22 Other machining processes

1. One of the most common features in mechanical assemblies is the hole because it is used for: A) Joining parts. B) Increasing surface hardness. C) Improving electrical conductivity. D) Reducing thermal expansion.

2. A hole that passes completely through a part is called a: A) Blind hole. B) Through‑hole. C) Counterbored hole. D) Threaded hole.

3. The aspect ratio of a hole refers to the relationship between: A) Diameter and material hardness. B) Length (depth) and diameter. C) Surface finish and tolerance. D) Tool speed and feed.

4. Deep holes are characterized by: A) Low L/D ratio. B) High L/D ratio. C) Large diameter only. D) Very smooth surfaces.

5. Drilling with a twist drill is considered a roughing process because: A) It produces no chips. B) It cannot cut metals. C) It has limited accuracy and surface finish. D) It requires no coolant.

6. A preparation process for drilling typically produces: A) A threaded entry. D) A small conical hole. C) A counterbored surface. B) A cylindrical finish.

7. If the desired diameter cannot be achieved in one drilling operation, the solution is to: A) Reduce spindle speed. B) Re‑drill using a larger drill bit. C) Increase coolant pressure. D) Use a shorter tool.

8. Counterboring and countersinking are considered: A) Roughing processes. B) Preparation processes. C) Finishing or modification processes. D) Chip‑evacuation processes.

9. Trepanning is especially useful for: B) Small blind holes. A) Large‑diameter through‑holes. C) Threaded holes. D) Cooling channels.

10. Internal turning can also produce holes and is commonly called: A) Reaming. B) Broaching. C) Boring. D) Tapping.

11. A major limitation in deep hole machining is: A) Excessive tool rigidity. B) Tool deflection due to slenderness. C) Lack of chip formation. D) Too much coolant reaching the tip.

12. Tool deflection increases because drilling forces are applied: A) Near the tool shank. D) At the cutting edges far from the clamping point. C) At the center of the spindle. B) On the coolant channels.

13. The stiffness of a drill bit depends strongly on: A) Its coating. B) Its color. C) Its diameter to the fourth power. D) Its flute length only.

14. A prior spot or center drilling operation is needed because: A) It reduces coolant consumption. B) It prevents tool overheating. C) It stabilizes the drill and reduces initial deflection. D) It increases cutting speed.

15. Chip evacuation is difficult in hole machining because: B) Chips are too small. A) The tool works in a confined space. C) Coolant dissolves the chips. D) Chips are ejected at high speed.

16. Peck drilling consists of: A) Increasing feed continuously. B) Drilling without coolant. D) Alternating short feeds with tool retraction to remove chips. C) Using only high‑speed steel tools.

17. Poor chip evacuation can lead to: A) Reduced tool wear. B) Tool breakage. C) Higher dimensional accuracy. D) Lower cutting temperatures.

18. Heat evacuation is difficult in hole machining because: A) The tool rotates too slowly. B) The cutting zone is open to the environment. C) The cutting action occurs in a confined space. D) Coolant is never used.

19. High temperatures in drilling mainly cause: A) Improved surface finish. B) Reduced tool life. C) Increased tool stiffness. D) Lower cutting forces.

20. Modern drills improve coolant delivery by using: A) External coolant nozzles only. B) Coolant‑absorbing coatings. C) Internal channels that reach the tool tip. D) Air‑cooling fins.

21. Drilling represents approximately what percentage of all machining processes?. A) 10%. B) 25%. C) 50%. D) 75%.

22. In conventional drilling, the cutting motion is: B) Linear displacement of the tool. A) Rotation of the tool. C) Rotation of the workpiece. D) Oscillation of the spindle.

23. The feed motion in drilling is: A) A helical movement. B) A circular movement. C) A straight linear displacement. D) A radial expansion.

24. In drilling, the depth‑of‑cut is determined by: A) Feed rate. B) Tool diameter. C) Spindle torque. D) Coolant pressure.

25. Cutting speed in drilling varies because: A) The tool is flexible. D) The cutting edge is not at a constant radius. C) The spindle speed changes continuously. B) The feed direction oscillates.

26. Feed (f) in drilling is defined as: A) Distance traveled per minute. B) Distance traveled per revolution. C) Distance traveled per cutting edge. D) Distance traveled per second.

27. The feed rate (vf) is calculated as: B) Feed × tool diameter. A) Feed × rotational speed. C) Cutting speed × radius. D) Cutting speed ÷ feed.

28. The cutting edge position angle κr in drilling equals: A) The full tool tip angle. B) Half the tool tip angle. C) Twice the tool tip angle. D) Zero for all drills.

29. Twist drills are mainly used for hole diameters: A) Below 20 mm. B) Between 20 and 40 mm. C) Above 50 mm. D) Only for threaded holes.

30. The chisel edge of a twist drill: A) Removes most of the material. B) Cuts at maximum speed. C) Scrapes material toward the main cutting edges. D) Produces the final surface finish.

31. The chisel edge increases: A) Radial force. B) Axial force. C) Cutting speed. D) Tool stiffness.

32. The sharp margin on a twist drill acts as: A) A primary cutting edge. B) A coolant channel. C) A secondary cutting edge that rubs the hole wall. D) A chip‑breaking feature.

33. Indexable insert drills are typically used for hole diameters: A) Less than 10 mm. B) Less than 20 mm. D) Greater than 20 mm. C) Only for blind holes.

34. Compared to twist drills, indexable insert drills are: C) More slender. B) Less rigid. A) More rigid. D) Only used for threading.

35. In indexable insert drills, the cutting work is: A) Identical for both inserts. B) Performed only by the chisel edge. C) Split between a peripheral insert and a central insert. D) Performed only at the tool center.

36. When drilling on a conventional lathe, the drill is mounted on the: A) Headstock. B) Tailstock. C) Tool turret. D) Worktable.

37. A center drill is required on a conventional lathe to: A) Increase spindle speed. B) Create a threaded entry. C) Produce a conical and small cylindrical hole for guidance. D) Remove chips more efficiently.

38. In CNC lathes, a pilot hole may be unnecessary if: A) The workpiece is very short. B) The drill is mounted on the tailstock. C) Rigid indexable insert drills are used. D) The spindle rotates slowly.

39. A drill press typically has: A) Multiple motors for each axis. B) A single motor for all movements. C) No feed mechanism. D) Only manual rotation.

40. A radial drill allows machining in: A) Only Cartesian coordinates. B) Only vertical directions. C) Polar coordinates. D) Helical paths only.

41. Redrilling consists of: A) Enlarging a hole using a larger drill bit. B) Creating a threaded hole. C) Removing only the core of the hole. D) Producing a conical entry.

42. Redrilling can be applied to: A) Only blind holes. B) Only through‑holes. C) Both blind and through‑holes. D) Only threaded holes.

43. The maximum drill diameter usable in redrilling is limited mainly by: A) Coolant pressure. B) Machine power and torque. C) Tool coating. D) Hole depth.

44. In redrilling, the depth‑of‑cut is defined as: B) The full tool diameter. A) The difference between final and previous hole radii. C) The feed per revolution. D) The tool tip angle.

45. Cutting power in redrilling depends primarily on: A) Tool material and coolant. D) Cutting force and cutting speed. C) Hole depth and chip size. B) Machine weight.

46. Trepanning removes: A) All material inside the hole. B) Only a cylindrical ring at the hole periphery. C) Only the core of the hole. D) Only the bottom of the hole.

47. Trepanning can only be used for: A) Blind holes. B) Threaded holes. C) Through‑holes. D) Counterbored holes.

48. In trepanning, the tool must include: A) A chisel edge. B) An internal cavity to hold the core. C) A helical flute. D) A threaded shank.

49. Boring cannot be used directly on solid material because: B) It produces too much heat. A) It requires a previous hole. C) It uses only one cutting edge. D) It cannot rotate.

50. Finish boring tools typically have: A) Three cutting edges. B) Two cutting edges. C) One cutting edge. D) No cutting edges.

51. Boring improves: A) Only surface roughness. B) Only diameter accuracy. D) Diameter, cylindricity, and axis straightness. C) Only the position of the hole.

52. Typical tolerance grades achievable in finish boring are: A) IT12. B) IT10. C) IT6. D) IT4.

53. Reaming removes: C) Large amounts of material. B) Between 1 and 5 mm radially. A) Very small amounts of material (0.1–0.5 mm). D) Only the core of the hole.

54. Reaming requires the pre‑drilled hole to: A) Be smaller than the target diameter by several millimeters. B) Have a diameter close to the final size. C) Be threaded. D) Be conical.

55. Reaming tools cannot correct: A) Surface finish. B) Cylindricity. C) Straightness or position errors. D) Diameter accuracy.

56. In tapping, the feed must be equal to: A) The tool diameter. B) The thread pitch. C) The cutting speed. D) The hole depth.

57. During tapping, the tool must be withdrawn: A) Without rotation. B) Rotating faster than during cutting. C) Rotating in the opposite direction with the same feed. D) Using coolant pressure only.

58. Manual tapping typically uses: B) A single tap. A) A set of three taps in sequence. C) A drill press. D) A helical interpolation path.

59. Broaching uses: A) A rotating multi‑edge tool. B) A linear cutting motion with multiple cutting edges. C) A helical tool path. D) A single‑edge scraping tool.

60. A major advantage of broaching is that it: A) Requires no special tooling. B) Produces only simple shapes. C) Achieves sharp internal corners. D) Works well on very hard materials.