiece spindle axis should be increased by an angle equivalent to the gear's helix angle during hobbing the helical gear.

Question 5: What is the primary benefit of broaching versus shaping?

Removal of the whole material in one stroke (Correct answer)
Surfaces with obstruction can also be machined
Thin or fragile jobs can be conveniently machined because of lower cutting forces
Use of single point cutting tool which are inexpensive and can be grounded to any shape

Correct answer: Removal of the whole material in one stroke

In shaping, achieving full depth necessitates a number of strokes to gradually infeed the single point tool while removing the material in thin layers one at a time. In contrast, broaching uses gradually rising teeth on a cutter called a broach to allow removal of the entire material in a single motion. Some benefits of shaping processes include the inability of broaching to machine surfaces with obstructions.

Question 6: Which of the following operations can be carried out using broaching?

Spline cutting (Correct answer)
Threading
Increasing the size of the existing hole for a certain length
Grinding

Correct answer: Spline cutting

Broaching is a preferred method of machining for producing straight through holes of varied shapes and section sizes, internal and external through slots or grooves, external surfaces of various shapes, teeth of internal and external splines, and small spur gears.

Question 7: Which of the following materials is most suited for roll forming?

Non-metals
Spring steel
Mild steels and aluminium (Correct answer)
Chromium-molybdenum steel

Correct answer: Mild steels and aluminium

Roll forming can be used to shape both ferrous and non-ferrous metals as well as various non-metallic materials. The two materials utilized in the procedure most frequently are mild steel and aluminum. Roll-formed materials can also be polished, painted, coated, and plated.

Question 8: What time does spring back happen?

When the material is too soft
When the material is too hard
When the material is stressed beyond its elastic limit
When the material does not stress beyond its elastic limit (Correct answer)

Correct answer: When the material does not stress beyond its elastic limit

The elastic limit is the distance beyond which a material will no longer flex under tension. The propensity to assume one's original shape is called springback. As a result, it happens when the material is formed without experiencing stress that exceeds its elastic limit. In order to compensate for spring, materials are frequently overformed before being allowed to "spring back" into the desired profile.

Question 9: Which of the following is utilized in heavy-duty roll forming as lubricant?

Micro-emulsions
Non-ionic type solutions
Soap-type solutions (Correct answer)
Extreme pressure-type solutions

Correct answer: Soap-type solutions

Heavy-duty roll forming uses soap-like fluids. Extreme pressure-type solutions are employed for high strength alloys, whereas non-ionic type solutions are great for roll forming aluminum and coated components.

Question 10: Which of the following is best for lubrication when cold and hot rolled steel is formed into rolls?

SAE 20W 40
SAE 120
Macro-emulsion
Micro-emulsion (Correct answer)

Correct answer: Micro-emulsion

The combination of emulsifiers, water-soluble corrosion inhibitors, wetting agents, organic and inorganic salts, and occasionally severe pressure agents gives micro-emulsions some film strength.

Question 11: If unformed regions are less than ____ wide, the product can be seen to be wavy.

150 mm
125 mm (Correct answer)
120 mm
100 mm

Correct answer: 125 mm

Unless unformed regions are smaller than 125 mm broad, wide parts have some degree of wave to them. With the use of longitudinal stiffening ribs, waviness or other types of irregularity in broad areas can be avoided.

Question 12: The material of the workpiece should have a resistance of ____________ for the EMF procedure.

in the range 10-20 micro-ohm-cm
less than 15 micro-ohm-cm (Correct answer)
less than 8 micro-ohm-cm
greater than 10 micro-ohm-cm

Correct answer: less than 15 micro-ohm-cm

The resistivity of the metal being produced determines how effectively a magnetic pulse is created. The material's resistivity should be less than 15 micro-ohm-cm for optimal performance.

Question 13: Which of the following statements regarding EMF is untrue?

Does not require any cleanup
It is primarily applied in the forming of good conducting materials
Does not require lubrication
Leaves tool marks (Correct answer)

Correct answer: Leaves tool marks

In EMF, unlike other mechanical processes where a tool contacts a workpiece, pressure is applied by a magnetic field. As a result, it doesn't require lubrication, doesn't leave tool marks, and doesn't need to be cleaned up after shaping.

Question 14: Which of the following statements regarding electrochemical machining is accurate?

It can also be used for all non-metals
Major drawback is that the finished product has residual stresses
Material is removed from the anode and carried away by the electrolyte
Material is removed from the cathode and deposited on the anode (Correct answer)

Correct answer: Material is removed from the cathode and deposited on the anode

In ECM, material is removed from an anode workpiece (positive pole) and moved to a cathode tool (negative pole) in an electrolyte bath, but instead of being deposited on the cathode, the electrolyte, which flows quickly between the two poles, carries the material away.

Question 15: Which of the following laws governs the ECM process?

Law of chemical combination
Law of definite proportions
Coulomb’s law
Faraday’s law (Correct answer)

Correct answer: Faraday’s law

that metal can be removed from the anode and plated on the cathode via a process known as electroplating, in which the workpiece serves as the cathode and two electrodes are positioned in a bath containing a conducting liquid. ECM makes use of a workpiece as an anode by removing the material.

Question 16: Which of the materials listed below can be used to create a cathode tool?

Carbides
Monel (Correct answer)
Cast iron
Lead

Correct answer: Monel

Aluminum, brass, bronze, copper, carbon, stainless steel, monel, and reinforced polymers are among the materials that are widely used in the production of ECM tools. These materials can all be machined with ease.

Free Bachelor of Mechanical Engineering Advanced Manufacturing Questions and Answers

Which of the following applications also makes use of the hobbing process?