Chapter Tests
and Problems
ChaPTer 4 ManufaCTuring
MaTerials and ProCesses TesT
INSTRUCTIONS
Answer the questions with short, complete statements or draw–
ings as needed.
QUESTIONS
Part 1: Manufacturing Materials
1. Define ferrous metals.
2. Identify the two main types of ferrous metals.
3. Define nonferrous metals.
4. What is another name for plastics?
5. Define thermoplastic.
6. Define thermoset.
7. Define tensile strength.
8. Why are refractories used for such applications as furnace
liners?
9. What are composites?
10. Describe the characteristics of gray cast iron.
11. Given the gray cast iron material specification 30A, what
does the prefix 30 denote?
12. Define ductility.
13. What are the properties of white cast iron?
14. Which cast iron has the internal characteristics of gray cast
iron and the exterior properties of white cast iron?
15. Define malleable.
16. Identify at least two uses for nodular cast iron.
17. How is it possible to alter the properties of steel?
18. Name a steel that is low in carbon and is commonly used for
forged and machined parts.
19. Describe high carbon steel.
20. Describe the difference between hot- and cold-rolled steel.
21. Describe the properties of the following steel alloying ele-
ments: manganese, molybdenum, and tungsten.
22. Describe stainless steel.
23. Give the typical contents of stainless steel.
24. Identify the contents of the 200, 300, and 400 series stainless
steels as identified by the American Iron and Steel Institute.
25. Identify at least four common uses for stainless steel.
26. Given the steel identification number SAE 1020, describe
the components: SAE, 10, and 20.
27. Identify the steel recommended for the following general
applications: agricultural steel, bolts and screws, car and
truck gears, transmission shafts.
28. Define heat treating.
29. Define normalizing.
30. Define case hardening.
31. Define carburization.
32. Define tempering.
33. How is the Rockwell hardness test performed?
34. Describe the properties of aluminum.
35. Define extruded.
36. Identify the alloying elements in brass.
37. Identify the alloying elements in bronze.
38. What is the advantage of adding phosphorus to bronze?
39. Describe at least one industrial use for gold.
40. Identify the metal that has the weight advantage of alumi-
num and the strength of steel.
41. What are the elements of and process for making tungsten
carbide?
In Questions 42 through 57, identify the type of metal or metals
that are part of the given Unified Numbering System (UNS)
series:
42. A00001 to A99999
43. C00001 to C99999
44. E00001 to E99999
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45. L00001 to L99999
46. M00001 to M99999
47. P00001 to P99999
48. R00001 to R99999
49. Z00001 to Z99999
50. D00001 to D99999
51. F00001 to F99999
52. G00001 to G99999
53. H00001 to H99999
54. J00001 to J99999
55. K00001 to K99999
56. S00001 to S99999
57. T00001 to T99999
58. Give the general definition of plastic.
59. Name the process of joining two or more molecules to form
a more complex molecule with physical properties that are
different from the original molecules.
60. Identify the term that refers to polymer-based materials
that have elastic qualities not found in thermoplastics and
thermosets.
61. Give the name and basic characteristics of ABS.
62. Give the name and basic characteristics of ASA.
63. Give the name of the thermoplastic that has the versions
nitrate, acetate, butyrate, propionate, and ethyl cellulose.
64. Name the type of thermoplastics that are very resistant to
chemicals, friction, and moisture. These materials have ex-
cellent dimensional stability for use as wire coating and in-
sulation, nonstick surfaces, chemical containers, O-rings,
and tubing.
65. Identify the common name for the polyamide thermoplastic.
66. Name a thermoplastic that is rigid with very high impact
and stress fracture resistance at temperatures between
2408 and 210 8F (2408 to 99 8C), and is used when constant
bending is required in the function of the material design.
67. Give the name of a plastic that is inexpensive to produce
and that has many desirable properties, including heat,
chemical, scratch, and moisture resistance. It is also resis-
tant to continuous bending applications. Products include
appliance parts, hinges, cabinets, and storage containers.
68. Name the plastic that is inexpensive and easy to manufac-
ture, has excellent transparency, and is very rigid. However,
it can be brittle and has poor impact, weather, and chemical
resistance. Products include model kits, plastic glass, lenses,
eating utensils, and containers.
69. Name the plastic that is commonly called PVC.
70. Identify at least two applications for PVC and its character–
istics for these applications.
71. Briefly discuss the major differences between thermoplas-
tics and thermosets.
72. Name the plastic material that dates back to the late 1800s.
This plastic is hard and rigid, has good compression
strength, is tough, and does not absorb moisture, but it is
brittle. These plastics are commonly used for the manufac-
ture of electrical switches and insulators, electronics circuit
boards, distributor caps, and binding material and
adhesive.
73. Name the material that is commonly used as a plastic for
reinforced composites, also known as reinforced thermoset
plastics (RTPs). Typical uses are for boat and recreational
vehicle construction, automobiles, fishing rods, tanks, and
other structural products.
74. Identify the type of plastics that are also referred to as syn-
thetic rubber.
75. Give the term that refers to the heating of the material in a
steel mold that forms the desired shape.
76. Name the material that has the trade name Neoprene and
was the first commercial synthetic rubber. This material has
better weather, sunlight, and petroleum resistance than
natural rubber. It is also very flame resistant, but does not
resist electricity. Common uses include automotive hoses
and other products where heat is found, gaskets, seals, and
conveyor belts.
77. Name the material that has a wide range of makeup from
liquid to solid. Liquid and semiliquid forms are used for lu-
bricants. Harder forms are used where nonstick surfaces are
required.
Part 2: Manufacturing Processes
78. What is another name for casting?
79. Define casting.
80. Name the most commonly used method of making castings.
81. Discuss the function of cores in the casting process.
82. List at least two advantages of using cores.
83. Describe centrifugal casting.
84. List at least two advantages of the die casting process.
85. Describe the permanent casting process.
86. Name the casting technique that is referred to as “lost wax.”
87. Why is shrinkage allowance required in casting design?
88. What is the estimated shrinkage for most irons?
89. Define draft.
90. In casting design, is draft added to the minimum or maxi-
mum design sizes of the part?
91. Identify at least two reasons why fillets are used in casting
design.
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92. List at least three considerations that influence the amount
of extra material that must be left on a casting for machining
allowance.
93. What is the recommended standard finish allowance for
iron or steel?
94. Describe hot spots in casting.
95. Define forging.
96. What is the grain structure advantage of using the forging
process to manufacture a part rather than making a ma-
chined part?
97. Describe upset forging.
98. Describe swaging.
99. Describe bending.
100. Describe punching.
101. List at least two advantages of machine forging.
102. Briefly describe the stamping process.
103. Give the name of the machine that performs the stamping
operation.
104. Name the process that takes metal-alloyed powders and
feeds them into a die where they are compacted under pres-
sure to form the desired shape. The compacted metal is then
removed from the die and heated at temperatures below the
melting point of the metal.
105. What is the process called that takes the compacted metal
that has been removed from the die in the previous question
and then heats it at temperatures below the melting point of
the metal?
106. Briefly describe the metal injection molding (MIM) process.
107. Name the manufacturing process that is the most commonly
used process for creating thermoplastic products. The pro–
cess involves injecting molten plastic material into a mold
that is in the form of the desired part or product. The mold is
in two parts that are pressed together during the molding
process. The mold is then allowed to cool so the plastic can
solidify. When the plastic has cooled and solidified, the press
is opened and the part is removed from the mold.
108. Name the manufacturing process that is used to make con-
tinuous shapes such as moldings, tubing, bars, angle, hose,
weather stripping, films, and any product that has a con-
stant shape. This process creates the desired continuous
shape by forcing molten plastic through a metal die.
109. Name the manufacturing process that is commonly used to
produce hollow products such as bottles, containers, recep-
tacles, and boxes. This process works by blowing hot poly-
mer against the internal surfaces of a hollow mold.
110. Give the name of the manufacturing process that is gener–
ally used to create products such as vinyl flooring, gaskets,
and other sheet products. This process fabricates sheet or
film thermoplastic or thermoset plastics by passing the ma-
terial through a series of heated rollers.
111. Name the process that works by placing a specific amount
of polymer pellets into a metal mold. The mold is then
heated as it is rotated. This forces the molten material to
form a thin coating against the sides of the mold. When the
mold is cooled, the product is removed.
112. Give the name of the process that works by placing material
into an initial hot die where it takes the preliminary shape.
As the material cools, a die that matches to the shape of the
desired product forms the final shape.
113. Name the process that works by taking a sheet of material
and heating it until it softens and sinks down by its own
weight into a mold that conforms to the desired final shape.
Vacuum pressure is commonly used to suck the hot material
down against the mold.
114. Give the name of the process that uses a computer model
that is traced in thin cross sections to control a laser that
deposits layers of liquid resin or molten particles of plastic
material to form the desired shape.
115. Name the common fabrication process for thermosets that
uses a specific amount of material that is heated and placed
in a closed mold where additional heat and pressure are ap-
plied until the material takes the desired shape. The mate-
rial is then cured and removed from the mold.
116. Give the name of the process that is similar to casting, but
that uses a foam material that expands during the cure to fill
the desired mold.
117. Give the name of the material that is also commonly re-
ferred to as reinforced plastic.
118. Briefly describe the layering process that is used for making
reinforced plastic.
119. Give the name of a process where resin is used to make qual-
ity composite products with a smooth surface on both sides.
This method places reinforcing material into a mold and
then pumps resin into the mold.
120. Name the process that uses vacuum pressure to force a thin
layer of sheet-reinforced polymer around a mold.
121. Give the name of the process that uses machines to wind
resin-saturated reinforcement fibers around a shaft.
Part 3: Machine Processes
122. List at least two reasons why the mechanical drafter should
be familiar with machining processes.
123. List four types of machining operations that can be per–
formed on a drilling machine.
124. Identify one of the primary functions of the grinding
machine.
125. Describe the main function of a lathe.
126. Describe a feature of milling machines that influences the
ability of operations and shapes that can be performed.
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127. Identify two types of saw tools that can be used for cutoff
and machining operations.
128. Describe chemical machining.
129. Describe electrochemical machining (ECM).
130. Describe electrodischarge machining (EDM).
131. Describe electron beam (EB) machining.
132. What is another name for ultrasonic machining?
133. Describe the basic function of a laser device.
134. Laser machining may be used on what materials?
135. What does the abbreviation CNC mean?
136. Briefly explain the CNC process. Describe computer-
integrated manufacturing.
137. What is the purpose of boring?
138. Identify at least one function of a counterbore.
139. Describe drill depth.
140. Describe and give one application of a knurl.
141. Describe the primary function of a key.
142. Define keyseat.
143. What is the function of a reamer?
144. What action will the machinist take when no spotface depth
is given?
145. Define surface texture.
146. In what units is surface roughness height measured?
147. Discuss the results of designing a part with specifications
that require overmachining.
148. Describe the difference between jigs and fixtures.
149. Normally a jig or fixture is drawn as an assembly of the unit
ready for use, and the workpiece or part to be held is drawn
in position. How is the workpiece drawn in relationship to
the jig or fixture?
150. Name the quality control/detection system that uses statis-
tical techniques and problem solving to monitor, evaluate,
and provide guidance for adjusting the process to improve
quality.
ChaPTer 4 ManufaCT
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Chapter 4
Manufacturing Materials and Processes
Answers to End-of-Chapter Test Questions
Part 1: Manufacturing Materials
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