MAE 364: Manufacturing Processes

Practice Exam

Spring 2015

Sample Theory Questions

This section provides examples of how the theoretical content could be covered on the exam.
Exam questions will differ, both in structure and difficulty. Further, this set of problems is
intended to be representative, not exhaustive (i.e., it is likely that some exam questions will be
completely different).
Question 1
Identify and briefly describe the two stages of manufacturing.
Question 2
Identify two distinct uses of machining processes. Provide brief examples of each.
Question 3
Why are chip breakers used?
Question 4
Machining can generate significant heat. Where does this heat go? What is the preferred outlet for the
heat?
Question 5
What are the negative effects of a dull tool? For each effect identify the cause(s).
Question 6
Describe the general relationship between tool hardness and temperature.
Question 7
When selecting a cutting tool material, what tradeoffs might have to be made?
Question 8
Identify three subtractive techniques for creating holes. When would you use each technique?
Question 9
Identify two manufacturing processes that can only produce features with a constant cross-section.
Question 10
For a given machining process, know the potential problems and their probably causes.
Question 11
Discuss the range of geometry that can be produced with [Specific Subtractive] Process.
Question 12
Identify two distinct benefits of computer numerically controlled machines.
Question 13
What are the advantages of chemical machining, and when is it generally used?

MAE 364: Manufacturing Processes

Practice Exam

Spring 2015

Question 14
What is the basic mechanism that allows electrochemical machining to work? What restricts the
geometry of the features that can be created with the process?
Question 15
What are the advantages of electric discharge machining? When is the process used? Hint: consider
what influences the material removal rate.
Question 16
What are the advantages and disadvantages of laser beam machining processes?
Question 17
Describe the steps in the basic process of metal casting.
Question 18
Identify the two categories of mold type. Discuss the advantages and disadvantages of each.
Question 19
What cooling rates are desirable and why?
Question 20
What are the potential consequences of an incorrect flow rate when filling a mold?
Question 21
Describe the solidification process for a metal alloy?
Question 22
Given an image of a defect, identify the casting defect and its cause(s).
Question 23
Discuss the advantages and disadvantages of the [Modifier] Casting Process.
Question 24
What are the material requirements for die casting?
Question 25
What are the geometry requirements for permanent mold castings?
Question 26
Estimate the cost of a cast component.
Question 27
Identify the two main types of plastics. What is the primary difference that concerns manufacturing?
Question 28
Discuss the advantages and disadvantages of the [Specific Plastic Production] Process.

MAE 364: Manufacturing Processes

Practice Exam

Spring 2015

Question 29
Identify the two potential sources for melting plastic in an extruder.
Question 30
Discuss the range of geometry that can be produced with [Specific Plastic Production] Process.
Question 31
In blow molding, there are two methods to form the parison. What are they, and what are their repective
advantages and disadvantages?
Question 32
Identify one feature that cannot be created with a vacuum thermoforming process?
Question 33
Describe the range of component geometry and feature detail that can be created with vacuum
thermoforming.
Question 34
Given a defect in an injection molded part, identify the cause and suggest a possible remedy.
Question 35
Identify two techniques for creating undercuts.
Question 36
Given a component, identify the most like manufacturing process used to create it.

Sample Calculation Problems

This section provides examples of how the content covered could be turned into an exam
question where the theory is applied.

Exam questions will differ, both in structure and

difficulty. Further, this set of problems is intended to be representative, not exhaustive (i.e., it is
likely that some exam questions will be completely different).
Problem 1
Estimate the cost of machining a component.

Problem 2
Estimate the tool life for a machining operation.

Problem 3
Estimate the cost of a cast component.

Problem 4
Estimate solidification time for a cast component.