Froggy Jumps: Measurement, Materials, and Safety (K10 - materials - safety - measurements


Froggy Jumps Measurement, Materials, and SafetyVersion en ligne A fun interactive game to help HS level machinists prepare for NIMS. par Kurt Miller 1 The safest way to remove chips from a lathe or milling machine is to use a? a Air hose and high pressure nozzle b Glove covering the operators hand c Brush 2 Small chips left on the spindle nose of the lathe should be cleaned to avoid a Symmetry of Shapes b Run out on work holding devices c Scratches on the workpiece 3 Grease guns are used to insert grease into a Zerk fittings on machine tools b The short taper of a cam lock spindle nose c The T-slots of a vertical mill 4 To lubricate the ways of a lathe, the gibs of a mill, or the cross slide of a grinder a Use a grease gun with lithium grease b Use chalk as a lubricant since it doesn't attract dust c Use lubricant found in central lubricating systems ("one shots") 5 If a verticle mill table is loose and has side play, the best solution to alleviate side play is to a Tighten the clamps that lock the table b Tighten the taper gib adjustment c Loosen the taper gib adjustment 6 A machinist wants to find the proper type of lubrication, schedule and recommended maintenance practices for the headstock of a lathe. The best source to find this information is a Tooling and Manufacturing Engineer's Book b FMEA (Failure Mode Effects Analysis) c Preventative maintenance schedule and machine manual 7 General maintenance information for machine tools and machine work area can be found a On the capability report b In a general maintenance manual c On the inspection and sampling plan 8 Pinning refers to a Back filling b Draw filling unloading c Loading the file with metal chips 9 Files should be stored a In a toolbox separated from each other b In a large wooden box close to the bench area c With end mills, drills, and other cutting tools 10 The best way to clean the chips out of a file is to use a Brush b An air gun c File card 11 What is the most common injury that may occur during a filling operation a Slivers from pinning b Being stabbed with the tang (file without a handle) c Scratches from holding the file 12 The best lubricant to prevent wear and increase cutting efficiency for tapping common steels is a Sulfur-based oil b Mineral oil c Air jet 13 The process plan specifies tooling to be used by indicating a Tolerances on dimensions b Lubrication procedures c Tooling diameters and sizes 14 A reaming operation produces finish tears. The cause of the tears is a A reamer with a worn tip b Feeding too slow c Insuffcient stock allowance 15 What is the gage block height for an angle of 9 degrees on a 10-inch sine plate a 1.5643 inches b 0.7822 inches c 3.1287 inches 16 Which of the following combinations of gage blocks (from an 81-block set) can be used to gage a length of 0.9528 inches? a 0.152, 0.1008, 0.750 b 0.1008, 0.102, 0.750 c 0.1008, 0.325, 0.500 17 The process of displacing air between gage blocks for accurate measurements is called a Smoothing b Wringing c Honing 18 To check the height of multiple parts with gage blocks, a machinist would use a a Dial indicator and digital height gage b Digital height gage c Vernier caliper and telescoping gage 19 Surface finish is checked with a Optivisor b Comparison chart c Optical Comparator 20 A surface finish symbol is as follows a The surface finish is 15 millimeters b The surface finish is 0.015 inches c The surface finish is 15 micro inches 21 What is the most common type of surface finish callout a Roughness b Waviness c Lay 22 A part is considered a reject when a All the dimensions are in tolerance b The daily production rate is not achieved c Dimensions are out of tolerance 23 A sampling is referred to as a a Number of defects in a shift b The number of parts that meet all dimensions c Samples taken from a machine over a period of time 24 Inspections plans are needed to a Check dimensions in a repeatable and reliable way b All the above c Identify measuring tools and Coordinate inspection procedures 25 The first thing to do when constructing an inspection plan is to a Select the critical and important dimensions to inspect b Select the measuring instruments c Construct SPC charts for all dimensions 26 The most important factor in selecting measuring tools for inspection is a Tolerancing of dimensions to inspect b Access to measuring equipment c Process capability of the part in assembly 27 Sampling plans contribute to a quality control process by a Defining tolerances regardless of the print tolerances b Creating error margins in capability ratios c Providing an acceptable respresentation of all the parts produced 28 What features of a thread is checked with a thread micrometer a Pitch diameter b Root radius c Minor diameter 29 Dial bore gages are used to measure a Tapered shafts b Holes c Internal threads 30 To indicate an angled surface and make that surface parallel to a surface plate, the machinist would use a a V-Block and indicator b Angle plate and plate protractor c Sine plate 31 What sizes of gage pins would a machinist need for a dimension of 3/32 + 1/64th inches for a go/no go gage setup (rounded to three places) a 0.110/0.094 b 0.110/0.078 c 0.332/0.312 32 A measure of dispersion that uses the largest and smallest measurements of a sampling is a Median b Mode c Range 33 What is the range of the following sampling: 0.345, 0.382, 0.353, 0.380, 0.377 a 0.037 b 0.017 c 0.025 34 Which of the following is not found on an X-bar and R control chart a Mean b Upper control limit c Capability Ratio 35 The acronym MSDS means a Material Safety Data Sheet b Multiple System Diagnostic Sheet c Manual Safety Data System 36 Which of the following colors is not found on an HMIS label a Red b Yellow c Green 37 The threshold limit value (TLV) is defined as a The threshold temperature for explosion b The point at which a chemical becomes flammable c The safe limit of unprotected exposure to a material 38 MSDS information on new chemicals and materials found in the workplace can be reviewed and discussed at a All the Above b Right to know seminars and classes c Safety meetings 39 The acronym HMIS stands for a Hazardous Materials Information System b Hazardous Methods Instructional Safety c High Maintenance Inspection Survey 40 The acronym for the goverment agency that regulate safety is a OCAW b USFS c OSHA 41 Oily rags and wipes are stored in a red fireproof can with a lid to prevent a Obnoxious smells b Fire through spontaneous combustion c Oil from seeping on the floor 42 The first course of action to take if a material (solid) becomes lodged in the eye is to a Use light air pressure to blow out debris b Use a magnet to attract the object c Pull the top lid over the bottom lid 43 The first action to take with a bleeding wound is to a Apply a tourniquet b Apply pressure to the nearest artery c Stop the bleeding by applying pressure to the wound 44 The best technique for lifting is to a Lift with the legs and keep the back straight b Keep the legs straight and use only the back c keep feet wide as possible 45 When operating a lathe, long hair, dangling jewelry, or loose clothes can a Become dirty from oil and chips b Obstruct the view of operation c Become caught in the lathe pulling the operator toward the machine 46 Goverment safety regulations state that a person must wear a ________ when working on material stored overhead using cranes and hoists a Hard hat b Ear plugs or muffs c Insulated gloves 47 When working on machinery producing flying chips, the most important personal protection equipment a machinist must wear is a Ear plugs b Gloves c Safety glasses 48 Which one of the following procedures is a safe procedure for a milling operation a Using an air gun to clean the chips off the mill table b Adjusting the work only when the cutter is stopped c Extending the tool and quill to achieve a maximum length 49 The best technique for milling on a vertical mill that is not equipped with an automatic table is to a Conventional mill b Peck mill c Spotface mill 50 Tight threads produced by a tapping operation may be caused by a Large tap hole diameter b Tap wear c Material springback 51 Thread percentage is dependent on the a Number of threads per inch b Major diameter of the thread c Tap hole diameter 52 What is the root cause of warping when grinding long slender pieces a THe structure of the wheel is too open b Heat checking due to a hard wheel c Vibration of the work piece during the grinding operation 53 When dressing the grinding wheel, the diamond dresser should be located on the a Outfeed side of the wheel rotation (left side) b Bottom dead center of the wheell c Infeed side of the wheel rotation (right side) 54 Tough material causes accelerated tool wear. Machinists can ________ to reduce tool wear and possible tool breakage. a Increase the spindle speed b Increase the spindle speed and feed c Decrease the spindle speed 55 The print calls for 0.375 + 0.005 wide X 0.125 + 0.005 deep slot to be milled. The best procedure is to a Use 0.250 diameter end mill to depth of 0.100,then use 0.375 diameter end mill depth of 0.125 inches b EDM the slots with an electrode since a mill cannot hold the specified tolerances. c Use a 0.375 diameter end mill with a single pass 56 The most accurate method for aligning a vise mounted on a verticle mill table is to a Use a scale and measure distances b Use a dial indicator mounted on the quill or in a collet c Use calipers, perform triangulation and apply roll pins 57 Reamers cutting oversize due to built up edges may be caused by a A slow feed rate b Excessive stock allowance c Flute lengths 58 The clearance for a counterbore pilot should be a 0.000 to 0.0005 inches b 0.002 to 0.005 inches c 0.020 to 0.030 inches 59 What is the allowance for a shaft measuring one inch in diameter with an RC6 sliding fit (in inches) a +0.001 b -0.003 c -0.004 60 What does the acronym FN represent a Frontal fit b Fast fit c Force fit 61 Continous improvement and teamwork a Are used only in first piece inspections b Increase production and profability c Increase the work load 62 Which of the following items is a tool for continuous improvement a All of the above b Inspection plan and SPC charts c Problem solving methodology

1

The safest way to remove chips from a lathe or milling machine is to use a?

a

Air hose and high pressure nozzle

b

Glove covering the operators hand

c

Brush

2

Small chips left on the spindle nose of the lathe should be cleaned to avoid

a

Symmetry of Shapes

b

Run out on work holding devices

c

Scratches on the workpiece

3

Grease guns are used to insert grease into

a

Zerk fittings on machine tools

b

The short taper of a cam lock spindle nose

c

The T-slots of a vertical mill

4

To lubricate the ways of a lathe, the gibs of a mill, or the cross slide of a grinder

a

Use a grease gun with lithium grease

b

Use chalk as a lubricant since it doesn't attract dust

c

Use lubricant found in central lubricating systems ("one shots")

5

If a verticle mill table is loose and has side play, the best solution to alleviate side play is to

a

Tighten the clamps that lock the table

b

Tighten the taper gib adjustment

c

Loosen the taper gib adjustment

6

A machinist wants to find the proper type of lubrication, schedule and recommended maintenance practices for the headstock of a lathe. The best source to find this information is

a

Tooling and Manufacturing Engineer's Book

b

FMEA (Failure Mode Effects Analysis)

c

Preventative maintenance schedule and machine manual

7

General maintenance information for machine tools and machine work area can be found

a

On the capability report

b

In a general maintenance manual

c

On the inspection and sampling plan

8

Pinning refers to

a

Back filling

b

Draw filling unloading

c

Loading the file with metal chips

9

Files should be stored

a

In a toolbox separated from each other

b

In a large wooden box close to the bench area

c

With end mills, drills, and other cutting tools

10

The best way to clean the chips out of a file is to use

a

Brush

b

An air gun

c

File card

11

What is the most common injury that may occur during a filling operation

a

Slivers from pinning

b

Being stabbed with the tang (file without a handle)

c

Scratches from holding the file

12

The best lubricant to prevent wear and increase cutting efficiency for tapping common steels is

a

Sulfur-based oil

b

Mineral oil

c

Air jet

13

The process plan specifies tooling to be used by indicating

a

Tolerances on dimensions

b

Lubrication procedures

c

Tooling diameters and sizes

14

A reaming operation produces finish tears. The cause of the tears is

a

A reamer with a worn tip

b

Feeding too slow

c

Insuffcient stock allowance

15

What is the gage block height for an angle of 9 degrees on a 10-inch sine plate

a

1.5643 inches

b

0.7822 inches

c

3.1287 inches

16

Which of the following combinations of gage blocks (from an 81-block set) can be used to gage a length of 0.9528 inches?

a

0.152, 0.1008, 0.750

b

0.1008, 0.102, 0.750

c

0.1008, 0.325, 0.500

17

The process of displacing air between gage blocks for accurate measurements is called

a

Smoothing

b

Wringing

c

Honing

18

To check the height of multiple parts with gage blocks, a machinist would use a

a

Dial indicator and digital height gage

b

Digital height gage

c

Vernier caliper and telescoping gage

19

Surface finish is checked with

a

Optivisor

b

Comparison chart

c

Optical Comparator

20

A surface finish symbol is as follows

a

The surface finish is 15 millimeters

b

The surface finish is 0.015 inches

c

The surface finish is 15 micro inches

21

What is the most common type of surface finish callout

a

Roughness

b

Waviness

c

Lay

22

A part is considered a reject when

a

All the dimensions are in tolerance

b

The daily production rate is not achieved

c

Dimensions are out of tolerance

23

A sampling is referred to as a

a

Number of defects in a shift

b

The number of parts that meet all dimensions

c

Samples taken from a machine over a period of time

24

Inspections plans are needed to

a

Check dimensions in a repeatable and reliable way

b

All the above

c

Identify measuring tools and Coordinate inspection procedures

25

The first thing to do when constructing an inspection plan is to

a

Select the critical and important dimensions to inspect

b

Select the measuring instruments

c

Construct SPC charts for all dimensions

26

The most important factor in selecting measuring tools for inspection is

a

Tolerancing of dimensions to inspect

b

Access to measuring equipment

c

Process capability of the part in assembly

27

Sampling plans contribute to a quality control process by

a

Defining tolerances regardless of the print tolerances

b

Creating error margins in capability ratios

c

Providing an acceptable respresentation of all the parts produced

28

What features of a thread is checked with a thread micrometer

a

Pitch diameter

b

Root radius

c

Minor diameter

29

Dial bore gages are used to measure

a

Tapered shafts

b

Holes

c

Internal threads

30

To indicate an angled surface and make that surface parallel to a surface plate, the machinist would use a

a

V-Block and indicator

b

Angle plate and plate protractor

c

Sine plate

31

What sizes of gage pins would a machinist need for a dimension of 3/32 + 1/64th inches for a go/no go gage setup (rounded to three places)

a

0.110/0.094

b

0.110/0.078

c

0.332/0.312

32

A measure of dispersion that uses the largest and smallest measurements of a sampling is

a

Median

b

Mode

c

Range

33

What is the range of the following sampling: 0.345, 0.382, 0.353, 0.380, 0.377

a

0.037

b

0.017

c

0.025

34

Which of the following is not found on an X-bar and R control chart

a

Mean

b

Upper control limit

c

Capability Ratio

35

The acronym MSDS means

a

Material Safety Data Sheet

b

Multiple System Diagnostic Sheet

c

Manual Safety Data System

36

Which of the following colors is not found on an HMIS label

a

Red

b

Yellow

c

Green

37

The threshold limit value (TLV) is defined as

a

The threshold temperature for explosion

b

The point at which a chemical becomes flammable

c

The safe limit of unprotected exposure to a material

38

MSDS information on new chemicals and materials found in the workplace can be reviewed and discussed at

a

All the Above

b

Right to know seminars and classes

c

Safety meetings

39

The acronym HMIS stands for

a

Hazardous Materials Information System

b

Hazardous Methods Instructional Safety

c

High Maintenance Inspection Survey

40

The acronym for the goverment agency that regulate safety is

a

OCAW

b

USFS

c

OSHA

41

Oily rags and wipes are stored in a red fireproof can with a lid to prevent

a

Obnoxious smells

b

Fire through spontaneous combustion

c

Oil from seeping on the floor

42

The first course of action to take if a material (solid) becomes lodged in the eye is to

a

Use light air pressure to blow out debris

b

Use a magnet to attract the object

c

Pull the top lid over the bottom lid

43

The first action to take with a bleeding wound is to

a

Apply a tourniquet

b

Apply pressure to the nearest artery

c

Stop the bleeding by applying pressure to the wound

44

The best technique for lifting is to

a

Lift with the legs and keep the back straight

b

Keep the legs straight and use only the back

c

keep feet wide as possible

45

When operating a lathe, long hair, dangling jewelry, or loose clothes can

a

Become dirty from oil and chips

b

Obstruct the view of operation

c

Become caught in the lathe pulling the operator toward the machine

46

Goverment safety regulations state that a person must wear a ________ when working on material stored overhead using cranes and hoists

a

Hard hat

b

Ear plugs or muffs

c

Insulated gloves

47

When working on machinery producing flying chips, the most important personal protection equipment a machinist must wear is

a

Ear plugs

b

Gloves

c

Safety glasses

48

Which one of the following procedures is a safe procedure for a milling operation

a

Using an air gun to clean the chips off the mill table

b

Adjusting the work only when the cutter is stopped

c

Extending the tool and quill to achieve a maximum length

49

The best technique for milling on a vertical mill that is not equipped with an automatic table is to

a

Conventional mill

b

Peck mill

c

Spotface mill

50

Tight threads produced by a tapping operation may be caused by

a

Large tap hole diameter

b

Tap wear

c

Material springback

51

Thread percentage is dependent on the

a

Number of threads per inch

b

Major diameter of the thread

c

Tap hole diameter

52

What is the root cause of warping when grinding long slender pieces

a

THe structure of the wheel is too open

b

Heat checking due to a hard wheel

c

Vibration of the work piece during the grinding operation

53

When dressing the grinding wheel, the diamond dresser should be located on the

a

Outfeed side of the wheel rotation (left side)

b

Bottom dead center of the wheell

c

Infeed side of the wheel rotation (right side)

54

Tough material causes accelerated tool wear. Machinists can ________ to reduce tool wear and possible tool breakage.

a

Increase the spindle speed

b

Increase the spindle speed and feed

c

Decrease the spindle speed

55

The print calls for 0.375 + 0.005 wide X 0.125 + 0.005 deep slot to be milled. The best procedure is to

a

Use 0.250 diameter end mill to depth of 0.100,then use 0.375 diameter end mill depth of 0.125 inches

b

EDM the slots with an electrode since a mill cannot hold the specified tolerances.

c

Use a 0.375 diameter end mill with a single pass

56

The most accurate method for aligning a vise mounted on a verticle mill table is to

a

Use a scale and measure distances

b

Use a dial indicator mounted on the quill or in a collet

c

Use calipers, perform triangulation and apply roll pins

57

Reamers cutting oversize due to built up edges may be caused by

a

A slow feed rate

b

Excessive stock allowance

c

Flute lengths

58

The clearance for a counterbore pilot should be

a

0.000 to 0.0005 inches

b

0.002 to 0.005 inches

c

0.020 to 0.030 inches

59

What is the allowance for a shaft measuring one inch in diameter with an RC6 sliding fit (in inches)

a

+0.001

b

-0.003

c

-0.004

60

What does the acronym FN represent

a

Frontal fit

b

Fast fit

c

Force fit

61

Continous improvement and teamwork

a

Are used only in first piece inspections

b

Increase production and profability

c

Increase the work load

62

Which of the following items is a tool for continuous improvement

a

All of the above

b

Inspection plan and SPC charts

c

Problem solving methodology

Measurement, Materials, and Safety

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