a. 5.62 b. 5.63 c. 5.64 d. 5.

65

10. At 25°C, the specific volume of saturated liquid is 1.003 cm 3/g

Name: ________________________________________________
Industrial Materials and Processes
and the volume of saturated vapor is 43400 cm 3/g. What is the
volume of a mixture with vapor fraction, x=0.3?
a. 13020 cm3/g b. 13021 cm3/g c. 13022 cm3/g d. 13023 cm3/g
11. The atomic radius of Fe is 0.124 nm. Find the lattice
parameter of Fe.
a. 0.285 nm b. 0.286 nm c. 0.287 nm d. 0.288 nm

1. The Toyota truck plant in Indiana produces 150,000 trucks per 12. BCC Fe placed in an x-ray diffractometer using x-ray with λ =
year. The plant runs one eight-hour shift, 300 days per year, and 0.1541 nm. Diffraction from {110} planes was obtained at 2θ =
makes 500 trucks per day. About 1300 people work on the final 44.704o. calculate lattice constant a.
assembly line. Each car has about 20 labor hours per can in it. a. 0.5 FCC b. 0.5 BCC c. 0.4 FCC d. 0.4 BCC
Assuming the truck sells for $16,000 and workers earn $30 per
hour in wages and benefits, what percentage of the cost of the 13. An element that has either BCC or FCC structure shows
truck is in direct labor? diffraction peaks at following 2θ angles: 40, 58, 73, 86.8, 100.4
a. 9.3% b. 9.4% c. 9.5% d. 9.6% and 114.7. wavelength of x-ray λ = 0.154.
a. 0.67 b. 0.68 c. 0.69 d. 0.70
2. In Problem #1, what is the production rate of the final
assembly line? 14. For a slab milling operation using, a 5-in –diameter, 11-tooth
a. 62 trucks/hr b. 63 trucks/hr c. 64 trucks/hr d. 65 trucks/hr cutter (see Figure below), the feed per tooth is 0.005 in/tooth
with a cutting speed of 100 sfpm (HSS Steel). Calculate the rpm of
3. Most companies, when computing or estimating costs for a job, the cutter and feed rate (fm) of the table.
will add in an overhead cost, often tying that cost to some direct
cost, such as direct labor, through the academic job shop. How
would you calculate the cost per unit of a product to include
overhead?
a. Total Cost = Fixed cost + OH + VC
Q
b. Total Cost = Fixed cost + OH + VC
Q
c. Total Cost = Fixed cost + OH + VC
Q Q
d. Total Cost = Fixed cost + OH
Q Q

4. A prepared sample of metal reveals a structure with 64 grains

per square inch at 100 x magnification. What is its ASTM
(American Society for Testing and Materials) grain size number?
a. 4.2 in/min b. 4.3 in/min c. 4.4 in/min d. 4.5 in/min
a. 4 b. 5 c. 6 d. 7
15. For Problem #14, calculate the metal removal rate, (MRR),
5. In Problem #4, would this material be weaker or stronger than
where the width of the block being machined is 2 in and the
the same metal with an ASTM grain size number of 4? Why?
depth of cut is 0.25 in.
a. Have fewer, therefore larger, grains. Larger grain materials are
a. 2.0 in3/min b. 2.1 in3/min c. 2.2 in3/min d. 2.3 in3/min
weaker
b. Have fewer, therefore smaller, grain. Smaller grain materials
16. For Problem #14, calculate the time to machine (Tm) a 6 in-
are weaker
long block of metal with this set up.
c. Have fewer, therefore larger, grains. Larger grain materials are
a. 1.6 mins b. 1.7 mins c. 1.8 mins d. 1.9 mins
stronger
d. Have fewer, therefore smaller, grains. Smaller grain materials
17. In Problem #14, suppose you switched to a coated-carbide
are stronger
tool, so you increase the cutting speed to 400 sfpm. Now
recalculate the machining time (Tm) with all the other
6. Using Chvorinov’s rule as presented in the text with n = 2,
parameters the same.
calculate the dimensions of an effective riser for a casting that is a
a. 0.43 min b. 0.44 min c. 0.45 min d. 0.46 min
2 in x 4 in x 6 in rectangular plate. Assume that the casting and
riser are not connected, except through a gate and runner, and
18. The outside diameter of a roll for a steel (AISI 1015) rolling
that the riser is a cylinder of height/diameter ratio H/D = 1.5.
mill is to be turned. In the final pass, Starting diameter = 26.25 in
The finished casting is what fraction of the combined weight of
and Length = 48.0 in. The cutting conditions will be Feed =
the riser and casting?
0.0100 in/rev and Depth of cut = 0.125 in. A cemented carbide
a. 51% b. 52% c. 53% d. 54%
cutting tool is to be used, and the parameters of the Taylor tool
life equation for this set up are n = 0.25 and C = 1300. It is
7. A rectangular casting having the dimensions 3 in x 5 in x 10 in
desirable to operate at a cutting speed such that the tool will not
solidifies completely in 11.5 minutes. Using n = 2 in Chvorinov’s
need to be changed during the cut. Determine the cutting speed
rule, calculate the mold constant, B. Then, compute the
that will make the tool life equal to the time required to complete
solidification time of a 0.5 in x 0.8 in x 0.8 in casting poured under
this turning operation.
the same conditions.
a. 436 ft/min b. 437 ft/min c. 438 ft/min d. 439 ft/min
a. 0.89 min b. 0.90 min c. 0.91 min d. 0.92 min
19. What is the metal removal rate when a 1.5-in –diameter hole,
8. Consider the extrusion of a cylindrical billet, and assume the
2 in deep, is drilled in 1020 steel at a cutting speed of 200 fpm
starting billet to have a length of 0.3 m and a diameter of 15 cm.
with a feed of 0.010 ipr? What is the cutting time?
This is extruded into a cylindrical product that is 3 cm in
a. 9 in3/min b. 9.1 in3/min c. 9.2 in3/min d. 9.3 in3/min
diameter and 7.5 m long (a reduction ratio of 25). Neglecting the
areas on the two ends, compute the ratio between the product
20. If the specific horsepower for the steel in Problem 3 is 0.9,
surface area (wrap around cylinder) and the surface area of the
what horsepower would be required, assuming 80% efficiency in
starting billet.
the machine tool?
a. 2 b. 3 c. 4 d. 5
a. 8.0 hp b. 8.1 hp c. 8.2 hp d. 8.3 hp
9. In Problem #8, how would this ratio change if the product
were a square with the same cross-sectional area as that of the 3
21. What are major phases of a product life cycle?
cm diameter circle?
a. start up, rapid growth, decline
b. start up, maturation, commodity, decline 36. Its malleability and ductility are confined to certain narrow
c. start up, rapid growth, commodity, decline limits of temperature, and it must be maintained at a
d. startup, rapid growth, maturation, commodity or decline temperature of about 240°F when it is being rolled into sheets. It
is hard, brittle and highly crystalline in fracture, and if the
22. What are the major classifications of basic manufacturing fracture shows dull specks, an excess of iron is present.
processes? a. Zinc b. Tin c. Copper d. Magnesium
a. casting or molding, forming, (heat) treating, metal removal,
finishing, joining (welding), assembly, inspection 37. It resists oxygen and water but dissolves in acids and bases.
b. casting, molding, metal removal, finishing, joining (welding), a. Zinc b. Tin c. Copper d. Magnesium
assembly
c. molding, forming, (heat) treating, metal removal, joining 38. It possesses a highly crystalline structure and is moderately
(welding), inspection ductile.
d. casting, molding, (heat) treating, metal removal, joining a. Zinc b. Tin c. Copper d. Magnesium
(welding), assembly, inspection
39. Solubility, chemical resistance, thermal stability, reactivity
23. What are the physical elements in a manufacturing system? with water, flammability, heat of combustion.
a. machine tools, tooling like workholding devices, material a. Plastics b. Rubber c. Glass d. Wood
handling equipment, inspection equipment, people
b. machine tools, tooling like workholding devices, material 40. Some plastics are partially crystalline and partially amorhous
handling equipment, people in molecular structure, insulators, exremely solid and tenacious.
c. tooling like workholding devices, material handling equipment, Good sliding properties and high capacity of resistance to wear.
people, cycle time Contact with humidity may result in a change of properties.
d. machine tools, material handling equipment, people, cycle a. Plastics b. Rubber c. Glass d. Wood
time, throughput time
41. It is relative impermeable to gases. Resistant to water and
24. What is tooling in a manufacturing system? most chemical fluids.
a. shape or form the unfinished product a. Glass b. Wood c. Rubber d. Textiles
b. cut, shape, or form the unfinished product
c. hold, cut, shape, or form the unfinished product 42. A high molecular weight polymeric substance with
d. hold, cut, shape viscoelastic properties. The most important property of this
engineering material is its elasticity.
25. Unaffected by dry air and pure water at ordinary a. Glass b. Wood c. Rubber d. Textiles
temperature, but commercial iron rusts in moist air and water.
a. Iron b. Steel c. Titanium d. Magnesium 43. An excellent thermal and electrical insulator. Its optical
properties vary greatly, depending on the light wavelengths
26. A good conductor of heat and electricity. employed.
a. Iron b. Steel c. Titanium d. Magnesium a. Wood b. Textiles c. Polymers d. Glass

27. Ability to cool down quickly from a high temperature when 44. The physical properties (other than appearance) are
exposed to water or oil moisture content, shrinkage, density, permeability, and thermal
a. Tin b. Copper c. Steel d. Zinc and electrical properties. Moisture content is a major factor in the
processing of this engineering material because it influences all
28. Does not rust very easily on exposure to water and moisture. physical and mechanical properties, durability and performance
A high quality steel always contain less carbon content along with during use.
less chances of fracture. a. Wood b. Textiles c. Polymers d. Glass
a. Tin b. Copper c. Steel d. Zinc
45. A deformation produced by stress.
29. It reacts very slowly with cold water. It is not affected by dry a. Strain b. Stress c. Strain rate d. Unit strain
air but tarnishes in moist air, forming a thin protective coating of
basic magnesium carbonate. 46. It measures incorporate fixed reference quantities. In this
a. Zinc b. Tin c. Copper d. Magnesium case, undeformed cross-sectional area is used.
a.True stress and strain c. True strain
30. Known as industry's lightest structural metal. It is malleable b. True stress d. Engineering stress and strain
when heated. Highly flammable.
a. Zinc b. Tin c. Copper d. Magnesium 47. It measures account for changes in cross-sectional area by
using the instantaneous values for area, giving more accurate
31. Does not react with water but react with atmospheric oxygen. measurements for events such as the tensile test.
a. Tin b. Copper c. Steel d. Zinc a. True stress and strain c. True strain
b. True stress d. Engineering stress and strain
32. An excellent conductor of electricity and heat; it is strong,
ductile and easily joined by soldering or brazing; and it is 48. It is defined as the ratio of the applied load to the
hygienic, easy to alloy and resists corrosion. It can be combined instantaneous cross-se ctional area; it can be related to the
with other metals to make new alloys, like brass and bronze. engineering stress if we assume that there is no volume change in
These are harder, stronger and more corrosion resistant than the specimen.
pure copper. a. True stress and strain c. True strain
a. Tin b. Copper c. Steel d. Zinc b. True stress d. Engineering stress and strain

33. It is also insoluble in alcohol, though it can be soluble in water 49. It is defined as the sum of all the instantaneous engineering
in certain forms. strains. It can also be related back to the engineering strain,
a. Copper b. Steel c. Zinc d. Aluminum through the manipulation.
a. True stress and strain c. True strain
34. The element blends readily to make lightweight but very b. True stress d. Engineering stress and strain
strong alloys. It conducts both heat and electricity very well. Non-
magnetic, low density, low cost, and corrosion resistant. Has no 50. It is the phenomenon in which a material undergoes changes
odor. in dimensions in response to mechanical forces.
a. Copper b. Steel c. Zinc d. Aluminum a. Fatigue Failure c. Plastic Deformation
b. Deformation d. Failure
35. Chemically similar to magnesium, because its ion is of similar
size and its only common oxidation state.
a. Zinc b. Tin c. Copper d. Magnesium
Psalm 111:10 The fear of the LORD is the beginning of wisdom;
all who follow HIS precepts have good understanding. To HIM
belongs eternal praise.