Millwright Level 1 Exam Questions with 100% Correct Answers | Verified | Updated 2024, Exams of Advanced Education

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Millwright Level 1 Exam Questions with 100% Correct Answers | Verified | Updated 2024 On a pedestal grinder, the gap between the grinding wheel and work rest should not exceed: - Correct Answer-1/8 inch The kind of abrasive material used in grinding wheels for general purpose applications is: - Correct Answer-aluminum oxide A blotter is used on a grinding wheel to: - Correct 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: - Correct Answer-1/3 the diameter of the wheel The best wheel to use for cleaning scale and dirt off a workpiece is the: - Correct Answer-wire wheel pg. 1 professoraxe l What is a natural abrasive? - Correct Answer-made of natural material rather than synthetic Under properties of abrasives, to what does the term hardness refer? - Correct Answer-ability of a material to scratch or penetrate another material The ____ is the part of the wheel that holds the grains together - Correct Answer-bond Markings for the wheel identification can be found on the _______ - Correct Answer-Blotter What is the recommended speed to run a grinding wheel? - Correct Answer-Never run it faster that the max RPM of the grinding wheel How should you start a grinder? - Correct Answer-Stand off to the side and wait a full minute Is 46 or 60 the coarser grit? - Correct Answer-46 pg. 2 professoraxe l Prolonged use of power or air tools can cause carpal tunnel sydrome - Correct Answer-True Is it safe to run an impact wrench with a universal joint and socket attached - Correct Answer-No because it may throw off attachments What conditions would you use a GFCI - Correct Answer-Wet conditions What 3 things does a GFCI protect: - Correct Answer-1. Overload 2. Overcurrent 3. Ground fault protection A GFCI prevents all electrical shocks - Correct Answer-False Higher voltage on a battery means: - Correct Answer-Greater power of tool What type of power load must be used in the low velocity tool? Why? - Correct Answer-Power load with a crimped end must be used cause high power load would get lodged in the tool pg. 5 professoraxe l 6 colours ranging from lowest strength to highest strength for power load are: - Correct Answer-1. Grey 2. Brown 3. Green 4. Yellow 5. Red 6. Purple Power loads should not be carried loosely in pockets or aprons. Why? - Correct Answer-Could be set off causing serious injury or death Fasteners used in explosive actuated tools are: - Correct Answer-Manufactured from special steel and tempered A drive pin is a fastener used to: - Correct Answer- Permanently attach one material to another What is base material? - Correct Answer-Material which the fastener shank is driven into To determine the sustainability of a base material, use a fastener as a centre punch struck by a single average hammer blow. If the fastener is blunted ( meaning it can't fasten) the material is too: - Correct Answer-Hard pg. 6 professoraxe l To determine the sustainability of a base material, use a fastener as a centre punch struck by a single average hammer blow. If the fastener penetrates easily, do not fasten because the material is too: - Correct Answer-Soft To determine the sustainability of a base material, use a fastener as a centre punch struck by a single average hammer blow. If the material cracks or shatters, do not fasten because the material is too: - Correct Answer-Brittle A threaded knurled pin is designed for what material - Correct Answer-Mild steel To be a qualified operator of an explosive actuated tool you must posses: - Correct Answer-training in the use of each tool and familiarity with local safety regulations OH&S states that operators of explosive actuate tools should always wear: - Correct Answer-Eye protection If a tool is found to be defective, you should: - Correct Answer-Mark it defective and call a service representative pg. 7 professoraxe l How long should you wait if a power actuated tool misfires? - Correct Answer-30 seconds What is another name for a power saw? - Correct Answer- Reciprocating saw What determines the size (capacity) of a power hacksaw? - Correct 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? - Correct Answer-To prevent damage to the blade How is the speed of a power hacksaw expressed? - Correct Answer-Strokes per minute Describe the characteristics of a bimetal power hacksaw blade - Correct Answer-High speed tooth edge with a tough alloy steel back pg. 10 professoraxe l How does the blade set differ from the blade kerf? - Correct 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? - Correct Answer-It can only cut straight How is feed rate controlled on a horizontal band saw? - Correct 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? - Correct 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? - Correct Answer- They guide the blade and should be adjusted to as close as possible to the work pg. 11 professoraxe l If the blade jumps and shudders when you are using a horizontal band saw, what could be the problem? - Correct Answer-The feed rate is too high When cutting short pieces to length, what can be done to ensure that the jaws of the clamping device make good contact and do not distort - Correct Answer-Placing a similar piece in the back What is another name for a contour band saw? - Correct Answer-Vertical band saw What is tracking as it relates to band saw? - Correct Answer- Centering the blade on the pulleys What characteristics differentiate styles of band saw blades? - Correct Answer-Material, width, gauge, pitch, type of tooth What is the advantage of using a bimetal blade in a band saw? - Correct Answer-Greater wear and heat resistance, faster cutting and better durability pg. 12 professoraxe l In the lapping process, what is charged? - Correct Answer-the lap What is another name for Hand Pads or Rolls? - Correct Answer-Scotch-Brite pads The 3 hand taps found in a set are the: - Correct Answer- Taper, plug and bottoming What is the tap drill size for a 3/4-10 UNC 2B? - Correct Answer-21/32" If a high-speed steel hand tap breaks into a hole, one way to remove it is: - Correct 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? - Correct Answer-0.497" What is the correct tool to turn a die? - Correct Answer-Die stock pg. 15 professoraxe l The cutting action of a hand broach is performed by a series of successive teeth, each protruding: - Correct Answer-0.003" further that the preceding tooth Hand reamers must be rotated: - Correct Answer-Clockwise Pullers are used to: - Correct Answer-remove bearings, hubs and sprockets When using a puller or press and removing a bearing from a shaft what should you do? - Correct Answer-Inspect and clean shaft area Before working around a load that has been raised with a hydraulic jack: - Correct Answer-the load must be blocked If a milling machine is shit down for repair: - Correct Answer- Lock out the main breaker box Why is pressurized air NOT a good method of removing metal chips from hard to reach places on a milling machine? - pg. 16 professoraxe l Correct 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 - Correct Answer-The table can be swivelled When would you tighten the backlash eliminator - Correct Answer-When climb milling As a general rule, the maximum depth of cut for an endmill is equal to: - Correct Answer-1/2 the diameter of the endmill You can use V-blocks on a milling machine - Correct Answer- True The purpose of the overarm is to support the ____________, which in turn supports the __________ - Correct Answer-arbor supports, free end of arbor What controls the feed rate on a milling machine? - Correct Answer-Controlled by gearbox found in knee. Levers are picked for speed or can be picked with a dial for lighter milling pg. 17 professoraxe l What is the level of accuracy for a plate protractor? - Correct Answer-Within 1 degree What is the level of accuracy for a universal bevel protractor? - Correct Answer-5 minutes of a degree How many minutes are in a degree? - Correct Answer-60 minutes What is a vernier scale? - Correct Answer-Compares 2 sets of graduations to magnify the accuracy of the measuerment What does a dial caliper use to move its pointer around the face of a dial - Correct Answer-Rack and pinion What is the construction of a micrometer? - Correct Answer-1. Anvil 2. Spindle 3. Sleeve 4. Thimble 5. Ratchet pg. 20 professoraxe l 6. Lock nut 7. Frame What method provides most accurate measurement when it comes to a micrometer? - Correct Answer-Ratchet method because it releases at the same pressure every time Regular micrometer scale level of accuracy is: - Correct Answer-0.001" Vernier micrometer scale level of accuracy is: - Correct Answer-0.0001" What is an Intrimik? - Correct Answer-Has 3 contact points rather than 2 making it self centering What is different about the scale of a depth micrometer from a regular micrometer? - Correct Answer-The distance measured is covered by the thimble What kind of tool is a taper gauge? - Correct Answer-Direct reading tool pg. 21 professoraxe l What is a taper gauge used for ? - Correct 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: - Correct Answer-Application Why are thread forming screws used? - Correct Answer- Convenient in sheet metal assemblies The major diameter of a thread is shown on a drawing as 0.748 +/- 0.002. What is the tolerance on the major diameter? - Correct Answer-0.004 The pitch diameter of a thread is measured exactly halfway between the major and minor diameters - Correct Answer- False. Its APPROXIMATELY halfway between the major and minor diameter On a general purpose ISO metric thread, what character in the designation indicates a medium tolerance grade? - Correct Answer-Grade 6 pg. 22 professoraxe l What are cap screws made of? - Correct Answer-High tensile steel How is a Woodruff key sized? - Correct Answer-First 2 numbers are multiplied by 1/32" and second set of numbers are multiplied by 1/8" A rivet is: - Correct Answer-a permanent fastener What is the taper per foot of a tapered gib head key? - Correct Answer-1/8" per foot What is the taper per foot of a tapered dowel pin? - Correct Answer-1/4" per foot Cotter pins can be reused - Correct Answer-False. Cotter pins are a one time use Which variable is the most important when determining spindle speed? - Correct Answer-diameter of the drill pg. 25 professoraxe l Any machined surfaces on a drill press that could rust must be: - Correct Answer-Kept clean and oiled When installing a taper shank drill into the spindle bore, you must take several precautions. What are they and why? - Correct 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: - Correct Answer-Peripheral speed How fast should a 1/2" drill turn when drilling mild steel if the cutting speed is 90 sfpm? - Correct Answer-720 RPM Small drills require a higher feed per revolution than larger ones. - Correct Answer-False Which abbreviations is used to express the feed rate on a drill press? - Correct Answer-IPR A drill press has a #2 Morse taper. A twist drill with a #3 Morse taper shank must be mounted in the spindle. How pg. 26 professoraxe l should you secure the drill in the spindle? - Correct Answer- Use a drill socket To remove a tapered shank twist drill from the drill press spindle, use a: - Correct Answer-drill drift When using a sensitive drill press, what should you do as the drill breaks through the workpiece? - Correct Answer-Ease up on the pressure The included point angle of a countersunk hole for most flathead screws is: - Correct Answer-82 degrees Which type of machine tap pushes the hip out ahead of the tap? - Correct Answer-Spiral pint (gun) tap The lip relief (clearance) angle of a drill should be: - Correct Answer-8-12 degrees A general-purpose drill bit for drilling most metals has an included point angle of: - Correct Answer-118 degrees pg. 27 professoraxe l For maximum reliability when setting dividers to a dimension on a steel rule: - Correct Answer-set one point to the 1 inch or 10 MM graduation Trammels are used for scribing when: - Correct Answer-the circle to be scribe is beyond the range of the dividers When a radius is being laid out on a corner? - Correct Answer- the centre of the radius is located equidistant from the two adjacent sides before using a vernier height gauge it is important to: - Correct Answer-zero the vernier to the reference surface If the lines are scribed onto a workpiece it is considered to be: - Correct Answer-temporary layout The grade of surface plate which would be used in the shop is the: - Correct Answer-Grade B Which part of the combination set would be used to find the centre on the end of a shaft? - Correct Answer-a centre head and rule pg. 30 professoraxe l Precision layout with a vernier height gauge is accurate to: - Correct Answer-0.001" or 0.02MM What scribe has the highest degree of accuracy? - Correct Answer-Knife edge What are 2 types of dividers? - Correct Answer-Spring joint and firm joint What are permanent layout lines? - Correct Answer-used to make sure layout lines are still visible When changing back-gears on a lathe: - Correct Answer-Lock out the power supply When filing a workpiece in a lathe hold the file handle: - Correct Answer-in your left hand Lathes are considered to be more dangerous than other machines because: - Correct Answer-they have not evolved with safety features like most machines pg. 31 professoraxe l The size of a lathe is determined by: - Correct Answer- Maximum distance between the centres and the amount of swing The compound rest may be rotated: - Correct Answer-360 degrees The apron handwheel moves the carriage by means of: - Correct Answer-A rack and pinion The headstock of a lathe: - Correct Answer-is on the left and contains the spindle A lathe dog is used to: - Correct Answer-transmit drive power to a mandrel or workpiece held between centres A follower rest has: - Correct Answer-2 adjustable jaws A revolving centre is installed in the: - Correct Answer- Tailstock pg. 32 professoraxe l Once you have set a taper attachment to a desired angle, what important step must you follow? - Correct Answer-Take a trial cut and measure the taper The most common lathe operation is: - Correct Answer- turning Cutting speed refers to: - Correct Answer-How fast the workpiece travels past the tool Turning is usually done: - Correct Answer-with a right-hand tool An infeed of 0.050 on a direct reading cross-slide results in a diameter reduction of: - Correct Answer-0.050 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 be? - Correct Answer-RPM = (CS x 4)/ D (290 x 4)/4.5= 257.7777 or 255 pg. 35 professoraxe l The boring operation on a lathe: - Correct Answer-increases the diameter of a hole in a workpiece A reamer is used to: - Correct Answer-produce smooth accurate holes How does the speed and feed of a reamer compare to a drill? - Correct Answer-RPM is slower and feed is faster The pitch of a thread cut on a lathe is controlled y: - Correct Answer-The lead screw The finish on a thread can be enhanced by using: - Correct Answer-Coolant The thread-chasing dial: - Correct Answer-tells you when to engage the split nut When finishing with an emery cloth, the end held in your left hand passes under the workpiece and the end coming over the top it held in your right right hand - Correct Answer-True pg. 36 professoraxe l The result of knurling is: - Correct Answer-a workpiece slightly larger in diameter To achieve a good knurl, you should: - Correct Answer-flood the workpiece with coolant When grinding a workpiece between centres, you feed: - Correct Answer-with the carriage feed What is a negative result of using a tool post grinder on a lathe? - Correct Answer-The dust can destroy the ways Cutting fluids are mainly used for: - Correct Answer-decreasing heat and friction What feed rate is used for finishing? - Correct Answer-0.002- 0.005 inches per revolution A high feed rate cuts metal quickly but: - Correct Answer- decreases tool life pg. 37 professoraxe l What is the Workers' Compensation Act? - Correct Answer- Provincial legislation to protect workers What is a poor example of housekeeping? - Correct Answer- Poor lighting A temporary fall arrest system anchor point must have what minimum capacity to resist a fall? - Correct Answer-800 LBS What is the maximum sound intensity (dB) a worker can be exposed to during an 8 hour shift before hearing protection should be worn? - Correct Answer-85 dB What best describes a "confined space"? - Correct Answer- Partially/totally enclosed space not designed for human occupancy with a limited access What is required for every work platform? - Correct Answer- Safe access A rope grab in horizontal life line can cause what kind of hazard? - Correct Answer-Swing rope harzard pg. 40 professoraxe l What can a damaged plasma torch shield cause? - Correct Answer-Tip to overheat What is a hissing or squealing sound emitting from a cutting torch a sign of? - Correct Answer-Flashback Plasma cutting nozzles are normally made of what material? - Correct Answer-Copper What is the primary purpose of the secondary gas in plasma arc cutting? - Correct Answer-Cools the torch What is a major cause of incomplete penetration? - Correct Answer-incorrect joint design Flame temperature changes with the addition of: - Correct Answer-Oxygen What is the minimum safe distance from which an electric arc should be seen with the naked eye? - Correct Answer-12M (40ft) pg. 41 professoraxe l What is Voltage responsible for in arc welding? - Correct Answer-Starting arc Welding tip sizes are 000,00,0 and 1-10 - Correct Answer-True What type of electrode is used in the CAC-A process - Correct Answer-Carbon-graphite Which type of rod is best suite for high carbon steel in overhead postion? - Correct Answer-7018 What type of flame is used to fusion weld low carbon steel? - Correct Answer-Neutral What gas is most efficient for welding purposes? - Correct Answer-Acetylene Carbon arc cutting can trim or cut parts made of ferrous and some non-ferrous metals - Correct Answer-True pg. 42 professoraxe l What are the differences between acute an chronic toxic effects? - Correct Answer-Acute is short term exposure but in high concentrations and chronic is long term exposure but in low concentrations What are the types of hazardous energy? - Correct Answer- Kinetic, chemical, potential, thermal, electrical and radiation What is ZMS in terms of lockout? - Correct Answer-Zero mechanical state You must bleed all residual pressure when locking out - Correct Answer-True What is the difference between fall arrest and fall restraint? - Correct Answer-Fall arrest stops someones free fall and fall restraint stops someone from reaching a fall hazard What is the taper per foot for an arbor? - Correct Answer- 0.006-0.008" per foot What is the taper per foot for a jacobs taper? - Correct Answer-0.591-0.979" per foot pg. 45 professoraxe l What pitch of a hacksaw blade is for general shop use? - Correct Answer-18-pitch A high pitch blade number is generally used for: - Correct Answer-Harder and thinner material How many teeth should be in contact with material when using a hack saw? - Correct Answer-3 teeth What percentage does a tap drill leave for making threads? - Correct Answer-75 percent What taper do pipe taps have? - Correct Answer-3/4inch per foot How much material should leave for reaming? - Correct Answer-0.005" What is ageing in terms of cast iron? - Correct Answer-Its a stress relieving process pg. 46 professoraxe l What are the properties of oxygen? - Correct Answer- Colourless, odourless and tasteless as well as supports combustion In oxyacetylene, how pure is oxygen? - Correct Answer-99.5% pure oxygen What is the maximum safe working pressure for acetylene? - Correct Answer-15 PSI At what PSI is acetylene considered at its critical point? - Correct Answer-28 PSI What is the draw limit for acetylene? - Correct Answer-Can't be emptied faster than 1/7th of its capacity per hour What is backfire? - Correct Answer-Makes a bang/pop sound. cause by grossly unequal pressures and little gas flow What is flashback? - Correct Answer-Almost the same as backfire. Cause by grossly unequal pressures. One gas may go back into another line and create an explosive mixture pg. 47 professoraxe l Alternating current (AC) is: - Correct Answer-Positive and negative values that flow in 1 direction for the first half of the cycle and then flows in reverse in the next half of the cyle Direct current (DC) is: - Correct Answer-Flows 1 way and either has a positive or negative value What is voltage responsible for? - Correct Answer-Starting and maintaining arc, puddle fluidity, and flow What is amperage responsible for? - Correct Answer-Metal deposition rate and penetration What is straight polarity and what does it effect? - Correct Answer-Electrode negative (EN) work positive. Burns hotter, faster welding speed, wide metal flow, shallow penetration and hard to control when position welding What is reverse polarity and what does it effect? - Correct Answer-Electrode positive (EP) work negative. Cooler burning, slower weld speed, narrow metal flow, deeper penetration and better control when position welding pg. 50 professoraxe l What increases as hardness of a metal increases? - Correct Answer-Brittleness Anything over 1.7% of carbon is considered: - Correct Answer- Cast iron What is maraging steel? - Correct Answer-Carbon is considered an impurity. Made up of nickel, cobalt and molybdenum Ferrite is: - Correct Answer-Pure iron Pearlite is: - Correct Answer-Iron and carbon Cementite is: - Correct Answer-Iron and carbon where iron is dominant Martensite is: - Correct Answer-Rapid cooling of austenite Austenite is: - Correct Answer-Ferrite but heated to red hot pg. 51 professoraxe l Only steel with a carbon content of .10 and higher percent can be hardened - Correct Answer-False. Only steel with a carbon content of 0.20 percent and higher can be hardened What is full annealing? - Correct Answer-Opposite of hardening What is limestone? - Correct Answer-A flux that is added when forging steel to remove impurities What does C mean in AISI manufacturing process of steel? - Correct Answer-C= Basic open hearth carbon steel What are 3 types of technical drawings? - Correct Answer-1. Orthographic 2. Pictorial 3. Schematic What are the 2 angles of orthographic drawings? - Correct Answer-1. First angle (Europe) 2. Third (North America) pg. 52 professoraxe l