CHAPTER 15 SAMPLE QUIZ QUESTIONS
15.1. Which of the following describes the motion of a Type A gate?
a. gate goes down, ram goes down, gate goes up, ram goes up
c. gate goes down and stays down until the setup supervisor releases it
d. none of the above
ref. p. 385
15.2. Which of the following qualifies as a means of safeguarding the point of operation
of a mechanical power press?
b. awareness barrier
c. hand-feeding tool
d. sliding bolster
ref. p. 372-376
15.3. Which of the following safeguarding strategies is prohibited for a full-revolution
press?
a. die enclosure guard
b. Type B gate
c. Type A gate
ref. p. 388
15.4. Which of the following types of presses requires brake monitors and control
systems?
a. full revolution, hands-in, 2-hand trip
b. full revolution, hands-out, 2-hand trip
d. all of the above
ref. p. 388
15.5. Which of the following types of presses require point of operation safeguarding?
a. full revolution, hands-in
b. full revolution, hands-out
c. part revolution, hands-in
ref. p. 384
15.6. Which of the following devices does not qualify as an OSHA-acceptable method
of safeguarding the point of operation of mechanical power presses?
a. pull-outs (pull-backs)
c. two-hand controls
d. interlocked barrier guards
ref. p. 391
15.7. Label the figure with the OSHA specified gaps.
15.8. What type of safeguard for the point of operation is convenient for presses that
employ automatic feeding of coils of strip stock and automatic ejection of the
finished parts?
15.9. Which of the following point of operation safeguarding methods is most
appropriate for presses that employ automatic feeding of coils of strip stock and
automatic ejection of the finished parts?
a. awareness barrier
c. presence sensing device
d. two-hand controls
ref. p. 384
15.10. Which of the following point of operation safeguarding methods is most
appropriate for presses that employ automatic feeding of coils of strip stock and
automatic ejection of the finished parts?
a. tongs
b. brake monitor and control system
d. pullbacks
ref. p. 384
15.11. Which of the following point of operation safeguarding methods is most
appropriate for presses that employ automatic feeding of coils of strip stock and
automatic ejection of the finished parts?
a. awareness barrier
b. top stop limit device
c. anti-repeat
ref. p. 384
15.12. Which of the following point of operation safeguarding methods is most
appropriate for presses that employ automatic feeding of coils of strip stock and
automatic ejection of the finished parts?
a. die feeding devices
b. brake monitor and control system
d. awareness barrier
ref. p. 384
15.13. What similar alternative is suggested for an interlocked barrier guard when hand
feeding is to be used for feeding a punch press?
15.14. Which of the following alternatives is suggested for an interlocked barrier guard
when hand feeding is to be used for feeding a punch press?
a. fixed barrier guard
b. die enclosure guard
c. brake monitor and control system
ref. p. 377, 385
15.15. Which of the following alternatives is suggested for an interlocked barrier guard
when hand feeding is to be used for feeding a punch press?
a. anti-repeat
c. friction clutch
d. manual override
ref. p. 377, 385
15.16. To comply with OSHA standards for mechanical power presses, automatic
feeding is an alternative to safeguarding the point of operation.
15.17. A legal alternative to safeguarding the point of operation on a mechanical power
press is to employ hand feeding tools.
15.18. A legal alternative to safeguarding the point of operation on a mechanical power
press is to employ anti-repeat devices.
15.19. A legal alternative to safeguarding the point of operation on a mechanical power
press is to employ a top stop limit.
15.20. A legal alternative to safeguarding the point of operation on a mechanical power
press is to employ a brake monitor and control system.
15.21. Which of the following is most effective on a full-revolution press?
b. presence sensing device
c. top stop limit
d. brake monitor and control system
ref. p. 332-354
15.22. Which of the following is least effective on a full-revolution press?
a. die enclosure guard
c. fixed barrier
d. pullbacks
ref. Table 15.2, p. 398
15.23. Which of the following is least effective on a full-revolution press?
a. die enclosure guard
b. pullbacks
c. fixed barrier
ref. p. 372-398
15.24. A “14-PT Niagara” is a full revolution press with 14 engagement points on the
flywheel. Suppose that this press has a flywheel speed of 50 rpm. Calculate the
safety distance for two-hand trips.
60 sec/min
15.25. A mechanical power press equipped with brake and clutch has a stopping time of
.3 seconds.
a. Calculate the minimum distance for placement of a presence sensing
device.
b. Calculate the minimum distance for placement of a two-hand control
device.
15.26. A mechanical power press, having a flywheel speed of 75 rpm and equipped with
a brake and clutch, has a stopping time of .4 seconds.
a. Calculate the minimum distance for placement of a presence sensing
device.
b. Calculate the minimum distance for placement of a two-hand control
device.
c. Calculate the minimum distance for placement of a two-hand trip
device.
15.27. For full revolution presses with flywheel speeds of 75 rpm, calculate the
mathematical limit for the minimum possible safety distance permissible for two
hand trips, regardless of the design of the engagement mechanism.
15.28. Suppose that two hand trips are installed on a clutch-activated, part revolution
press, the trips being incapable of triggering a brake to interrupt a stroke mid-
cycle. If the flywheel speed is 120 rpm, calculate the safety distance for the two-
hand trips.
15.29. A manufacturing engineer is considering purchase of a mechanical, full
revolution, punch press for a high-efficiency workstation. You are asked to
compute an appropriate safety distance for a two-hand trip safeguarding device
for this machine.
a. What additional design specifications for this machine would you need
before responding to the manufacturing engineer’s problem?
b. What would be your response? (You may assume any arbitrary value(s)
for data you listed in part (a) above as necessary to solve this problem.)
2. number of engagement points
b) Assume: 1. flywheel speed = 60 rpm
2. number of engagement points = 2
60 sec/min
S.D. = ————- [1/2 +1/2]rev x 63 in/sec = 63 in.
60 rev/min
ref. p. 393-396
15.30. A manufacturing engineer is considering purchase of a mechanical, full
revolution, punch press for a high-efficiency workstation. You are asked to
compute an appropriate safety distance for an infrared barrier safeguarding
device for this machine.
a. What additional design specifications for this machine would you need
before responding to the manufacturing engineer’s problem?
b. What would be your response? (You may assume any arbitrary value(s)
for data you listed in part (a) above as necessary to solve this problem.)
15.31. For which of the following would a brake monitor and control system be required
for applications in which the operator places his or her hands in the dies for
feeding the press?
a. flywheel punch press with a four-point positive engagement
c. hydraulic press for deep-drawing
d. press brake
ref. p. 386-388, 398
15.32. For which of the following would a brake monitor and control system be required
for applications in which the operator places his or her hands in the dies for
feeding the press?
a. part revolution press with a type A gate
c. part revolution press with an adjustable barrier guard
d. full revolution press with a sweep
ref. Table 15.2, p. 398
15.33. For a part revolution mechanical power press used with hands-in-the-dies
feeding and equipped with a Type A gate, does the OSHA standard permit an
alternative to having a brake monitor and control system on the press? If so,
what is this alternative?
15.34. For a part revolution mechanical power press used with hands-in-the-dies
feeding and equipped with a Type B gate, does the OSHA standard permit an
alternative to having a brake monitor and control system on the press? If so,
what is this alternative?
15.35. For a part revolution mechanical power press used with hands-in-the-dies
feeding and equipped with two hand controls, does the OSHA standard permit an
alternative to having a brake monitor and control system on the press? If so,
what is this alternative?
15.36. For a part revolution mechanical power press used with hands-in-the-dies
feeding and equipped with a presence sensing device, does the OSHA standard
permit an alternative to having a brake monitor and control system on the press?
If so, what is this alternative?
15.37. Under what circumstances is a full revolution mechanical power press required to
have a brake monitor and control system?
15.38. Under what circumstances is a “normal limit reasonably established by the
employer” required for top-stop overrun?
15.39. What system checks for top-stop overrun? How often is it required to check it?
15.40. Which of the following safeguarding methods may require the monitoring of top-
stop overrun beyond a “normal limit reasonably established by the employer”?
a. type A gate
c. presence sensing device
d. two-hand control
ref. p. 397 and Table 15.2, p. 398
15.41. Label the nip point(s).
ref. p. 364
15.42. Label the nip point(s).
ref. p. 364
15.43. Label the nip point(s).
ref. p. 364
15.44. Label the nip point(s).
ref. p. 364
15.45. Label the nip point(s).
ref. p. 364
15.46. Label the nip point(s).
ref. p. 364
15.47. Label the nip point(s).
ref. p. 364
15.48. The type of guarding shown is
a. by brake monitor
b. by presence sensing
c. by location
ref. p. 365-366
14.49. Which of the following replaces the function of a point of operation guard?
none of these
(a) (b) (c) (d)
ref. p. 372-373
14.50. Which of the following employs a sliding die?
(a) (b)
(c) (d)
14.50. Which of the following employs an interlock?
(a) (b)
(c) (d)
14.51. Which of the following is a jig guard?
(a) (b)
(c) (d)
14.52. Which of the following has adjustable members?
(a) (b)
(c) (d)
15.53. The device pictured is an adjustable barrier guard.
15.54. The device pictured is an awareness barrier.
15.55. The machine pictured is
b. a press brake
c. a punch press
d. an OBI
ref. p. 379
15.56. The press pictured is an OBI.
15.56. The press pictured is an OBI.
14.57. Which press is part revolution?
(a) (b)
14.58. Which press is full revolution?
(a) (b)
15.59. The drawing illustrates a sliding die or bolster.
15.60. The drawing illustrates a Type A or B gate.
15.61. The device pictured is a Type A or B gate.
15.62. The device pictured is a presence-sensing device.
15.63. The device pictured is a presence-sensing device.
15.64. The device pictured is an infrared sensor.
15.65. The device pictured is not appropriate for a full revolution press.
15.66. The device shown is prohibited for hand feeding.
15.67. The device shown is not an acceptable safeguard for a mechanical power press.
15.68. The device pictured is a brake monitor.
15.69. The device pictured is a brake stop-time measurement device.
15.70. At tripping time which position of the flywheel is luckiest from a safety standpoint
on a mechanical power press?
(a) (b)
15.71. Which switch is the overrun switch?
(a) (b)
15.72. Label the overrun switch.
15.73. The machine pictured is a
a. table saw
b. bench saw
d. band saw
ref. p. 402
15.74. The device pictured
a. removes carbon monoxide
c. increases pressure
d. none of the above
ref. p. 409
15.75. According to safety standards what is the air pressure limit for compressed air
used for cleaning?
15.76. What is the principal hazard when compressed air is used for cleaning?
15.77. What two hazards are described in the text for the use of compressed air for
cleaning?
2. human body internal overpressures resulting from horseplay can even
be fatal
ref. p. 409
15.78. In what way is compressed air for cleaning considered a fatality hazard?
15.79. In a machine shop a machinist is spraying metal chips off a machine using a
compressed air hose connected to the shop’s piped system from the shop air
compressor. What safety precautions are recommended for this procedure?
2. Install chip guarding shield(s)
3. Use personal protective equipment (such as goggles)
ref. p. 408-409
15.80. Which of the following is not among the standard requirements for safe use of
compressed air for cleaning?
a. warning label to beware of flying chips
b. pressure reduced to less than 30 psi
c. chip guarding
d. personal protective equipment
ref. p. 408-409
15.81. Compressed air used for cleaning is required to be reduced to less than 20 psi.
15.82. Compressed air used for cleaning is required to be reduced to less than 30 psi.
15.83. Chip guarding and/or personal protective equipment
b. are not required when compressed air is used for cleaning
c. are always required when compressed air is used for cleaning
d. none of the above
ref. p. 408-409
15.84. One approach to guarding air compressors is to place them in a room by
themselves.
15.85. What three precautions are recommended if air compressors are guarded by
placing them in a separate room?
2. Keep the door locked.
3. Protect maintenance personnel who must enter the room to service the
compressor, by means of administrative procedures and training.
ref. p. 408
15.86. A mechanical power press is equipped with a gate-like device that closes before
the ram goes down and reopens during the upward stroke. Which of the following
types of safeguarding devices does the arrangement comply with?
a. Type A gate
c. Type C gate
d. Interlocked barrier guard
ref. p. 385
15.87. A mechanical power press is equipped with a gate-like device that closes before
the ram goes down and stays closed until the ram has completed its upward
stroke. Which of the following types of safeguarding devices does the
arrangement comply with?
b. Type B gate
c. Type C gate
d. Interlocked barrier guard
ref. p. 385
15.88. A full revolution punch press operates at 60 rpm and has a safety distance of
exactly 63 inches. From this data figure out the number of engagement points
and justify your answer with calculations.
15.89. It can be said that for some presses the slower the speed of the ram, the safer
the press, but for other presses, the faster the speed of the ram, the safer the
press. Explain the logic behind this apparent contradiction, and describe the
physical features that distinguish these two types of presses.
15.90. Interlocked barrier guards are similar to “gates” but somewhat different. Explain
this difference. Also, explain the difference between “Type A” and “Type B”
gates. Comment on the legality of hand feeding of punch presses with each of
these three devices (interlocked barrier guards, Type A gates, and Type B
gates).
15.91. In the field of protection of the point of operation of dangerous machines a
distinction is made between the terms “guarding” and “safeguarding.” Explain
the difference between these two terms. Also comment on the legality of the use
of each of the following methods to protect the operator:
a. awareness barriers
b. tongs and other handfeeding tools
c. sweeps
15.92. Which of the following methods of safeguarding the point of operation of a
machine is classified as “no hands in the dies.”
b. pullbacks
c. presence-sensing devices
d. two-hand controls
ref. 391-392
15.93. For a certain class of industrial machines OSHA standards require “brake
monitors.” The standards also make reference to “brake stop-time measurement
devices.” Name the class of machines and explain the difference in purpose
between the two devices “brake monitor” and “brake stop-time measurement
device.”
15.94. Without going into formulas and numerical specifics, explain the OSHA standard
for the required DISTANCE between the operator and the danger zone on
mechanical power presses. In other words, what variables are taken into
consideration in determining what this distance should be?
15.95. OSHA does not recognize “guarding by location” as a valid method of protecting
the operator from the point of operation of a machine.
15.96. Although OSHA may recognize “guarding by location” as a valid method of
guarding, such methods of guarding are illegal.
15.97. Explain the difficulty in defending “guarding by location” as a strategy for
guarding the point of operation.
15.98. The strategy of “guarding by distance” is a positive control to keep the operator
or other personnel out of the danger zone at all times.
15.99. Explain the difference between the strategies of “guarding by location” and
“guarding by distance.”
15.100. Which do you think is safer, guarding by “location” or guarding by “distance?”
Justify your answer.
15.101. Recent advances in plastics and films have introduced which of the following
additional hazards to the point of operation?
a. electrical shock
b. noise exposure
d. amputation hazards
ref. p. 399
15.102. Describe circumstances under which the point of operation of a machine might
present a radiation hazard.
15.103. Presence sensing devices can be used to effectively protect operators from
burns from heat processes.
15.104. Interlocked barrier guards can be used to effectively protect operators from
burns from heat processes.
15.105. Describe two strategies for dealing with microorganisms that may develop in
metalworking fluids.
15.106. Describe a drawback to using biocides in metalworking fluids to combat
microorganism growth.
15.107. Metalworking fluids present which of the following concerns that should be
addressed by the safety and health manager?
a. Guarding by location
c. Guarding by distance
d. Presence-sensing systems
ref. p. 410
15.108. All of the following are concerns when using metalworking fluids, EXCEPT:
a. toxicity of the ingredients
b. fire hazards
c. disposal
ref. p. 410
15.109. Which of the following methods of dealing with machining chips has inherent
hazards associated with it? Explain these hazards.
a. chip removal by the machine during the cutting process
b. barriers to insure the chips do not escape the chip bin during removal
c. blowing the chips away from the point of operation using compressed air
15.110. Explain how industrial robots can enhance the safety of the workplace.
15.111. The versatility of industrial robots is a direct result of their characteristic:
a. strength
b. power
c. size
ref. p. 411
15.112. Describe the principal safety hazard associated with industrial robots?
15.113. A valid issue to be considered in a decision to employ industrial robots in the
workplace is public sentiment.
15.114. Explain the term “work envelope” in the context of industrial robots.
15.115. Which of the following is not considered a feasible method of protecting workers
against injuries in the work envelope during the programming of an industrial robot?
Explain your reasoning.
a. Assuring that the technician doing the programming is well-trained
b. Providing readily accessible EPOs
c. Assuring that the programmer has immediate control of robot motion power at
all times via a hand-held “teach pendant” while programming.
d. A fixed barrier guard.
EXPLANATION OF REASON FOR CHOICE “d”: A fixed barrier guard, by definition,
prevents the entry of any worker or part of the worker’s body from entering the
15.116. Describe a way in which the hazard can be alleviated when a worker must feed
workpieces to an industrial robot, and both the robot and the worker share the
same space.