21 Milling

1. What characterizes milling as a machining process?. A) Continuous cutting with a single edge. B) Interrupted cutting with multiple edges. C) Cutting only soft materials. D) Producing only cylindrical shapes.

2. In its basic conception, milling is mainly used to manufacture: B) Axisymmetric parts. A) Prismatic geometric shapes. C) Welded assemblies. D) Cast components.

3. Milling can generate complex 3D geometries depending on: A) Coolant pressure. B) Tool geometry and machine type. C) Workpiece material only. D) Operator skill alone.

4. The primary cutting motion in milling is: A) Linear feed of the workpiece. D) Rotation of the tool. C) Axial penetration. B) Radial engagement.

5. Cutting speed 𝑣 𝑐 in milling refers to: A) The axial speed of the table. B) The tangential speed at a point on the cutting edge. C) The feed per edge. D) The spindle acceleration.

6. Feed per edge 𝑓 𝑧 is defined as: A) Displacement per minute. D) Displacement per revolution and per cutting edge. C) Axial depth of cut. B) Radial engagement.

7. The feed rate 𝑣 𝑓 depends on: B) Tool diameter and coolant flow. A) Feed 𝑓 and rotation speed 𝑛. C) Workpiece hardness only. D) Tool coating.

8. The radial depth of cut is represented by: A) 𝑎 𝑝. B) 𝑓 𝑧. C) 𝑎 𝑒. D) 𝑣 𝑓.

9. The cutting edge position angle 𝜅 𝑟 defines: A) Tool material composition. B) Orientation of the main cutting edge. C) Spindle torque. D) Chip color.

10. A milling machine provides: A) Only feed motion. B) Only tool rotation. C) Torque, power, and positioning movements. D) Cooling and lubrication only.

11. In milling, machining paths are programmed using: A) X, Y, and Z axes. B) Only X and Z axes. C) Polar coordinates. D) A single linear axis.

12. Indexable‑insert milling cutters: A) Are made of a single solid material. B) Have replaceable inserts with multiple edges. C) Cannot machine metals. D) Are used only for drilling.

13. Solid end milling cutters: A) Can sometimes machine axially like a drill. B) Have no face cutting edges. C) Are only used in horizontal milling machines. D) Cannot be coated.

14. Solid shell end milling cutters are typically used: A) In vertical milling machines. B) In horizontal milling machines. C) Only for finishing operations. D) Only for plastics.

15. A major source of vibration in milling is: A) Constant chip thickness. B) Continuous tool engagement. C) Cutting edges entering and exiting the material. D) Excessive coolant pressure.

16. Thermal cracks in milling tools occur because: A) Milling is a continuous cutting process. D) Milling is an interrupted cutting process. C) Tools are always cooled excessively. B) Chips are too small.

17. Tool deflection is more pronounced when: A) The tool has a large diameter. B) The tool is short and rigid. C) The tool is slender with a small diameter. D) The workpiece is very thick.

18. Milling cannot produce sharp internal corners because: A) Feed rate is too high. B) Tool geometry always includes a radius. C) Spindle speed is limited. D) Workpieces deform excessively.

19. Production rates in milling depend mainly on: A) Tool color. D) Degree of automation. C) Coolant temperature. B) Workpiece material only.

20. Five‑axis milling is used for: A) Simple prismatic blocks. B) Only flat surfaces. C) Complex shapes like turbine blades. D) Thread cutting.

21. Axial (plunge) milling is characterized by: A) Feed movement in the direction of the cutter axis. B) Feed movement perpendicular to the cutter axis. C) Removing the full cutter diameter. D) Using only peripheral edges.

22. In axial milling, the chip section is removed by: A) Peripheral cutting edges. B) Face cutting edges. C) Tool shank edges. D) Coolant jets.

23. Tangential milling is defined by: A) Feed movement parallel to the cutter axis. B) Feed movement in any direction except along the cutter axis. C) Removing chips only with face edges. D) Using only solid end mills.

24. In conventional milling machines, tangential feed movement is typically: A) Circular. D) Perpendicular to the cutter axis. C) Parallel to the cutter axis. B) Helical.

25. Cylindrical milling keeps the tool axis: A) Perpendicular to the target surface. B) Parallel to the target surface. C) At a 45° angle. D) Randomly oriented.

26. In cylindrical milling, the surface finish depends mainly on: A) Tool coating. D) Peripheral cutting edges. C) Coolant pressure. B) Face cutting edges.

27. In face milling, the tool axis is: A) Parallel to the target surface. B) Perpendicular to the target surface. C) Tilted at 30°. D) Randomly oriented.

28. In face milling, the surface finish depends on: A) The transition between peripheral and face edges. B) Only the radial depth of cut. C) Only the axial depth of cut. D) Spindle bearings.

29. Up milling is also known as: A) Conventional milling. B) Climb milling. C) Tangential milling. D) Axial milling.

30. In up milling, chip thickness: D) Starts at zero and increases. B) Starts large and decreases. C) Remains constant. A) Is unrelated to feed direction.

31. A disadvantage of up milling is: A) Rubbing and burnishing of the surface. B) Reduced friction. C) Low cutting temperatures. D) Chips that are too fine.

32. Up milling can be advantageous when: D) The machine has backlash. B) The tool is very rigid. C) The workpiece is extremely soft. A) The cutter has only one edge.

33. In down milling, chip thickness: A) Starts large and decreases. B) Starts at zero and increases. C) Remains constant. D) Is unrelated to tool rotation.

34. A benefit of down milling is: D) Lower friction and less rubbing. B) Reduced process safety. C) Cutting into a hardened surface. A) Higher risk of tool breakage.

35. A drawback of down milling is: B) Increased risk of chatter if backlash exists. A) Excessive rubbing. C) High tensile loads on the tool. D) Workpiece lifting from the table.

36. In face milling, distinguishing up vs. down milling is difficult because: C) Radial engagement can be very large. B) The cutter does not rotate. A) Feed direction is irrelevant. D) The tool has no face edges.

37. Slot milling often results in: A) A combination of up and down milling. B) Only up milling. C) Only down milling. D) No chip formation.

38. Machining planar surfaces is most commonly performed using: D) Face milling with indexable inserts. B) Axial milling. C) Plunge drilling. A) Cylindrical milling only.

39. A 90° cutting edge angle in face milling produces: A) Maximum chip thickness equal to feed per edge. B) Minimum chip thickness. C) No chip formation. D) Only axial cutting.

40. A 10° cutting edge angle in face milling results in: A) Balanced radial and axial forces. B) Large axial forces and minimal radial forces. C) Large radial forces and minimal axial forces. D) No influence on force components.

41. Shoulder milling requires the tool position angle to be: A) 45°. B) 60°. C) 90°. D) 10°.

42. Shoulder milling machines two surfaces simultaneously, which means it is: A) Axial milling. B) Combined milling. C) Plunge milling. D) Thread milling.

43. The choice of tool for slot milling depends mainly on: A) Coolant pressure. B) Slot dimensions. C) Tool coating. D) Machine spindle speed.

44. For deep but narrow slots, the most suitable tool is: A) Solid end mill. B) “Hedgehog” cutter. C) Disc milling cutter. D) Ball nose cutter.

45. Form tools are used to: A) Reduce vibration. B) Reproduce the inverse shape of the tool in the slot. C) Increase spindle torque. D) Improve coolant flow.

46. Milling cavities often requires a prior drilling operation because: A) Milling cutters cannot rotate at high speed. B) Milling cutters cannot remove the full circular cross‑section. C) Drill bits produce better surface finish. D) CNC machines cannot interpolate circular paths.

47. Machining on “2½ axes” means: A) Only one axis moves. D) Interpolation occurs on one plane while the third axis is positioned. C) All three axes interpolate simultaneously. B) Only rotary axes are used.

48. Ball nose milling cutters are recommended for finishing because they: A) Have no cutting edges. B) Produce flat surfaces only. C) Minimize marks between adjacent tool paths. D) Can only be used on two axes.

49. Thread milling requires the machine to: A) Stop the workpiece rotation completely. B) Produce helical tool paths. C) Use only disc‑type cutters. D) Remove the entire hole diameter in one pass.

50. Turn‑milling differs from milling with power tools on a CNC lathe because: A) Only the tool rotates. B) Only the workpiece rotates. C) Both tool and workpiece rotate simultaneously. D) Neither rotates during cutting.

51. The base of a conventional milling machine serves to: A) Support the head movement. B) House the speed gearboxes. D) Support all other machine components. C) Hold the tool magazine.

52. The column of a milling machine supports: A) The worktable only. B) The head or overarm and vertical guideways. C) The automatic palletizer. D) The tool magazine.

53. The overarm is found in: B) Vertical‑spindle milling machines. A) Horizontal‑spindle milling machines. C) Machining centers only. D) Travelling column machines.

54. The arbor is used to: A) Hold end mills in vertical machines. D) Mount cylindrical and shell end cutters. C) Support the knee movement. B) Clamp the workpiece.

55. In vertical‑spindle milling machines, the tools are attached to the: A) Knee. B) Saddle. C) Head. D) Overarm.

56. The knee allows: A) Horizontal movement of the workpiece. B) Vertical movement of the workpiece. C) Rotation of the spindle. D) Automatic tool changing.

57. The saddle provides: A) The longest horizontal stroke. B) Vertical positioning. C) One of the horizontal movements, usually the shorter one. D) Support for the overarm.

58. The worktable includes T‑slots to: A) Increase spindle torque. D) Facilitate clamping of workpieces. C) Support the overarm. B) Store cutting tools.

59. Conventional milling machines typically have: A) One motor for all movements. B) Two motors: one for spindle and one for feed. C) Three motors for each axis. D) No dedicated spindle motor.

60. Fixed‑bed milling machines transfer vertical movement to: B) The workpiece. A) The head holding the tool. C) The saddle. D) The overarm.

61. In bridge‑type milling machines, linear movement is transferred to: A) The workpiece only. B) The tool via a bridge structure. C) The knee. D) The arbor.

62. Gantry milling machines allow: A) Only vertical movement of the tool. D) All linear movements to be transferred to the tool. C) The workpiece to move in all axes. B) Only manual feed.

63. Travelling‑column milling machines feature: A) A stationary column. B) A column that moves longitudinally. C) A spindle that cannot change orientation. D) No vertical movement.

64. A machining center is essentially a: A) Manual milling machine with a large table. C) CNC milling machine with automatic tool changing. B) Horizontal lathe with a turret. D) Drill press with a tool magazine.

65. Automatic palletizers in machining centers: A) Increase tool wear. B) Reduce idle time by enabling part changing. C) Replace the need for a tool magazine. D) Eliminate the need for CNC programming.

66. HMC and VMC classifications are based on: A) Worktable size. B) Tool material. C) Orientation of the main spindle. D) Number of axes.

67. A 3‑axis machining center controls: B) Only rotational axes. A) X, Y, and Z linear axes. C) Two linear axes and one rotary axis. D) Five simultaneous axes.

68. In a 4‑axis VMC, the fourth axis is typically: A) Rotation of the tool. B) Rotation of the workpiece around a horizontal axis. C) Tilting of the spindle head. D) Rotation of the column.

69. In a 4‑axis HMC, the fourth axis is: A) Rotation of the worktable around a vertical axis. B) Tilting of the spindle head. C) Rotation of the tool around its own axis. D) Movement of the saddle.

70. A 5‑axis machining center allows: A) Only planar machining. B) Any relative orientation between tool and workpiece. C) No rotation during machining. D) Only manual part loading.

71. The main purpose of workpiece fixtures is to: A) Increase spindle speed. D) Ensure stability and correct orientation during machining. C) Reduce tool wear. B) Improve coolant flow.

72. Vises are primarily used to clamp: A) Cylindrical parts. B) Prismatic parts. C) Flexible sheet metal. D) Large castings.

73. Strap clamps apply pressure to the workpiece by using: A) Magnetic force. B) Hydraulic pistons. C) The law of the lever. D) A rotating cam.

74. A dividing head allows: A) Automatic tool changing. B) Machining equiangularly distributed features. C) Cooling of the workpiece. D) Mounting of shell end mills.

75. Modular fixtures are widely used because they: A) Are designed only for prismatic parts. B) Require long setup times. C) Offer flexibility and versatility for different geometries. D) Can only be used on vertical machining centers.

76. An arbor is mainly used to: A) Mount small‑diameter end mills. B) Hold shell end mills in horizontal milling machines. C) Clamp the workpiece to the table. D) Rotate the workpiece during machining.

77. A milling chuck is used for: A) Mounting indexable‑insert milling cutters. B) Holding drill bits only. C) Clamping large workpieces. D) Measuring tool wear.

78. A collet chuck clamps the tool by: A) Using a magnetic field. B) Compressing the collet around the tool shank. C) Tightening a hydraulic piston. D) Locking the tool with a threaded pin.

79. Automatic palletizers reduce idle time by: A) Increasing spindle torque. D) Allowing part loading and unloading outside the machining area. C) Storing additional cutting tools. B) Measuring machined surfaces.

80. A swivel head allows the tool to: A) Rotate only around the vertical axis. B) Be oriented and rotated during 4‑ or 5‑axis machining. C) Clamp multiple workpieces simultaneously. D) Store additional inserts.