Machine Design, Materials and Machine Shop Practice

Elements
SET 1
Which of the following is the largest size drill?
A. A C. Z
B. X D. XX
Answer: C.
The size of a drill is stamped on the:
A. point C. margin
B. shank D. flute
Answer: B.

Which of the following safety precautions should be followed when pouring babbitt?
A. operator must wear goggles
B. the surface to be babbitted must be free of moisture
C. the surface to be babbitted must be clean
D. all of the above
Answer: D.
Which of the following safety precautions should be followed when renewing a flange
gasket?
A. drain the line thoroughly C. isolate the section to be worked on
B. tie down isolation valves D. all of the above

Answer: D.
Before installing a new flange gasket be sure that the:
A. flange faces are painted C. isolating valves are open
B. flange faces are absolutely clean D. old gasket is in place
Answer: B.
When measuring a drill for size measure across the:
A. margins C. shank
B. flutes D. point
Answer: A.

The tool used in precision work to smooth or enlarge holes is called a:

A. round out C. reamer
B. drift pin D. protractor
Answer: C.

Which of the following chisels would be used for cutting oil grooves?
A. diamond-point chisel C. round-nose chisel
B. cold chisel D. hot chisel
Answer: C.

Which of the following is not a cut of file?

A. smooth C. half-round
B. second cut D. bastard
Answer: C.

Which of the following is the smallest size drill?

A. # 80 C. # 1
B. # 60 D. # 0
Answer: A.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
On a standard wire gage:
A. #10 is larger than #5 C. # 1is smaller than #2
B. #25 is smaller than #20 D. #30 is larger than #25
Answer: B.

Which of the following tools would be most useful when taking leads on bearings?
A. dividers C. micrometer
B. outside calipers D. center gage
Answer: C.

The cutting action in on both stokes in:

A. Open side planer C. Double housing planer
B. Pit planer D. Universal planer
Answer: D.

The straddle milling is done by means of two

A. Side milling cutters C. Plain milling cutters
B. Face milling cutters D. Form cutters
Answer: A.

The formula to find out the number of turn of the crank simple indexing is
A. T=20/N C. T=N/20
B. T=40/N D. T=N/40
Answer: B.

In a standard dividing head the ratio between the worm wheel and the worm is
A. 10:1 C. 20:1
D. 30:1 D. 40:1
Answer: D.

There are two different movements of the crank in

A. Simple indexing C. Compound indexing
B. Differential indexing D. Angular indexing
Answer: C.

In a vertical milling machine the spindle is situated to the

A. Horizontal C. vertical
B. Angular D. None of the above
Answer: C.

Planer type built machine is built up for work of

A. light duty C. heavy duty
B. medium duty D. None of the above
Answer: C.

In a straddle milling operation how many cutters are used to mill the work?
A. One C. Two
B. Three or more D. Any one of the above
Answer: C.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
For gear cutting which cutter is used?
A. End mill cutter C. Plain milling cutter
B. Form relieve cutter D. All of the above
Answer: B.

In a slotter, the table gets ___ different feeds

A. One C. Two
B. Three D. None of the above
Answer: B.

If a clearance of a cutting edge is 15 deg, the lip (wedge) angle in 75 deg, the rake
angle will be
A. 80 deg C. 70 deg
B. 10 deg D. None of the above
Answer: B.

The approximate hardness of HSS end mill cutter is

A. 45 HRC C. 52 HRC
B. 62 HRC D. 72 HRC
Answer: B.

When the feed motion takes place in a slotting machine

A. during the cutting motion. C. at the end of return motion.
B. after each forward stroke. D. after each double stroke.
Answer: D.

Which of the following conditions may cause error during knurling?

A. to much longitudinal feed.
B. clamped length of tool too short.
C. surface speed too low.
D. unnecessary support with tail stock center.
Answer: A.

Mark the milling method during which the formation of the chatter marks is very likely
A. during down cut milling with a straight tooth cutter.
B. during up cut milling with a straight tooth cutter.
C. during face milling with a straight tooth cutter.
D. while using spiral tooth cutter.
Answer: B.

Mark the cutter which works simultaneously with up cut and down cut process
A. Side milling cutter.
B. Semi-circular milling cutter.
C. Shell end mill.
D. Plain milling cutter.
Answer: C.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
A polygon with 9 flats is to be milled using the indexing head. The indexing head
transmission ratio is 40:1.Determine the number of crank rotation and mark the correct
answer
A. 9 full rotation.
B. 5 full rotation, 2 holes on the 36 hole circle.
C. 4 full rotation, 12 holes on the 27 hole circle.
D. 2 full rotation, 16 hole on the 47 hole circle.
Answer: C.

Where the relieved cutters are reground?

A. on the circumstances
B. relieved cutters are not reground
C. on the flank
D. on the side faces
Answer: C.

What happens if the job is loosely fitted between centers in cylindrical grindings?
A. the job will be out of round. C. the job will be thrown out.
B. the job will be oversize. D. the job will not rotate.
Answer: A.
Internal and external taper on cylindrical jobs are ground in
A. plain cylindrical grinding machine.
B. universal cylindrical grinding machine.
C. internal grinding machine.
D. centerless grinding machine.
Answer: B.

Which of the following is used to clean the gauge blocks before and after use?
A. Brush
B. Cotton waste
C. Chamois leather or linen cloth
D. None of the above
Answer: C.

The grade of grinding wheel depends upon

A. Grain size C. Structure
B. Kind of abrasive D. Hardness of bond
Answer: D.

Which kind of bond is commonly used?

A. Vitrified C. Rubber
B. Shellac D. None of the above
Answer: A.

The symbol conventionally used for resinoid bond is

A. ‘V’ C. ‘R’
B. ‘B’ D. ‘E’
Answer: B.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
A grinding wheel is marked as 51A 46L 5V 23, out of these 5 means
A. Kind of abrasive C. Kind of bond
B. Structure D. Grain size
Answer: B.

Balancing of grinding wheel is done to

A. make the outside diameter concentric with the bore.
B. make the sides of wheel parallel.
C. equalize the weight in every portion of the wheel.
D. None of the above.
Answer: C.

Taps are re-sharpened by grindings

A. Flutes C. Threads
B. Diameter D. Relief
Answer: A.

The purpose of ______ is to prevent gears from jamming together and making contact
on both sides of their teeth simultaneously
A. tooth fillet C. backlash
B. stress relieving D. all of these
Answer: C.

Choose the economical type of material for gears that give/sustain good operating
quality/life for intended operation
A. plane carbon steel C. all of these
B. high alloy steel D. heat treated carbon steel
Answer: D.

Allowance added in the casting pattern to compensate for the contraction of metal
A. tapering allowance C. finish allowance
B. shrinkage allowance D. draft pattern
Answer: B.

The principal materials used in the production of metal working tools:

A. high carbon steel
B. titanium, phosphorous
C. tungsten, silicon, hadfield Mn
D. vanadium, chromium, molybdenum
Answer: A.

Cold rolled shafting is not available in diameter larger than__________

A. 6 inches C. 6 ½ inches
B. 5 inches D. 5 ½ inches
Answer: B.

The use of hardened steel for the mating metal gear appears to give the best results
and longer operational life. The usual hardness is in the range of-
A. over 600 BHN C. below 350 BHN
B. 300 to 400 BHN D. over 400 BHN
Answer: A.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
A coupling that allows axial flexibility/movement in the operation. Made of alternate
bolting of steel, leather, fabric and/or plastic material into the two flanges
A. Flexible disk coupling C. Flexible toroidal spring coupling
B. flexing Oldham coupling D. Elastic-material bonded coupling
Answer: A.

When high strength and durability are a requirements for choosing gear materials it is
preferable to use _________ material
A. hardened bronze C. phenolic laminated
B. steel D. white iron
Answer: B.

The use of hardened steel for the mating metal gear appears to give the best results
and longer operational life. The usual hardness is in the range of-
A. over 600 BHN C. below 350 BHN
B. 300 to 400 BHN D. over 400 BHN
Answer: A.

The most known lubricants being utilized in whatever category of load and speed are
oil, air, grease and dry lubricants like
A. bronze C. silicon
B. lead D. graphite
Answer: D.

It consists of two cranks, a stationary piece called the line of centers and the connecting
rod is a
A. five-bar linkage C. three-crank linkage
B. four-crank braces D. four-bar linkage
Answer: D.

When working on bearings and checking for high spots, it is customary to apply:
A. white lead C. dykem blue
B. red lead D. Prussian blue
Answer: D.

If you wanted to check the face of a pump slide valve or other flat-faced valve, you
could check for trueness on a:
A. flat board C. piece of glass
B. surface plate D. bearing plate
Answer: B.

Before splicing electric wires, they should be:

A. tinned C. soldered
B. cleaned and tinned D. insulated
Answer: B.

Which of the following is not a standard thread form?

A. Square C. Double flute
B. American National D. 60 deg. sharp V
Answer: C.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
Hand taps are provided in sets of three called:
A. taper, plug and end C. taper, plug and bottom
B. short, taper and bottom D. short, medium and long
Answer: C.

When preparing to tap a hole, the size of the drill will be

A. equal to the size of the tap
B. larger than the size of the tap
C. smaller than the size of the tap
D. none of the above
Answer: C.

When preparing to tap a hole for a pipe fitting the size of the drill will be:
A. larger than the tap size
B. smaller than the tap size
C. equal to the size of the tap
D. none of the above
Answer: A.

Which of the following does not have to be lubricated when drilling?

A. steel C. monel
B. brass D. tool steel
Answer: B.

The tool to use when cutting a hole in the side of a round piece of metal is called a:
A. vise C. “V” block
B. jaw holder D. chuck
Answer: C.

This radial distance in a gear is measured between the addendum and dedendum
circle, and is the sum of the addendum and dedendum. How do you call this distance?
A. addendum C. whole depth
B. working depth D. space width
Answer: C.

This minimum distance is measured between the non – driving side of a tooth and the
adjacent side of the mating tooth. It is the amount by which the width of a tooth space
exceeds the thickness of the engaging tooth measured on the pitch circle. What is this
distance?
A. circular pitch C. whole depth
B. backlash D. space width
Answer: B.

What is the algebraic difference between the maximum limit and the corresponding
basic size?
A. fundamental deviation C. lower deviation
B. upper deviation D. tolerance
Answer: B.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
What is the algebraic difference between the minimum limit and the corresponding basic
size?
A. fundamental deviation C. lower deviation
B. upper deviation D. tolerance
Answer: C.

This is either the upper or the lower deviation depending on which is closer to the basic
size. How do you call this deviation?
A. fundamental deviation C. lower deviation
B. upper deviation D. tolerance
Answer: A.

How do you call the strain energy per unit volume required to stress a material from an
unloaded state to the point of yielding?
A. modulus of roughness C. modulus of rigidity
B. modulus of elasticity D. modulus of resilience
Answer: D.

It is the capacity of a material to absorb energy when it is deformed elastically and then,
upon unloading to increase this energy. What is this capacity of a material?
A. resilience C. toughness
B. rigidity D. ductility
Answer: A.

How do you call a structural member designed to support loads perpendicular to its
longitudinal axis?
A. cantilever beam C. beam
B. overhanging beam D. column
Answer: B.

It is a load applied transversely to longitudinal axis of member. How do you call this
load?
A. bending load C. combined load
B. distributed load D. cyclic load
Answer: A.

What is a load distributed over an entire area?

A. bending load C. combined load
B. distributed load D. cyclic load
Answer: B.

It is a design approach where no catastrophic loss can occur as a result of a component

failure. What is this design approach?
A. Fall – safe design approach
B. Fault tree analysis approach
C. Manifest danger approach
D. Redundancy approach
Answer: A.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
How do you call a statistically data used to identify the most likely failure mode?
A. Fall – safe design approach
B. Fault tree analysis approach
C. Failure analysis
D. Random analysis
Answer: B.

It is a computational method used for solving complex shapes, such as those found in
machinery; replaces the complex shape with a set of simple elements interconnected at
a finite set of a specific purpose. What is this computational method?
A. Finite element analysis
B. Numerical method
C. Fault tree analysis
D. Synthesis
Answer: A.

When a hot part is cooled suddenly by quenching momentarily a high temperature

gradient that include a stress gradient. Some metal parts under certain conditions crack
as a result. How do you call this phenomenon?
A. thermal shock failure C. thermal fatigue
B. honing D. quenching
Answer: A.

How do you call the diameter of the imaginary cylinder that bounds the crest of an
external thread and the roots of an internal threads?
A. mean diameter C. stress diameter
B. minor diameter D. major diameter
Answer: D.

It is a measure of the change in length of a material subjected to a change in

temperature. How do you call this property of the material?
A. toughness C. thermal conductivity
B. coefficient of thermal expansion D. electric resistivity
Answer: B.

How do you call the circle on a gear that corresponds to the contact surface of the
friction wheel?
A. addendum circle C. root circle
B. pitch circle D. base circle
Answer: C.

What is the condition where one surface is comparatively free of stress?

A. octahedral plane C. biaxial stress
B. strain plane D. principal normal stress
Answer: C.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
This material is the most popular alloy spring steel for conditions involving higher
stresses that can be used with the high carbon steels and for use where fatigue
resistance and long endurance are needed which is also good for shock and impact
loads.
A. chrome silicon C. chrome vanadium
B. hard drawn wire D. oil tempered wire
Answer: C.

What is the largest roller chain size that can be used for power transmission at sprocket
speed of 100 rpm?
A. RC 35 C. RC 80
B. RC 50 D. RC 60
Answer: D.

These are gears with teeth formed on conical surfaces and are used mostly for
transmitting motion between intersecting shafts. How do you call these gears?
A. spur gears C. bevel gears
B. helical gears D. worm gears
Answer: C.

A bearing that primarily guides the motion of a machine member without specific regard
to the direction of load application.
A. journal bearing C. guide bearing
B. clearance bearing D. thrust bearing
Answer: C.

Which of the following are the composition of stainless steel 502?

A. 18% chromium and 8% nickel
B. 18% nickel and 8% chromium
C. 18% chromium and 9% phosphor bronze
D. 18% bronze and 8% vanadium
Answer: A.

These springs are made from one or more flat strips of brass, bronze, steel or other
materials loaded as cantilevers or simple beam?
A. torsion springs C. garter springs
B. leaf springs D. drawbar springs
Answer: B.

This refers to the space between adjacent coils when the spring is compressed to its
operating length.
A. coil clearance C. pitch
B. lead D. deflection
Answer: A.

In a lathe machine, it is the diameter of the largest workpiece it can rotate in a chuck or
between centers without hitting the bed.
A. chuck diameter C. distance between centers
B. swing D. spindle diameter
Answer: B.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
This is a lubricant condition where non – conformal surfaces are completely separated
by lubricant film and no asperities are in contact. How do you call this lubrication
condition?
A. Elastohydrodynamic lubrication
B. Boundary lubrication
C. Hydrodynamic lubrication
D. Hydrostatic lubrication
Answer: A.
How do you call the process of producing the residual compressive stress of machine
parts which is performed by directing a high velocity stream of hardened balls of pallets
at the surface to be treated.
A. nitriding C. shot blasting
B. peening D. tempering
Answer: C.

It is a process that produces residual compressive stress on the machine part, which
uses a series of hammer blows on the surface.
A. nitriding C. shot blasting
B. peening D. tempering
Answer: B.

It is a surface hardening process for alloy steels in which the material is heated to 950 F
in a nitrogen atmosphere typically ammonia gas, followed by slow cooling.
A. nitriding C. quenching
B. peening D. tempering
Answer: A.

Which of the following gases is typically used in nitriding process of surface hardening?
A. nitrogen gas C. carbon dioxide
B. ammonia gas D. hydrogen gas
Answer: C.

Which of the following is the benefit in using nitriding as a surface hardening process for
alloy steel?
A. Improvement of endurance strength, 50% or more
B. Improvement of endurance strength, less than 50%
C. Improvement of endurance strength, more than 50%
D. 80% improvement of endurance strength
Answer: A.

How do you call the level of stress that the part will be permitted to see under operating
conditions?
A. Yield stress C. Design stress
B. Endurance stress D. Ultimate stress
Answer: C.

Which of the following column formulas is applicable to cast iron columns?

A. Euler’s formula C. Secant formula
B. J.B. Johnson’s formula D. Straight line formula
Answer: D.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
Which of the following ferrous metals has the lowest carbon content?
A. Carbon steel C. Cast iron
B. Wrought iron D. SAE 4140
Answer: B.

If stiffness is the main criterion in selecting a material, which of the following is the most
economical choice?
A. SAE 3130 C. SAE 6150
B. SAE 1020 D. AISI 310
Answer: B.

Wood is an _____________ material that is its mechanical properties are unique and
independent in three mutually perpendicular directions, longitudinal, radial, and
tangential.
A. Isotropic C. Orthotropic
B. Anisotropic D. any of these
Answer: C.

The steel part is heated to a temperature of 900 – 1150 degrees F in an atmospheric of

ammonia gas and dissociated ammonia for an extend period of time that depends on
the case depth desired.
A. Nitriding C. Case hardening
B. Carburizing D. Cyaniding
Answer: A.

The primary application of high speed steel tools used for the working of metals ______.
A. that are too hard C. that are too soft
B. at high cutting speeds D. at slow cutting speeds
Answer: B.

The principal raw materials used in steel making are iron ore, coal, and ________.
A. coke C. slag
B. limestone D. flux
Answer: B.

Flywheel arms are usually of elliptical cross section the strength of the arms should
equal ________ the strength of the shaft in torsion.
A. three fourths C. two thirds
B. one half D. one fourth
Answer: A.

This alloy nickel, iron, chromium, cobalt, is a non – magnetic, corrosion resistant
material suitable for subzero temperatures and temperatures up to about 750 F
provided that torsional stresses are kept below 75,000 psi. It is precipitation hardened to
produce hardness of 48 to 50 Rockwell C and is used in watch and instrument springs.
A. elinvar C. inconel
B. monel D. dynavar
Answer: D.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1
To ensure an adequate factor of safety in the design of a shaft with standard keyway,
the key width should be about:
A. one half of the shaft diameter
B. one fourth of the shaft diameter
C. one eight of the shaft diameter
D. one third of the shaft diameter
Answer: B.

This is defined as the cutting time to reach a predetermined wear called the tool wear
criterion.
A. Wear duration C. Tool life
B. Cycle life D. Life cycle
Answer: C.

The variable polarity plasma arc (VPPA) process was developed for welding metals that
form an oxide skin such as ____________.
A. steel C. cast iron
B. copper D. aluminum
Answer: D.

Which of the following G – codes refers to rapid traverse in CNC machining?

A. G00 C. G02
B. G01 D. G03
Answer: A.

An acronym in CNC machining which means access of the machine operator to insert
machining instructions directly into the NC machine control system via push buttons,
pressure pads, knobs, or other arrangements.
A. FMS C. CIM
B. FMC D. MDI
Answer: D.

Stainless steels generally contain at least ___ percent chromium with or without other
elements.
A. 18 C. 12
B. 16 D. 10
Answer: D.

What grades of stainless steels are non - magnetic in the annealed condition although
some may become slightly magnetic after cold working?
A. Ferrite grades C. Martensitic grades
B. Austenitic grades D. any of these
Answer: B.
Machine Design, Materials and Machine Shop Practice
Elements
SET 1

Which of the following statements is NOT TRUE?

A. The terms “polishing” and “buffing” are sometimes applied top similar classes of
work in different plants.
B. Polishing is any operation performed with wheels having abrasive to the working
surfaces.
C. Buffing is done with wheels having the abrasive applied loosely.
D. Polishing is not so harsh an operation as buffing and it is commonly utilized to
obtain very fine surfaces having a stainless finish.
Answer: D.

If the steel is strongly deoxidized by the addition of deoxidizing elements, no gas is

evolved and the steel is technically called _________ because it lies quietly in the
molds.
A. quenched C. killed
B. annealed D. tempered
Answer: C.

Steel is heated to a temperature above the critical range after which it is cooled in still
air to produce generally fine pearlite structure. The purpose is to promote uniformity of
structure and properties after a hot – working operation such as forging or extrusion.
What was the heat treatment involved?
A. annealing C. tempering
B. normalizing D. stress relieving
Answer: B.

These steels (SAE 1006, 1008, 1010, 1015) are the lowest carbon steels of the plain
carbon type, and are selected where _______ is the primary requisite of the user.
A. strength C. ductility
B. cold formability D. durability
Answer: B.