INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

KULLIYYAH OF ENGINEERING

MEC1105 WORKSHOP TECHNOLOGY

Semester II, 2004 ~ 2005
End of Semester Test
12 March 2005 (02:30 ~ 03:00 PM)
th

Name

Khairul Amri Bon Tofrowaih

Instructions:

Matric. No.

0634571

(a) Answer all thirty (30) questions (total six [6] printed pages).
(b) Each question carries 1 mark.

1.

Heat treatment is a process of heating metal to a range of temperatures and then cooling
at a control rate to produce certain microstructures. (YES/NO)

2.

In quenching process the heated steel is cooled (CIRCLE THE RIGHT ANSWER)
a.
b.

by dipping into water

in air

c.
d.

in the furnace
none of the above

3.

Tempering treatment increases hardness in the quenched steel. (YES/NO)

4.

Annealed steel is harder than normalized steel. (YES/NO)

5.

In arc welding, joining occurs by melting only the electrode. (YES/NO)

6.

The material used for joining purpose in your practical work is

a.
b.

Copper
Mild steel

c.
d.

Cast iron
Aluminum

7.

In gas welding, no filler metal is required (YES/NO).

8.

Chipping hammer is used to remove slag from the weld bead. (YES/NO)

9.

Pattern is the first forming tool for a foundry man and an exact replica of a part to be cast:
(TRUE/FALSE)

10.

In gas welding process the following two gases are used to produce the flame.
(UNDERLINE THE RIGHT ANSWER)
a.
b.
c.

Acetylene gas
Methane gas
Air

d.
e.

Hydrogen
Oxygen

11.

The pattern that you produce for casting had a core print. (YES/NO)

12.

The metal used for casting in the workshop shop was: cast iron / copper / aluminum /
steel. (UNDERLINE THE RIGHT ANSWER)

13.

The furnace used to melt the metal in the foundry shop is known as
a.
b.

Blast furnace
Induction furnace

c.
d.

Cupola furnace
Heat treatment furnace

14. The molding sand is a mixture of sand, clay and water. (YES/NO)
15.

The sheet metal used for making funnel is made of low carbon steel / aluminum / titanium /
silver. (UNDERLINE THE RIGHT ANSWER)

16.

The following statements are incorrect except

a.
b.
c.
d.

17.

Safety is a judgment of the acceptability of danger in terms of hazard and risk

Hazard is the probability of occurrence of an unsafe situation
Floor with spilled oil is a hazard-free working environment.
First aid is one of the principles of hazard control

Identify correct statement(s) for good safety practices from the followings:
I
II

III

a.
b.

18.

Cleaning working place and striving for good order

Stopping a machine or a process when facing an uncertainty
Ensuring machine parts such as chuck key is left on the rotating part of
the machine
I
I & II

c.
d.

I, II & III
III only

A cylindrical bar of 20 mm diameter is to be turned to make a motor shaft of 15 mm

diameter. If the machining is to be completed by a single turn only, the depth of cut is to be
a.
b.

5.0 mm
2.5 mm

c.
d.

2.0 mm
1.5 mm

19.

In metal machining, the cutting fluid is used to

a.
b.

20.

cool the cutting zone

reduce wear and friction

c.
d.

both a and b
none of a and b

You have been asked to turn a shaft of diameter 20 0.5 mm. The limits of allowable
diameters should be
a.
b.

20.0 21.0 mm
20.0 20.5 mm

c.
d.

19.5 20.5 mm
19.5 20.0 mm

21.

Both instrument and gauge serve the same purpose in checking dimensions (TRUE /
FALSE).

22.

The measurement indicated by the illustration in Fig. 1 below is

cm
Fig. 1
a.
b.
23.

0.75 mm
0.075 mm

c.
d.

0.75
1.50

cm
cm

The measurement indicated by illustration in Fig. 2 below is (CHOOSE THE RIGHT

ANSWER)
a.
b.

3.48 mm
4.48 mm

c.
d.

3.98 mm
4.00
mm

Fig. 2

5
0
0

4
5

4
0

24.

The cutting speed, V of a milling cutter of diameter 50 mm with spindle speed of 1000 rpm
is to be
a.
b.

25.

157, 080 m/min

157
mm/min

Ceramic

Carbide High Speed Steel High Carbon Steel

In face milling the axis of rotation of the tool is

a.
b.

27.

c.
d.

Draw an arrowhead on the line given below to indicate decreasing cutting speeds using the
stated cutting tool materials.
CBN

26.

157
m/min
0.157 m/min

parallel to the workpiece

surface
perpendicular to the workpiece
surface

c.

inclined to the workpiece surface

d.

of any position

A 24 mm diameter stainless steel rod is reduced to 16 mm diameter by turning with 0.5

mm/rev feed, 2 mm depth of cut and 300 rpm ( MRR Davg fdN with usual meaning of
the notations). The MRR is
a.
b.

22850 mm3/min
20850 mm3/min

c.
d.

18850 mm3/min
none of the above

28.

Reaming speed is normally carried out at

a.
b.

29.

2 x drilling speed
1 x drilling speed

x drilling speed
none of the above

Which of the followings is NOT true when cutting thread using tap and die
a.
b.

30.

c.
d.

tap is used to cut internal thread

die is used to cut external
thread

c.
d.

die is used to cut internal thread

pecking must be done as in
drilling

High friability of abrasive in grinding means

a.

ease of which grinding wheel

burns
degree of heat checking

b.

c.
d.

ease of adhesive fracture into smaller

pieces for self-sharpening
lower grain sizes

Extra questions
Both instrument and gauge serve the same purpose in checking dimensions.
(one question related to vernier can be removed)
Semester I, 2005/2006
Q1. The colour of emergency button in a machine tool is usually
a.
b.

Blue
Red

c.
d.

Black
Green

Q2. In the context of a measure of safety which of the following statement is not acceptable
a.

Do not use hands to clear metal

chips.

c.

b.

Do not report the case of injury

or accident as it may frighten
others

d.

Do not take measurement while

the machine or work-piece is
rotating.
Do not set the tools when the
machine is running.

Q3. Identify the correct instruction (s) for good safety practices from the followings:
I
II

Clean the working place and strive for good order.

Stop a machine or a process if you face an uncertain situation

III

a.
b.

Be indifferent whether machine parts such as chuck key is left on the

rotating part of the machine or not.
I
I & II

c.
d.

I, II & III
III only

Q.4 Identify the statement(s) which is/are not true.

In machining operation the coolant is used to
a. cool the cutting zone
c. remove the chip
b. reduce wear and friction
d. increase MRR
Q.5 Reaming speed is normally carried out at
a.
b.

2 x drilling speed
1 x drilling speed

c.
d.

x drilling speed
none of the above

Q.6 A 24 mm diameter stainless steel rod is reduced to 16 mm diameter by turning with 0.5
mm/rev feed, 2 mm depth of cut and 300 rpm (with usual meaning of the notations). The
MRR is
a.
b.

22850 mm3/min
20850 mm3/min

c.
d.

18850 mm3/min
none of the above

Q.7 In peripheral milling the axis of rotation of the tool can be

a.

parallel
surface

to

the

work-piece

c.

b.

perpendicular to the work-piece

surface

d.

set to either parallel or

perpendicular to the work-piece
surface
independently set to any position

Q.8 Draw an arrowhead on the line given below to indicate increasing cutting speeds for
machining of the stated materials.
Aluminium

< Copper

<

High Speed Steel < High Carbon Steel

Q.9 A cylindrical bar of 20 mm diameter is to be turned to make a motor shaft of 15 mm

diameter. If the machining is to be completed by a single turn only, the depth of cut is to
be
a.

5.0 mm

c.

2.0 mm

b.

2.5 mm

d.

1.5 mm

Q.10. Given the small division of the main scale is 1 mm, the measurement indicated by the
illustration in Fig. 1 below is

cm
Fig. 1
a.
b.

0.75 mm
0.075 mm

c.
d.

0.75
1.50

cm
cm

Q.11 Given the small division of the main scale is 1 mm, the measurement indicated by
illustration in Fig. 2 below is (CHOOSE THE RIGHT ANSWER)
a.
b.

3.48 mm
4.48 mm

c.
d.

3.98 mm
4.00
mm

Q.12.The bursting speed of a broken grinding wheel can be

a.
b.

increased
decreased

c.
d.

remain same
either of the three

Fig. 2

5
0
0

4
5

4
0