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Rolling - Test 2 - Materials Processing | TMET 3343, Exams of Mechanical Engineering

Georgia Southern University (GS)Mechanical Engineering
Prof. David Williams

Material Type: Exam; Professor: Williams; Class: Materials Processing; Subject: TMET Mech Engineering Tech; University: Georgia Southern University; Term: Spring 2011;

Typology: Exams

2010/2011

Uploaded on 05/10/2011

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Materials Processing TMET – 3343 Test 2 Spring 2011
Chapter 13 - Rolling
PART 1 Instructions: Select the best answer and mark your choice in the blank provided.
_____1. The thickness designation of flat rolled steel stock determines whether we call the material
‘sheet’ or ‘plate’. Which of the following is a true statement? (318.1.1)
A. plate is any material with a thickness of .125 inches or greater.
B. sheet stock is any stock less than .250 inches in thickness
C. flat rolled stock must be at least .375 inches thick to be called “plate”
D. none of the above
_____2. The speed of flat rolled stock is greatest at the exit of the roll gap in the rolling process because:
(318.4.4)
A. as with an incompressible fluid, flow is faster as it moves thru a converging channel
B. the speed of the rollers causes slippage of the metal in the process
C. The above statement is false because the speed is NOT greatest at the exit due to the phenomenon of
the “neutral” or “non-slip” point (see inset below).
D. none of the above
_____3. The opening between the rolls (roll gap) on a rolling mill must be: (320.1.4)
A. set to the exact thickness of the of the product’s final desired thickness
B. set to a thickness less than the desired thickness to compensate for deflection of the rolls when
subjected to the heavy pressures required for rolling.
C. set to a thickness greater than the desired thickness to compensate for shrinkage which will occur as
the final product cools
_____4. Spreading (which can be compared to rolling dough with a rolling pin and represented by Wf in
the inset below) can be controlled in a rolling mill operation by rolling the material: (322.4.3)
A. at lower temperatures C. in an edger mill
B. at higher temperatures D. in thermal camber mills
_____5. What types of defects commonly occur in rolled metals? (fig. 13.8)
A. surface defects
B. internal structural defects
C. ‘zipper’ cracks in the center of the strip & wavy edges
D. alligatoring & edge cracks
E. all of the above
Wf Materials Processing TMET – 3343 Test 2 Spring 2011
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Materials Processing TMET – 3343 Test 2 Spring 2011

Chapter 13 - Rolling PART 1 Instructions: Select the best answer and mark your choice in the blank provided. _____1. The thickness designation of flat rolled steel stock determines whether we call the material ‘sheet’ or ‘plate’. Which of the following is a true statement? (318.1.1) A. plate is any material with a thickness of .125 inches or greater. B. sheet stock is any stock less than .250 inches in thickness C. flat rolled stock must be at least .375 inches thick to be called “plate” D. none of the above _____2. The speed of flat rolled stock is greatest at the exit of the roll gap in the rolling process because: (318.4.4) A. as with an incompressible fluid, flow is faster as it moves thru a converging channel B. the speed of the rollers causes slippage of the metal in the process C. The above statement is false because the speed is NOT greatest at the exit due to the phenomenon of the “neutral” or “non-slip” point (see inset below). D. none of the above _____3. The opening between the rolls (roll gap) on a rolling mill must be: (320.1.4) A. set to the exact thickness of the of the product’s final desired thickness B. set to a thickness less than the desired thickness to compensate for deflection of the rolls when subjected to the heavy pressures required for rolling. C. set to a thickness greater than the desired thickness to compensate for shrinkage which will occur as the final product cools _____ 4. Spreading (which can be compared to rolling dough with a rolling pin and represented by Wf in the inset below) can be controlled in a rolling mill operation by rolling the material: (322.4.3) A. at lower temperatures C. in an edger mill B. at higher temperatures D. in thermal camber mills _____5. What types of defects commonly occur in rolled metals? (fig. 13.8) A. surface defects B. internal structural defects C. ‘zipper’ cracks in the center of the strip & wavy edges D. alligatoring & edge cracks E. all of the above

Wf Materials Processing TMET – 3343 Test 2 Spring 2011

_____6. Pickling is a process that conditions the surface of metals that have previously been hot rolled prior to cold rolling. Pickling is NOT : (323.2.3) A. a process used to remove heavy scale produced by hot rolling B. an acid etch process C. blasting with high pressure water to remove scale _____7. When a material is rolled, the amount of reduction taken with each pass of the material between the rolls is known as: (318.6.1) A. camber C. draft B. deflection D. flattening _____8. In which process do the greatest residual stresses occur? A. cold rolling B. hot rolling _____9. What types of lubricants are used in metal rolling processes? A. graphite C. oils, emulsions, & fatty acids B. water based solutions D. all of the above _____10. Chatter is defined as “self excited vibration”; it can occur in: (322.5.2) A. rolling processes only B. machining processes only C. extrusion processes only D. rolling, extrusion, drawing, machining, and grinding operations _____ 11. In the rolling process, chatter can reduce productivity by as much as: A. 10% C. 40% B. 30% D. 50%

_____12. The formula ho-hf = μ 2 R shows:

A. Roll force B. Roll torque C. Power required for a 2-high mill stand D. Maximum reduction possible as a function of roll radius and the coefficient of friction _____13. What formula would be used to determine the roll force in a flat rolling operation?

A. ho-hf = μ 2 R

B. F = LwYavg

C. Ptotal = 2πFLN / 33,000 FLN / 33,000 (in English units)

_____14. Aluminum foil is a product produced by which of the following processes listed below? The fact that there are two distinct surfaces (one side shiny and the other side matte ) on either side of aluminum foil is an indication of the process used. (323.4.1&2) A. cold rolling C. mill-side rolling B. hot rolling D. pack rolling _____15. Rotary tube piercing is used to make the finest seamless tube and pipe, it was demonstrated in the video “Drama of Metal Forming”; this process is also known as:? A. skew rolling C. Pilger Mill tube rolling B. the Mannesmann Process D. None of the above Materials Processing TMET – 3343 Test 2 Spring 2011

_____31. Which of the following is not a system for sizing twist drills? A. decimals C. letters B. fractions D. numbers _____32. Which of the following drill sizing systems has the smallest drill size? A. numbers B. letters _____33. Which machine listed below could be called a “fancy drill press”. A. lathe B. horizontal milling machine C. vertical milling machine D. horizontal cut-off saw _____34. The smaller the diameter the hole being drilled: A. the slower the drilling RPM B. the faster the drilling RPM _____35. A blind hole refers to: A. a hole that does not go through the thickness of the material B. a pilot hole that will ultimately have threads tapped into it C. a hole drilled with a center drill _____36. If you were drilling a deep hole, which drill would be superior for that process? A. chisel-edge drill B. crankshaft drill _____37. When drilling holes, it is common for the finished hole to be slightly oversized (larger than the size of the twist drill used). What material has a unique property and typically produces a hole that is slightly undersized rather than being oversized? A. glass C. plastic B. copper D. brass Instructions: Below are a list of statements. Each statement has a term or terms missing which you must supply to complete the statement.

38. Your textbook identifies four (4) series used to size twist drills; they are 1) numerical, 2) fractional, 3) millimeter (metric) and 4) _____________________. 39. The formula 4CS/D is used to determine the RPM for machine tools. Where do you get the value for ‘D’ in this formula when calculating RPM on a band saw? ________________________________. 40. The formula 4CS/D is used to determine the RPM for machine tools. Where do you get the value for ‘D’ in this formula when calculating RPM on a drill press? ________________________________. 41. The formula 4CS/D is used to determine the RPM for machine tools. Where do you get the value for ‘D’ in this formula when calculating RPM on a lathe?_____________________________________ Materials Processing TMET – 3343 Test 2 Spring 2011

Best Answer Instructions: Select the best answer from the alternatives for each item and place the letter of your choice in the blank provided. _____42. Radial arm drill presses have: A. no power feed B. ½ inch or smaller twist drill capacity C. multiple spindles D. no table for clamping stock E. none of the above _____43. The margin on a twist drill provides: A. a chip breaking function B. a means of dissipating heat generated by the drilling operation C. a relief for chips produced in the drilling operation D. a bearing surface for the drill against the walls of the hole _____44. Which of the following types of drill presses would be, physically, the largest machine tools? A. sensitive drill press B. vertical drill press C. floor model vertical drill press D. radial arm drill press _____45. Expansion reamers are: A. adjustable for small variations in hole sizes B. can be adjusted to compensate for cutting edge wear C. can be adjusted for non-standard hole sizes D. all of the above E. none of the above _____46. Of the following types of cuts, which could not be cut on a shaper? A. internal keyways B. contour surfaces C. gear cutting D. all of the above can be accomplished on a shaper E. none of the above could be cut on a shaper _____47. What would the tap drill size for a 3/8-24 UNF bolt be? A. 3/ B. No. 24 drill C. minor diameter of fastener specifications D. major diameter of fastener specifications E. insufficient information to determine the tap drill size _____48. What is the proper name for the two spiral grooves that run along the length of the body of a twist drill? A. flutes B. margins C. carbide inserts D. none of he above Materials Processing TMET – 3343 Test 2 Spring 2011

_____ 62. The lathe control lever which is always found on the right-hand side of the apron and which is used only during threading operations is called: A. threading B. longitudinal feed C. half-nut D. feed E. none of the above _____ 63. Which of the following is a way of turning a taper on a lathe? A. compound slide method B. offset tailstock method C. taper attachment method D. all of the above E. none of the above