Design and Manufacturing Lab (DML) Practice Exam

These questions are part of the practice quiz. Start practicing

• Which of the following is dangerous to wear when operating powered equipment?
• For the 1/2 inch drill bit, what is the unscaled feed rate in inches per minute before applying the 60% reduction?
• Under what circumstance is it acceptable to leave the cutting tool or workpiece rotating when taking a measurement?
• Which thread specification is given for steel in the example?
• How is horsepower defined?
• Compared to casting and billets, forged metal is known for which characteristics?
• Which of the following should be checked before/when turning on milling machines?
• Which item is not typically considered safety equipment for milling?
• When specifying hole bottoms, which is typically chosen for ease of manufacturing and seating?
• Which statement about weighting objectives in a decision matrix is true?
• Which of the following is not a common workholding method on a lathe?
• Which statement is true about keeping objects away from the milling cutting zone while the spindle is running?
• Which statement best reflects proper initial wiring of the control box?
• In casting, the suitability of parts is independent of the desired quantity.
• To facilitate manufacturing, should you select stronger or weaker material?
• In milling, what influences the maximum safe depth per pass?
• What is the structural benefit of bending sheetmetal edges or flanges?
• True or False: Once the spindle completely stops, it is still dangerous to remove cutting chips by hand.
• What item should never be left in the lathe chuck?
• What is the most important rule when using manual lathes?
• Which equipment is used to create bends in sheet metal?
• For mounting bracket using M6x1.0 fasteners in aluminum with loose tolerances, what clearance hole size would you specify?
• Which of the following is not a common component of an engine lathe?
• To minimize tooling changes, which approach is preferred?
• Which of the following is NOT one of the three most common types of electric arc welding?
• Spindle speeds on the lathe, mill and drill press should be adjusted while the machines are OFF.
• Which statement best describes the forging process?
• In arc welding, which arc heats pieces of similar material to a temperature high enough to melt and coalesce?
• Drawings quality?
• Casting is good for which type of parts?
• Which practice aligns with making parts easier to manufacture by reducing material removal?
• Which capability is used to create holes in sheet metal?
• Which parameter should be adjusted with the mills, lathes, and drill presses running?
• Which dimension convention should be used?
• In industry, what happens if we cant communicate effectively, design simple parts that can be easily manufactured, create decent part drawings, or read measuring instruments correctly?
• Based on the over versus under tightening example, properly torqued fasteners can withstand how many more force application cycles before failure?
• Tool size preference?
• To ease manufacturing, should you use larger feature tolerances or smaller feature tolerances?
• Which item provides additional information about breaking sharp edges?
• Which two items are the two common methods of programming CNC machines?
• Bringing 1:1 scale printed and trimmed sheetmetal templates to lab is recommended to expedite part fabrication.
• Which pairing is best for manufacturability?
• Which lathe component is primarily used to feed the cutting tool across the workpiece?
• Milling is typically used to generate which type of surfaces?
• The suitability of parts for the forging process is independent of desired quantity.
• Is it advisable to use mirror-image parts in a design?
• Is manufacturing time an example of a qualitative assessment?
• Which of the following should a proper detail drawing include?
• Which option is NOT a feature that CNC machines possess to increase productivity?
• What is the purpose of flux or shielding gas in welding?
• What information is required to properly denote fasteners in assembly BOMs?
• What is a stated safety requirement when working in the shop?
• Which statement about the headstock on a lathe is true?
• Should you always design parts with room for assembly tools?
• In addition to drawings, whose feedback is valuable to simplify parts while maintaining function?
• What should be used to remove chips from machines instead of using your hands?
• When designing parts for cutting tools, which L:D ratio is preferred?
• For holes that pass completely through the part, which hole type is recommended?
• During design, should room for assembly tooling be considered?
• Which items should be present in assembly BOMs created for this course?
• In the spindle speed calculation for a 1/2 inch HSS drill bit in mild steel on a manual milling machine, what value of surface speed (SFM) is used?
• The speed range on the mills or lathes should be set before the machine is turned on.
• Which practice is appropriate when securing a workpiece for milling?
• Which action illustrates best practice when initiating contact with the workpiece on the milling machine?
• Which of the following is a consideration when designing motor hubs?
• CNC machines always require less time to make a part than manual machines.
• To minimize raw-stock removal, design parts for which level of removal?
• What are principal benefits of allocating individual member tasks via a works schedule?
• Never reach over the rotating part on the lathe due to the danger of protruding what?
• Decision matrix objectives are weighted because not all objectives are of equal importance.
• The cross slide on a lathe primarily moves the cutting tool in which direction relative to the spindle axis?
• On a lathe, where should the tool bit be positioned for normal cutting?
• What is the maximum material removal per pass permissible on a mill or lathe?
• Which sheetmetal capability is NOT listed as a capability in the lab?
• For slots or pockets in traditional manufacturing, which corner geometry is easier to machine?
• Which item should be removed from the lathe chuck to avoid danger?
• Whose name should appear on a detailed drawing as the designer/ drawer?
• Which unit is used for the final velocity in the velocity example?
• Which components rotate on a lathe?
• Which statement about sheetmetal is true regarding surface area to thickness ratio?
• Forging is particularly suitable for which type of parts?
• What is the typical tolerance range for turning and milling?
• In the steel example, which UNF thread is specified?
• What is the recommended mindset regarding experienced colleagues in professional development?
• In a milling setup, which components typically rotate?
• Which machine in the lab is not listed as CNC-automatable?
• Which statement about MIG welding is true?
• Which material is explicitly permitted to be cut on the Marvel bandsaw?
• Which of the following is a type of milling machine commonly used in shops?
• There is no such thing as a dumb question in this course.
• What is the typical tolerance range for free hand flame/plasma cutting?
• If you must choose between fasteners and pins for locating parts, which is the typical choice?
• If a material's machinability refers to its ability to be easily machined to final shape, would stronger materials possess higher or lower machinability?
• Given a motor shaft speed of 150 rpm, a 6 inch diameter wheel and 75% efficiency, what is the linear velocity of the robot?
• Summarize the relationship between relative production time and feature surface finish.
• Which dimensioning mistake involves omitting tolerances for any dimension?
• Calculation of required fastener tightening torque depends on two variables. Which pair correctly identifies these variables?
• Which of the following is a benefit of using 80/20 framing?
• In relation to chamfers and fillets, should parts be designed with or without them?
• Which approach to tool size is recommended to ease manufacturing?
• Before changing tools in the lathe, the spindle must be raised to its uppermost position.
• Which items are required to bring every week to the lab and TA office hours?
• True or False: The best manufacturing shops emphasize that parts should be easy to manufacture by using proven DFM techniques, clear drawings, and by listening to supplier feedback.
• One advantage of keyways and/or pin joints is that they always provide what?
• Dissimilar metals can be joined using the arc welding process if the proper filler metal is used.
• Which welding process uses a tungsten electrode to conduct electricity and provide the heat source?
• Fillet count?
• What is the typical tolerance range for bandsaw cutting, sheetmetal shearing, and sheetmetal bending?
• Which machines could be automated via CNC technology in the lab?
• A vital part of your success as a design engineer is to realize what an enormous resource those with more design and manufacturing experience can be to your professional development.
• What is the limiting factor for how fast a drill or endmill can feed through any material?
• Which of the following is an advantage of TIG welding?
• Select the appropriate tap drill size for tapping a 1/4-28 thread in steel.
• Lathe, mill and drill press spindle speeds must be adjusted while the machines are OFF.
• Which of the following is an advantage of MIG welding?
• All sheetmetal parts are razor sharp after shearing and should therefore be deburred immediately after cutting.
• Which of the following is not listed as a required item on a proper detail drawing?
• The lathe chuck key should be removed from the chuck after clamping the tool securely.
• After creating a decision matrix, the concept with the highest overall value should always be selected for use in the final design.
• Before changing tools on the milling machine, which two actions should you perform on the spindles over the plastic table cover?
• If someone doesn't understand how each part of your design works, what should happen?
• Which type of parts are manual machines a better choice for?
• To reduce complexity, should you specify fewer or more finished surfaces?
• For raw stock removal, should you design parts for minimum or maximum removal?
• Fasteners are primarily designed to do what?
• What is the limiting factor for how fast a drill or endmill can rotate in a particular material?
• Which hole type is recommended for through-bolting clearance to ease assembly?
• What should you not pull off the machines using your hands; use a rag instead?
• According to lab procedures, when using raw materials in the lab, purchase orders must be submitted before use.
• In design sizing, should parts be made larger or smaller?
• Which of the following statements about chuck keys is correct?
• Summarize the relationship between (minimum) achievable dimensional tolerance and part size.
• Which practice should be followed when dealing with sharp edges after sheetmetal shearing?
• Regarding chamfers and fillets, what guideline aligns with simplifying manufacturing?
• What keeps a bolted joint tight?
• When cutting flexible workpieces compared with rigid workpieces, which of the following cutting speeds should you generally use?
• Which action is a recommended practice for groups aiming for project success?
• Which statement best describes UNC and UNF thread forms?
• Before changing the lathe between HI and LOW range you must ask for TA help.
• Which rules apply when turning on the milling machine?
• Which item is NOT one of the four steps of the listed design process?
• Every part you design or drawing you make from this point forward is a reflection of your intelligence and design capability.
• Which statement about fasteners in BOMs is true?
• Which is an advantage of press fits?
• It is acceptable to leave a machine running in which scenario?
• Which factor directly relates to material properties in determining cutting speed?
• Which of the following is not among the listed factors affecting optimum cutting speed for drilling and milling?
• For the 1/4-28 thread in steel, which option is the correct tap drill size from the data provided?
• What should be done with parallels after clamping the workpiece in the vise?
• This is the point in the semester when a serious accident is most likely to occur because of how easy it is to drop our guard and forget how dangerous the equipment can be if not used properly.
• What completes the phrase in the design process step: 'gather information/ _____ research'?
• When working with sheet metal, what should you wear, except when using power tools such as bandsaws, drill presses, grinders, and sanders?
• How much radial clearance does a close fit hold for a 1/4 inch bolt?
• What is the thread pitch for a 10-32 fastener?
• Which UNC thread is specified for aluminum in the example?
• If any fasteners do not freely thread together by hand, which action should you take to prevent damage to expensive components?
• Heavy/ light cuts will use lower cutting speeds. Which type of cuts uses the lower speeds?
• Preparing for the Tapped Hole Quiz is listed as a recommended activity.
• In the velocity example, what wheel diameter was used?
• When operating a lathe, where should the tool bit typically be positioned?
• How should you engage the workpiece to avoid chipping the fragile cutting inserts and edges?
• What rotates on a milling machine?
• Which dimension convention is preferred to avoid arbitrary size decisions?
• What is the feed rate after applying the 60% reduction?
• If you must identify the weakest among billet, cast, and forged based on the given scores, which material is weakest?
• Which is the most common workholding method on a milling machine?
• Which action is recommended when someone makes excuses for not completing their work?
• Define the casting process.
• To simplify inspection, should you specify fewer or more dimension datums?
• Which statement about sheets and plates thickness is correct?
• When changing spindle speeds on the milling machine, must the spindle be running?
• Which equation represents spindle speed N in terms of surface speed V and drill diameter D?
• Before turning on the milling machines and lathes, what range should they be in?
• What is the primary difference between MIG and TIG welding?
• Which option is NOT a listed drawback of CNC machining centers?
• Safety glasses must be worn any time you are in the shop, including during TA hours.
• Is it acceptable to temporarily leave dial calipers and parallels out of their storage boxes while working on the equipment in the shop?
• Which dimensioning mistake is associated with shading in views?
• Which item identifies a part with a unique name and/or number?
• When scaling the part size to aid manufacturing, which action is recommended?
• Why are separate evaluation matrices created for separate functional subunits of a design?
• Which process can weld virtually any conductive metal?
• Which statement correctly describes the documentation requirements for off-the-shelf parts (OTS) used in a project?
• Most lab motor fasteners are metric and should be obtained by telling the TAs what size you need.
• When wiring the control box on subsequent occasions, what safety step is required?
• When choosing between an off-the-shelf part and a custom part, which should generally be used?
• What is the typical tolerance range for boring?
• Which option lists the two common methods of programming CNC machines?
• When connecting the control box to the motors for the first time, what must you do?
• Before changing spindle directions on a lathe, what is required?
• ECNs are used to formally track design changes and corrections through which phases?
• What is the typical tolerance range associated with reaming?
• Select the six factors that affect optimum cutting speed for drilling and milling.
• What does OTS stand for in manufacturing terminology?
• Should parts that can be bought off the shelf be designed to do so?
• For fastener threads, should they be placed in shear or tension?
• What material is the Marvel bandsaw allowed to cut?
• How should engineers select materials to meet strength and manufacturability requirements?
• What is the typical tolerance range for drilling?
• Which of the following is NOT among the three things you should check before/when turning on milling machines?
• What is a recommended method for locating parts relative to each other?
• Which thickness defines plates?
• Which action is recommended when connecting to motors for the first time?
• Torque vs speed curves for electric motors are which shape?
• What does ECN stand for in product development?
• Which statement describes a characteristic that makes casting suitable for mass production?
• Which item should be specified for surface finishing on every surface?
• Which hole type is preferred for ease of assembly in the provided context: tapped holes or thru-bolted holes?
• CNC technology is particularly advantageous for which scenario?
• Which thread size is specified for aluminum in the examples?
• The electrode used in MIG welding is consumed as the weld is made.
• What is the primary purpose of a design matrix in this course?
• When cutting stronger materials you will use lower cutting speed. Which material condition requires lower speeds?
• Gearing can be used to increase motor torque at the expense of what?
• Which statement best describes the relationship between cutting speed and tool life in drilling and milling?
• When reasonable, which hole type should be used?
• Which item would include the designer/ drawer's name?
• Rank the four common torque-transmission methods from strongest to weakest.
• Which item is used to specify the material to be used on a part?
• Mirror image parts?
• Which of the following rules apply when using the milling machine?
• What is the purpose of tolerances in engineering drawings?
• Which bottom shape is preferred for holes?
• Which is a dimensioning mistake that causes confusion?
• Define design for manufacturability (DFM).
• For holes intended for fasteners, which fit is typically used?
• For each part manufactured in the lab, what is required for part drawings?
• Which statement is NOT among the three most common sheetmetal operations as listed?
• Which set lists the four steps of the design process?
• Fastener threads should always be loaded in which mode?
• To facilitate manufacturing, which approach to part tolerances is recommended?
• What is the calculated spindle speed N before applying the 60% reduction in the given example?
• What is the typical tolerance range for free hand grinding?
• In the velocity example, what drivetrain efficiency was assumed?
• CNC machines are better suited than manual machines for which types of parts?
• There is no such thing as a dumb question once you are hired and start working for a company.
• During forging, the metal is typically in which state?
• Which statement is true about the threshold between sheet and plate?
• Which items are required to be worn or brought to the lab each week?
• When specifying slots or pockets for traditional manufacturing equipment, which corner is preferred?
• What is the function of a vise in milling?
• For mounting bracket using M6x1.0 fasteners in steel with precise tolerances, what clearance hole size would you specify?
• Which UNF thread is provided as an option for steel in the example?
• To maximize tool life, you will use lower cutting speeds. Which statement best describes this relationship?
• Which two actions should you perform on the milling machine spindles before changing tools?
• What are the three most common types of electric arc welding?
• Decision matrices are used to unbiasedly evaluate different ideas based on a weighted set of objectives the design team decides are important for solving the problem.
• The lab's brake is used for what operation?
• What is the limiting factor for how deep to cut (per pass) with an endmill in a particular material (assuming sufficient flute length)?
• Which type of drawing quality is emphasized to support easier manufacturing?
• Which of the following is a design mistake that can make a part look poorly designed?
• Which statement best describes relay control compared to proportional control?
• What is the purpose and benefit of peck drilling?
• Casting typically yields parts that are near net shape.
• Which item should be worn when handling sheet metal to ensure safety, except when using power tools?
• As a waste-reduction strategy, you should only cut the shortest over-size pieces to the necessary lengths.
• Which practice helps demonstrate that parts will be easier to manufacture relative to competitors?
• Cutting sizes approach?
• To simplify production, which surface finish is recommended?
• Which practice reduces inventory variety?
• What is the easiest mistake to make when changing tools on milling machines?
• The presence and efficiency of cutting fluid is listed as a factor affecting optimum cutting speed. True or false?
• For design, should parts be made to use larger or smaller cutting tools to ease manufacturing?
• What is the term called for the arrangement using D-shaped shafts with small flats cut into them and set screws?
• What is a key outcome of forging for metal parts?
• What is the radial clearance value for a close fit on a 1/4 inch bolt as given?
• Which statement is NOT a recommended practice when installing or removing tools on the milling machine?
• To simplify achieving surface finishes, should you specify coarser or finer surface finishes?
• Which statement about the tool post on a lathe is true?
• Which tool size choice reduces setup complexity?
• Casting is good for which production scenario?
• Which equation governs maximum peripheral tool velocity as a function of tool size?
• What is the process called to remove sharp edges from a cut workpiece?
• Which thread specification is specified for aluminum?
• Turning is primarily used to generate which type of surface?
• Rank the following materials by strength: billet metal, cast metal, forged metal (4 weakest to 10 strongest).
• In MIG welding, how is filler wire supplied to the weld pool?
• Which practice is unsafe while the milling machine is in operation?
• Which statement about lathe safety is NOT a correct practice?
• Milling is a metal cutting process used primarily for the generation of cylindrical surfaces.