Metalworking Techniques and Tools, Exams of Nursing

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MILLWRIGHT LEVEL 1 FINAL EXAM

2024-2025 WITH ACTUAL CORRECT

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What is another name for Hand Pads or Rolls? Scotch-Brite pads The 3 hand taps found in a set are the: Taper, plug and bottoming What is the tap drill size for a 3/4-10 UNC 2B? 21/32" If a high-speed steel hand tap breaks into a hole, one way to remove it is: 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? 0.497" What is the correct tool to turn a die? Die stock The cutting action of a hand broach is performed by a series of successive teeth, each protruding:

0.003" further that the preceding tooth Hand reamers must be rotated: Clockwise Pullers are used to: remove bearings, hubs and sprockets When using a puller or press and removing a bearing from a shaft what should you do? Inspect and clean shaft area Before working around a load that has been raised with a hydraulic jack: the load must be blocked If a milling machine is shit down for repair: 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? 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 The table can be swivelled When would you tighten the backlash eliminator When climb milling As a general rule, the maximum depth of cut for an endmill is equal to: 1/2 the diameter of the endmill You can use V-blocks on a milling machine True The purpose of the overarm is to support the ____________, which in turn supports the __________ arbor supports, free end of arbor What controls the feed rate on a milling machine? Controlled by gearbox found in knee. Levers are picked for speed or can be picked with a dial for lighter milling What is the taper per foot used on milling machine spindles? 3 1/2" per foot

60 minutes What is a vernier scale? 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 Rack and pinion What is the construction of a micrometer?

1. Anvil
2. Spindle
3. Sleeve
4. Thimble
5. Ratchet
6. Lock nut
7. Frame What method provides most accurate measurement when it comes to a micrometer? Ratchet method because it releases at the same pressure every time Regular micrometer scale level of accuracy is: 0.001" Vernier micrometer scale level of accuracy is: 0.0001" What is an Intrimik? 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? The distance measured is covered by the thimble What kind of tool is a taper gauge? Direct reading tool What is a taper gauge used for? 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: Application Why are thread forming screws used? 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?

The pitch diameter of a thread is measured exactly halfway between the major and minor diameters 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? Grade 6 An ISO metric thread is designated by M14 x 2 - 6g. What is the pitch of this thread? 2MM What are 2 types of tapered thread form? NPT and NPTF The unified thread class that offers the tightest fit is: 3 The designation that identifies a nut is: B Marks on the head of a bolt indicate the: grade and tensile strength A thread is designated 5/8 - 11 Class 2A. The thread shown: is an external thread The thread angle from an American National Acme Thread is: 29 degress A no go ring gauge is easliy identified by: annular ring on the knurled surface Thread comparison gauges use __________ as a basis for thread size Pitch diameter Rolled threads are advantageous over machined threads because: They have increased tensile strength They produce a burnished thread finish They have better wear resistance which reduces fatigue and shear problems

720 RPM

Small drills require a higher feed per revolution than larger ones. False Which abbreviations is used to express the feed rate on a drill press? 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 should you secure the drill in the spindle? Use a drill socket To remove a tapered shank twist drill from the drill press spindle, use a: drill drift When using a sensitive drill press, what should you do as the drill breaks through the workpiece? Ease up on the pressure The included point angle of a countersunk hole for most flathead screws is: 82 degrees Which type of machine tap pushes the hip out ahead of the tap? Spiral pint (gun) tap The lip relief (clearance) angle of a drill should be: 8-12 degrees A general-purpose drill bit for drilling most metals has an included point angle of: 118 degrees The hand drill is quicker and more versatile than any drill press for: drilling small non-vertical holes Electric hand drills are limited by: the amount of feed pressure (and rpm) that can apply to large-diameter drills How are step drills used? Used to drill and then countersink You must used the correct RPM when using a center drill or you will dull/break the bit True What speed should a countersink and counterbore be set at?

Approximately 1/4 of what you would use for a drill What are the drill point included angles for soft, general and hard material? 60-90 degrees for soft, 118 degrees for general and 150 degrees for hard material What are 2 dial reading styles? Balanced and continuous What are 3 types of dial indicators? Bottom plunger, test indicators and back plunger What are dial bore gauges? Comparison measurement tool What is the advantage of a dial bore gauge? You can move it to various positions with making any adjustments Copper sulphate layout solution should be used on: Ferrous metals When angles are laid out with a bevel protractor, the accuracy attainable is: +/- 0.5 degrees (30mins) The surface gauge is used: to layout lines parallel to an edge For maximum reliability when setting dividers to a dimension on a steel rule: set one point to the 1 inch or 10 MM graduation Trammels are used for scribing when: the circle to be scribe is beyond the range of the dividers When a radius is being laid out on a corner? the centre of the radius is located equidistant from the two adjacent sides before using a vernier height gauge it is important to: zero the vernier to the reference surface If the lines are scribed onto a workpiece it is considered to be: temporary layout The grade of surface plate which would be used in the shop is the: Grade B

Tailstock The thread chasing dial is used to: time engagement of the split nut when cutting a thread The tailstock is in position on the ways of the lathe with the: Tailstock clamp The chuck best suited to holding odd-shaped pieces is the: four-jaw chuck An O-ring groove would be cut with: a form tool When grinding HSS, you must remember to: Quench often Cemented carbides are sharpened on aluminum oxide wheels False The manual oil pump on the carriage pumps oil to: The ways Worn wipers could allow chips to get between the carriage and the ways True Chips left on the ways are a concern because: Coolant on chips can cause rusting What type of taper is used in the tailstock? Morse taper How are metric tapers designated? As a ratio 1: What is the amount of taper on taper pins? 1/4" per foot Cutting a taper with a compound rest has what major disadvantage? There is no power feed What is affected when drill bit tapers get damaged? Alignment and locking capability

Once you have set a taper attachment to a desired angle, what important step must you follow? Take a trial cut and measure the taper The most common lathe operation is: turning Cutting speed refers to: How fast the workpiece travels past the tool Turning is usually done: with a right-hand tool An infeed of 0.050 on a direct reading cross-slide results in a diameter reduction of:

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? RPM = (CS x 4)/ D (290 x 4)/4.5= 257.7777 or 255 The boring operation on a lathe: increases the diameter of a hole in a workpiece A reamer is used to: produce smooth accurate holes How does the speed and feed of a reamer compare to a drill? RPM is slower and feed is faster The pitch of a thread cut on a lathe is controlled y: The lead screw The finish on a thread can be enhanced by using: Coolant The thread-chasing dial: 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 True The result of knurling is:

40 TPI

Before using a gauge block, you should take which of the following actions? Remove the rust preventative compound If you are cleaning parts in a typical solvent tank, which of the following would provide the best protection for your eyes? Goggles What would be best suited for your protection if you are required to work with electric power in a damp/wet space GFCI At what dB level would most people start feeling pain in there ears? 140 dB What classification of ladders may be used for construction purposes? Grade 3 What is the Workers' Compensation Act? Provincial legislation to protect workers What is a poor example of housekeeping? Poor lighting A temporary fall arrest system anchor point must have what minimum capacity to resist a fall? 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? 85 dB What best describes a "confined space"? Partially/totally enclosed space not designed for human occupancy with a limited access What is required for every work platform? Safe access A rope grab in horizontal life line can cause what kind of hazard? Swing rope harzard What can a damaged plasma torch shield cause? Tip to overheat

What is a hissing or squealing sound emitting from a cutting torch a sign of? Flashback Plasma cutting nozzles are normally made of what material? Copper What is the primary purpose of the secondary gas in plasma arc cutting? Cools the torch What is a major cause of incomplete penetration? incorrect joint design Flame temperature changes with the addition of: Oxygen What is the minimum safe distance from which an electric arc should be seen with the naked eye? 12M (40ft) What is Voltage responsible for in arc welding? Starting arc Welding tip sizes are 000,00,0 and 1- True What type of electrode is used in the CAC-A process Carbon-graphite Which type of rod is best suite for high carbon steel in overhead postion? 7018 What type of flame is used to fusion weld low carbon steel? Neutral What gas is most efficient for welding purposes? Acetylene Carbon arc cutting can trim or cut parts made of ferrous and some non-ferrous metals True What is a worker responsible for? For own safety Wear proper PPE

What are the types of hazardous energy? Kinetic, chemical, potential, thermal, electrical and radiation What is ZMS in terms of lockout? Zero mechanical state You must bleed all residual pressure when locking out True What is the difference between fall arrest and fall restraint? 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? 0.006-0.008" per foot What is the taper per foot for a jacobs taper? 0.591-0.979" per foot What pitch of a hacksaw blade is for general shop use? 18-pitch A high pitch blade number is generally used for: Harder and thinner material How many teeth should be in contact with material when using a hack saw? 3 teeth What percentage does a tap drill leave for making threads? 75 percent What taper do pipe taps have? 3/4inch per foot How much material should leave for reaming? 0.005" What is ageing in terms of cast iron? Its a stress relieving process What are the properties of oxygen? Colourless, odourless and tasteless as well as supports combustion In oxyacetylene, how pure is oxygen?

99.5% pure oxygen What is the maximum safe working pressure for acetylene? 15 PSI At what PSI is acetylene considered at its critical point? 28 PSI What is the draw limit for acetylene? Can't be emptied faster than 1/7th of its capacity per hour What is backfire? Makes a bang/pop sound. cause by grossly unequal pressures and little gas flow What is flashback? Almost the same as backfire. Cause by grossly unequal pressures. One gas may go back into another line and create an explosive mixture What is burnback? When combustion takes place in tip/mixer causing black smoke, red sparks and a screeching sound from the tip Carburizing flames are rich in: Acetylene Oxidizing flames are right in: Oxygen What is brazing? Filler metal is spread through capillary attraction What is braze welding? Form of gas welding, filler metal is built up on surface What is a scarf joint? A mix of a butt and lap joint For brazing, what fit up produces highest strength ratings? 0.001-0.005" What is amalgamation? Action/process or result of combining/uniting

Cast iron What is maraging steel? Carbon is considered an impurity. Made up of nickel, cobalt and molybdenum Ferrite is: Pure iron Pearlite is: Iron and carbon Cementite is: Iron and carbon where iron is dominant Martensite is: Rapid cooling of austenite Austenite is: Ferrite but heated to red hot Only steel with a carbon content of .10 and higher percent can be hardened False. Only steel with a carbon content of 0.20 percent and higher can be hardened What is full annealing? Opposite of hardening What is limestone? A flux that is added when forging steel to remove impurities What does C mean in AISI manufacturing process of steel? C= Basic open hearth carbon steel What are 3 types of technical drawings?

1. Orthographic
2. Pictorial
3. Schematic What are the 2 angles of orthographic drawings?
4. First angle (Europe)
5. Third (North America) What are the 2 types of pictorial drawings?

1. Orthographic
2. Oblique Isometric has __ angle: 30 degree Oblique has __ angle: 45 degree What are the 3 types of tolerances?
3. Unilateral
4. Bilateral
5. Direct On a pedestal grinder, the gap between the grinding wheel and work rest should not exceed: 1/8 inch The kind of abrasive material used in grinding wheels for general purpose applications is: aluminum oxide A blotter is used on a grinding wheel to: 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: 1/3 the diameter of the wheel The best wheel to use for cleaning scale and dirt off a workpiece is the: wire wheel What is a natural abrasive? made of natural material rather than synthetic Under properties of abrasives, to what does the term hardness refer? ability of a material to scratch or penetrate another material The ____ is the part of the wheel that holds the grains together bond Markings for the wheel identification can be found on the _______ Blotter What is the recommended speed to run a grinding wheel?