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WorksheetsMachining and Quality Control Quiz
Total questions: 8
Worksheet time: 4mins
Describe how a cutting tool is mounted on a lathe. (4 marks)
Held by the chuck jaws and supported by the tailstock while turning
Mounted in a tool holder on the tool post, clamped securely, set to center height, and kept with minimal overhang
Taped to the carriage and positioned by eye for each pass
Hand-held against the rotating work to follow the contour
Explain how the turning speed changes when the diameter of the workpiece changes. (2 marks)
Spindle speed increases proportionally with diameter
Spindle speed is inversely proportional to diameter; larger diameter requires lower rpm for the same surface speed
Spindle speed remains constant regardless of diameter
Spindle speed decreases at small diameters and increases only beyond a threshold
Explain why the process parameters are different when milling brass and mild steel. (2 marks)
Both materials have identical machinability, so parameters are the same
Brass is generally freer-cutting and allows higher speeds and lighter feeds, while mild steel is tougher and typically uses lower speeds and different tool geometry
Mild steel is softer than brass and therefore uses higher speeds than brass
Parameters differ only because brass is nonferrous and cannot be milled
Describe the difference between a symptom and a cause of a defect in a machined product. (2 marks)
A symptom is the underlying source of the defect; a cause is the visible result
A symptom is the visible effect of the defect; a cause is the underlying condition that creates it
Both symptom and cause are the same and interchangeable
A symptom occurs before machining and a cause occurs after machining
Describe two methods of monitoring machine performance. (4 marks)
Conduct vibration analysis or temperature trending on the machine (condition monitoring)
Record random operator notes without measurements
Measure part dimensions and track them using statistical process control (SPC) charts
Ignore tool wear and rely only on final inspection
State two documents that contain engineering information that products are typically evaluated against. (2 marks)
Engineering drawing
Product specification/technical specification
Purchase order
Material safety data sheet (MSDS)
Describe three quality criteria that a turned product should be evaluated against. (6 marks)
Dimensional accuracy and tolerance compliance
Surface finish (roughness)
Concentricity/runout of features
Paint color consistency
Weight of the raw stock used
State two applications of visual inspection. (2 marks)
Detecting surface defects such as scratches, pits, or burrs
Confirming assembly completeness and the presence of correct components/labels
Measuring exact hole diameter to within ±0.005 mm
Calculating spindle speed during turning
