Download Metalworking Tools and Techniques and more Exams Nursing in PDF only on Docsity!
Millwright Level 1 Exam Questions and Answers 2024
On a pedestal grinder, the gap between the grinding wheel and work rest should not exceed: - ANSWER 1/8 inch The kind of abrasive material used in grinding wheels for general purpose applications is: - ANSWER aluminum oxide A blotter is used on a grinding wheel to: - ANSWER protect the flanges from the abrasize grit, display information about the wheel and compensate for the uneven surfaces on the wheel Flanges should at least be: - ANSWER 1/3 the diameter of the wheel The best wheel to use for cleaning scale and dirt off a workpiece is the: - ANSWER wire wheel What is a natural abrasive? - ANSWER made of natural material rather than synthetic Under properties of abrasives, to what does the term hardness refer? - ANSWER ability of a material to scratch or penetrate another material The is the part of the wheel that holds the grains together - ANSWER bond Markings for the wheel identification can be found on the
- ANSWER Blotter What is the recommended speed to run a grinding wheel? - ANSWER Never run it faster that the max RPM of the grinding wheel How should you start a grinder? - ANSWER Stand off to the side and wait a full minute Is 46 or 60 the coarser grit? - ANSWER 46 What are the 2 most commonly used abrasive materials? - ANSWER Aluminum oxide and silicone carbide For what purpose is the diamond dresser used? - ANSWER
If a grinding wheel makes a ringing sound what does that mean? - ANSWER wheel is not cracked What is the purpose of truing a grinding wheel? - ANSWER Restores the shape of the wheel and makes the outer surface of the wheel concentric with its bore An out of balance wheel: - ANSWER vibrates Belt grinders are useful for: - ANSWER quickly deburring and chamfering a workpiece What is the purpose of a GFCI? - ANSWER Senses drop in current and switches power off The kind of abrasive material use in grinding wheels for general purpose application is: - ANSWER aluminum oxide Is it safe to carry a portable grinder by the power cord? - ANSWER False Is it safe to use standard sockets with electric impact wrenches - ANSWER False The larger the power drill, the slower the RPMs and the higher the torque - ANSWER True Can you use conventional drill bits with a hammer drill? Why or why not? - ANSWER Yes of the hammer drill has a switch to turn off hammer action Most cordless drills have torque control - ANSWER True Prolonged use of power or air tools can cause carpal tunnel sydrome - ANSWER True Is it safe to run an impact wrench with a universal joint and socket attached - ANSWER No because it may throw off attachments What conditions would you use a GFCI - ANSWER Wet conditions
- Overload 2. Overcurrent 3. What 3 things does a GFCI protect: - ANSWER Ground fault protection
regulatio ns OH&S states that operators of explosive actuate tools should always wear: - ANSWER Eye protection If a tool is found to be defective, you should: - ANSWER Mark it defective and call a service representative According to OH&S, what safety equipment is required when using an explosive actuate tool in a confined area such as a small room?
- ANSWER ear plugs and eye protection Who is responsible if an accident occurs as a result of an unattended explosive actuated tool? - ANSWER The operator Should an explosive actuated tool be used in explosive or flammable area? - ANSWER No How often should an explosive actuated tool be cleaned under normal working conditions? - ANSWER It should be cleaned daily or when it becomes sluggish How much oil should be added to the tool parts after cleaning? - ANSWER None What part requires replacement most often in a low velocity tool? - ANSWER Buffer With a low velocity tool, what is a general rule of thumb for the placement and depth of fasteners in steel? - ANSWER 1/2" from the edge, 2" apart and 1/4" deep Do not fasten near welds with a low velocity tool because the steel may have been hardened making the metal brittle - ANSWER True Tension load in regards to explosive actuated tools is: - ANSWER a force applied perpendicular to the base of the material Shear load in regards to explosive actuated tools is: - ANSWER a force applied perpendicular to the fastener Bending load in regards to explosive actuated tools is: - ANSWER shear force that is applied at a distance for the surface base of the material
depth of fasteners in concrete? - ANSWER 3" from the edge and from each other How long should you wait if a power actuated tool misfires? - ANSWER 30 seconds What is another name for a power saw? - ANSWER Reciprocating saw What determines the size (capacity) of a power hacksaw? - ANSWER Largest square piece that can be cut Why is the pressure removed from the blade of a power hack saw on the return stroke? - ANSWER To prevent damage to the blade How is the speed of a power hacksaw expressed? - ANSWER Strokes per minute Describe the characteristics of a bimetal power hacksaw blade - ANSWER High speed tooth edge with a tough alloy steel back How does the blade set differ from the blade kerf? - ANSWER Kerf is the width the blade cuts and set is the way individual teeth are bent out of line with the body What are the limitations of a horizontal band saw as it relates to cutting curves or round corners? - ANSWER It can only cut straight How is feed rate controlled on a horizontal band saw? - ANSWER An adjustable hydraulic cylinder IS it necessary to turn a horizontal band saw off manually after completing a cutting operation? Why or Why not? - ANSWER No because a switch is automatically activated by the downward motion of the upper frame What re the saw guides and where should you place them when you are using a horizontal band saw? - ANSWER They guide the blade and should be adjusted to as close as possible to the work If the blade jumps and shudders when you are using a horizontal band saw, what could be the problem? - ANSWER The feed rate
Alkaline cleaning must only be used on what metal?
- ANSWER Iro n Barrel finishing: - ANSWER IS a quick and inexpensive cleaning method In the lapping process, what is charged? - ANSWER the lap What is another name for Hand Pads or Rolls? - ANSWER Scotch-Brite pads The 3 hand taps found in a set are the: - ANSWER Taper, plug and bottoming What is the tap drill size for a 3/4- 10 UNC 2B?
- ANSWER
If a high-speed steel hand tap breaks into a hole, one way to remove it is: - ANSWER with an electrical discharge machine You have to choose between 4 steel rods to cut 1/2-13 UNC 2A thread with an adjustable split die. What diameter rod would you use? - ANSWER 0.497" What is the correct tool to turn a die? - ANSWER Die stock The cutting action of a hand broach is performed by a series of successive teeth, each protruding: - ANSWER 0.003" further that the preceding tooth Hand reamers must be rotated: - ANSWER Clockwi se Pullers are used to: - ANSWER remove bearings, hubs and sprockets
When using a puller or press and removing a bearing from a shaft what should you do? - ANSWER Inspect and clean shaft area Before working around a load that has been raised with a hydraulic jack: - ANSWER the load must be blocked Lock out the main If a milling machine is shit down for repair: - ANSWER breaker box Why is pressurized air NOT a good method of removing metal chips from hard to reach places on a milling machine? - ANSWER It can get jammed under the ways or caught in the spindle taper. They can also cause burns/infections What makes a universal horizontal milling machine different from a plain horizontal milling machine - ANSWER The table can be swivelled When would you tighten the backlash eliminator - ANSWER When climb milling As a general rule, the maximum depth of cut for an endmill is equal to: - ANSWER 1/2 the diameter of the endmill You can use V-blocks on a milling machine - ANSWER Tru e The purpose of the overarm is to support the , which in turn supports the - ANSWER arbor supports, free end of arbor What controls the feed rate on a milling machine?
Why should you clean an lightly oil milling machine tables? - ANSWER To prevent rusting which causes loss of accuracy Cuttin g Why should you store end mills separate from one another? - ANSWER edges could chip and wear What is climb milling? - ANSWER Feeds into the rotation of the cutter and bites into the material pushing it down and into the table Feeds against the rotation of the cutter What is conventional milling? - ANSWER and tends to lift the workpiece What is the level of accuracy for a plate protractor?
- ANSWER Within 1 degree What is the level of accuracy for a universal bevel protractor? - ANSWER 5 minutes of a degree How many minutes are in a degree? - ANSWER
minutes Compares 2 sets of graduations to magnify the What is a vernier scale? - ANSWER accuracy of the measuerment What does a dial caliper use to move its pointer around the face of a dial - ANSWER Rack and pinion What is the construction of a micrometer? - ANSWER
Anvil
2.Spindle 3.Sleeve 4.Thimbl e 5.Ratche t 6.Lock nut 7.Frame What method provides most accurate measurement when it comes to a micrometer? - ANSWER Ratchet method because it releases at the same pressure every time Regular micrometer scale level of accuracy is:
Vernier micrometer scale level of accuracy is: - ANSWER
Has 3 contact points rather than 2 making it self What is an Intrimik? - ANSWER centering What is different about the scale of a depth micrometer from a regular micrometer? - ANSWER The distance measured is covered by the thimble What kind of tool is a taper gauge? - ANSWER Direct reading tool What is a taper gauge used for? - ANSWER Determining the width of a slot or diameter of a hole and amount of angular misalignment The difference between a screw and a bolt is the:
The thread angle from an American National Acme Thread is: - ANSWER 29 degress annular ring on the knurled A no go ring gauge is easliy identified by: - ANSWER surface Thread comparison gauges use as a basis for thread size - ANSWER Pitch diameter Rolled threads are advantageous over machined threads because: - ANSWER They have increased tensile strength They produce a burnished thread finish They have better wear resistance which reduces fatigue and shear problems What does API stand for - ANSWER American Petroleum Institue What kind of threads do Acme threads have? - ANSWER 29 degree angle and the root and crests are flat Hex set screws may sometimes be doubled up - ANSWER Tru e What are cap screws made of? - ANSWER High tensile steel How is a Woodruff key sized? - ANSWER First 2 numbers are multiplied by 1/32" and second set of numbers are multiplied by 1/8"
A rivet is: - ANSWER a permanent fastener What is the taper per foot of a tapered gib head key? - ANSWER 1/8" per foot What is the taper per foot of a tapered dowel pin?
- ANSWER 1/4" per foot Cotter pins can be reused - ANSWER False. Cotter pins are a one time use Which variable is the most important when determining spindle speed? - ANSWER diameter of the drill Kep t Any machined surfaces on a drill press that could rust must be: - ANSWER clean and oiled When installing a taper shank drill into the spindle bore, you must take several precautions. What are they and why? - ANSWER Ensure taper and bore are clean, wipe with a rag without scraping/marking internal taper, any burrs are removed or it'll throw the bit off center Cutting speed refers to: - ANSWER Peripheral speed How fast should a 1/2" drill turn when drilling mild steel if the cutting speed is 90 sfpm? - ANSWER 720 RPM Small drills require a higher feed per revolution than larger ones. - ANSWER False
rpm) that can apply to large- diameter drills How are step drills used? - ANSWER Used to drill and then countersink You must used the correct RPM when using a center drill or you will dull/break the bit - ANSWER True What speed should a countersink and counterbore be set at? - ANSWER Approximately 1/4 of what you would use for a drill What are the drill point included angles for soft, general and hard material? - ANSWER 60- 90 degrees for soft, 118 degrees for general and 150 degrees for hard material What are 2 dial reading styles? - ANSWER Balanced and continuous Bottom plunger, test indicators What are 3 types of dial indicators? - ANSWER and back plunger What are dial bore gauges? - ANSWER Comparison measurement tool You can move it to various What is the advantage of a dial bore gauge?
- ANSWER positions with making any adjustments Copper sulphate layout solution should be used on:
- ANSWER Ferrous metals When angles are laid out with a bevel protractor, the accuracy attainable is: -
ANSWE
R
+/- 0.5 degrees (30mins) The surface gauge is used: - ANSWER to layout lines parallel to an edge For maximum reliability when setting dividers to a dimension on a steel rule: - ANSWER set one point to the 1 inch or 10 MM graduation the circle to be scribe is beyond Trammels are used for scribing when: - ANSWER the range of the dividers the centre of the radius is When a radius is being laid out on a corner? - ANSWER located equidistant from the two adjacent sides zero the vernier before using a vernier height gauge it is important to: - ANSWER to the reference surface If the lines are scribed onto a workpiece it is considered to be: - ANSWER temporary layout The grade of surface plate which would be used in the shop is the: - ANSWER Grade B Which part of the combination set would be used to find the centre on the end of a shaft? - ANSWER a centre head and rule 0.001" or Precision layout with a vernier height gauge is accurate to: - ANSWER 0.02MM
A follower rest has: - ANSWER 2 adjustable jaws A revolving centre is installed in the: - ANSWER Tailstoc k time engagement of the split nut The thread chasing dial is used to: - ANSWER when cutting a thread Tailstoc k The tailstock is in position on the ways of the lathe with the: - ANSWER clamp four- jaw The chuck best suited to holding odd-shaped pieces is the: - ANSWER chuck An O-ring groove would be cut with: - ANSWER a form tool When grinding HSS, you must remember to: - ANSWER Quench often Cemented carbides are sharpened on aluminum oxide wheels - ANSWER False The manual oil pump on the carriage pumps oil to:
- ANSWER The ways Worn wipers could allow chips to get between the carriage and the ways - ANSWER True Coolant on chips can Chips left on the ways are a concern because:
- ANSWER cause rusting
What type of taper is used in the tailstock? - ANSWER Morse taper How are metric tapers designated? - ANSWER As a ratio 1: What is the amount of taper on taper pins? - ANSWER 1/4" per foot Cutting a taper with a compound rest has what major disadvantage? - ANSWER There is no power feed Alignment and What is affected when drill bit tapers get damaged?
- ANSWER locking capability Once you have set a taper attachment to a desired angle, what important step must you follow? - ANSWER Take a trial cut and measure the taper The most common lathe operation is: - ANSWER turnin g Cutting speed refers to: - ANSWER How fast the workpiece travels past the tool Turning is usually done: - ANSWER with a right-hand tool An infeed of 0.050 on a direct reading cross-slide results in a diameter reduction of: - ANSWER 0. You are machining a 4.5 inch diameter steel shaft with a carbide tool. To machine it at 290 surface feet per minute, what should the approximate rpm of the spindle
