Safety Guidelines and Technical Information for Using Grinders, Drills, and Lathes, Exams of Physics

Download Safety Guidelines and Technical Information for Using Grinders, Drills, and Lathes and more Exams Physics in PDF only on Docsity! 1 Millwright Level 1 Exam Questions and Answers 2024 On a pedestal grinder, the gap between the grinding wheel and work rest should not exceed: - ANSWER 1/8 inch The kind of abrasive material used in grinding wheels for general purpose applications is: - ANSWER aluminum oxide A blotter is used on a grinding wheel to: - ANSWER protect the flanges from the abrasize grit, display information about the wheel and compensate for the uneven surfaces on the wheel Flanges should at least be: - ANSWER 1/3 the diameter of the wheel The best wheel to use for cleaning scale and dirt off a workpiece is the: - ANSWER wire wheel What is a natural abrasive? - ANSWER made of natural material rather than synthetic Under properties of abrasives, to what does the term hardness refer? - ANSWER ability of a material to scratch or penetrate another material The is the part of the wheel that holds the grains together - ANSWER bond Markings for the wheel identification can be found on the - ANSWER Blotter What is the recommended speed to run a grinding wheel? - ANSWER Never run it faster that the max RPM of the grinding wheel How should you start a grinder? - ANSWER Stand off to the side and wait a full minute Is 46 or 60 the coarser grit? - ANSWER 46 What are the 2 most commonly used abrasive materials? - ANSWER Aluminum oxide and silicone carbide For what purpose is the diamond dresser used? - ANSWER When a very fine finish is required What is the purpose of ring test? - ANSWER to check for cracks 2 If a grinding wheel makes a ringing sound what does that mean? - ANSWER wheel is not cracked What is the purpose of truing a grinding wheel? - ANSWER Restores the shape of the wheel and makes the outer surface of the wheel concentric with its bore An out of balance wheel: - ANSWER vibrates Belt grinders are useful for: - ANSWER quickly deburring and chamfering a workpiece What is the purpose of a GFCI? - ANSWER Senses drop in current and switches power off The kind of abrasive material use in grinding wheels for general purpose application is: - ANSWER aluminum oxide Is it safe to carry a portable grinder by the power cord? - ANSWER False Is it safe to use standard sockets with electric impact wrenches - ANSWER False The larger the power drill, the slower the RPMs and the higher the torque - ANSWER True Can you use conventional drill bits with a hammer drill? Why or why not? - ANSWER Yes of the hammer drill has a switch to turn off hammer action Most cordless drills have torque control - ANSWER True Prolonged use of power or air tools can cause carpal tunnel sydrome - ANSWER True Is it safe to run an impact wrench with a universal joint and socket attached - ANSWER No because it may throw off attachments What conditions would you use a GFCI - ANSWER Wet conditions What 3 things does a GFCI protect: - ANSWER 1. Overload 2. Overcurrent 3. Ground fault protection 5 depth of fasteners in concrete? - ANSWER 3" from the edge and from each other How long should you wait if a power actuated tool misfires? - ANSWER 30 seconds What is another name for a power saw? - ANSWER Reciprocating saw What determines the size (capacity) of a power hacksaw? - ANSWER Largest square piece that can be cut Why is the pressure removed from the blade of a power hack saw on the return stroke? - ANSWER To prevent damage to the blade How is the speed of a power hacksaw expressed? - ANSWER Strokes per minute Describe the characteristics of a bimetal power hacksaw blade - ANSWER High speed tooth edge with a tough alloy steel back How does the blade set differ from the blade kerf? - ANSWER Kerf is the width the blade cuts and set is the way individual teeth are bent out of line with the body What are the limitations of a horizontal band saw as it relates to cutting curves or round corners? - ANSWER It can only cut straight How is feed rate controlled on a horizontal band saw? - ANSWER An adjustable hydraulic cylinder IS it necessary to turn a horizontal band saw off manually after completing a cutting operation? Why or Why not? - ANSWER No because a switch is automatically activated by the downward motion of the upper frame What re the saw guides and where should you place them when you are using a horizontal band saw? - ANSWER They guide the blade and should be adjusted to as close as possible to the work If the blade jumps and shudders when you are using a horizontal band saw, what could be the problem? - ANSWER The feed rate is too high When cutting short pieces to length, what can be done to ensure that the jaws of the clamping device make good contact and do not distort - ANSWER Placing a similar piece in the back What is another name for a contour band saw? - ANSWER Vertical band saw What is tracking as it relates to band saw? - ANSWER Centering the blade on the 6 pulleys What characteristics differentiate styles of band saw blades? - ANSWER Material, width, gauge, pitch, type of tooth What is the advantage of using a bimetal blade in a band saw? - ANSWER Greater wear and heat resistance, faster cutting and better durability Where should you place the weld when you are welding band saw blades? - ANSWER Bottom of a tooth gullet The width of the saw blade cut in the workpiece is called: - ANSWER kerf The purpose of draw filing is to: - ANSWER produces a smooth and flat surface The removable serrated jaws on a bench vise made from: - ANSWER aluminum How do you designate the size of a bench vise? - ANSWER Width of jaws A standard screwdriver blade maintains a better grip in the slot if the blade is ground slightly: - ANSWER Concave The included angle that should be ground of the point of a center punch is: - ANSWER 90 degrees When tightening a bolt with a wrench: - ANSWER Never push: always pull The reason for the crown on the end of a flat scraper is: - ANSWER so that the outside edges do not dig into the finished workpiece What is a purpose of a flat (cold) chisel? - ANSWER cutting off rivets What is a chisel made from? - ANSWER high carbon steel What are 2 types of cleaning? - ANSWER 1. Chemical 2. Mechanical 7 Alkaline cleaning must only be used on what metal? - ANSWER Iron Barrel finishing: - ANSWER IS a quick and inexpensive cleaning method In the lapping process, what is charged? - ANSWER the lap What is another name for Hand Pads or Rolls? - ANSWER Scotch-Brite pads The 3 hand taps found in a set are the: - ANSWER Taper, plug and bottoming What is the tap drill size for a 3/4-10 UNC 2B? - ANSWER 21/32" If a high-speed steel hand tap breaks into a hole, one way to remove it is: - ANSWER with an electrical discharge machine You have to choose between 4 steel rods to cut 1/2-13 UNC 2A thread with an adjustable split die. What diameter rod would you use? - ANSWER 0.497" What is the correct tool to turn a die? - ANSWER Die stock The cutting action of a hand broach is performed by a series of successive teeth, each protruding: - ANSWER 0.003" further that the preceding tooth Hand reamers must be rotated: - ANSWER Clockwise Pullers are used to: - ANSWER remove bearings, hubs and sprockets 10 Why should you clean an lightly oil milling machine tables? - ANSWER To prevent rusting which causes loss of accuracy Why should you store end mills separate from one another? - ANSWER Cutting edges could chip and wear What is climb milling? - ANSWER Feeds into the rotation of the cutter and bites into the material pushing it down and into the table What is conventional milling? - ANSWER Feeds against the rotation of the cutter and tends to lift the workpiece What is the level of accuracy for a plate protractor? - ANSWER Within 1 degree What is the level of accuracy for a universal bevel protractor? - ANSWER 5 minutes of a degree How many minutes are in a degree? - ANSWER 60 minutes What is a vernier scale? - ANSWER Compares 2 sets of graduations to magnify the accuracy of the measuerment What does a dial caliper use to move its pointer around the face of a dial - ANSWER Rack and pinion What is the construction of a micrometer? - ANSWER 1. Anvil 11 2. Spindle 3. Sleeve 4. Thimble 5. Ratchet 6. Lock nut 7. Frame What method provides most accurate measurement when it comes to a micrometer? - ANSWER Ratchet method because it releases at the same pressure every time Regular micrometer scale level of accuracy is: - ANSWER 0.001" Vernier micrometer scale level of accuracy is: - ANSWER 0.0001" What is an Intrimik? - ANSWER Has 3 contact points rather than 2 making it self centering What is different about the scale of a depth micrometer from a regular micrometer? - ANSWER The distance measured is covered by the thimble What kind of tool is a taper gauge? - ANSWER Direct reading tool What is a taper gauge used for ? - ANSWER Determining the width of a slot or diameter of a hole and amount of angular misalignment The difference between a screw and a bolt is the: - ANSWER Application 12 Why are thread forming screws used? - ANSWER Convenient in sheet metal assemblies The major diameter of a thread is shown on a drawing as 0.748 +/- 0.002. What is the tolerance on the major diameter? - ANSWER 0.004 The pitch diameter of a thread is measured exactly halfway between the major and minor diameters - ANSWER False. Its APPROXIMATELY halfway between the major and minor diameter On a general purpose ISO metric thread, what character in the designation indicates a medium tolerance grade? - ANSWER Grade 6 An ISO metric thread is designated by M14 x 2 - 6g. What is the pitch of this thread? - ANSWER 2MM What are 2 types of tapered thread form? - ANSWER NPT and NPTF The unified thread class that offers the tightest fit is: - ANSWER 3 The designation that identifies a nut is: - ANSWER B Marks on the head of a bolt indicate the: - ANSWER grade and tensile strength A thread is designated 5/8 - 11 Class 2A. The thread shown: - ANSWER is an external thread 15 Which abbreviations is used to express the feed rate on a drill press? - ANSWER IPR A drill press has a #2 Morse taper. A twist drill with a #3 Morse taper shank must be mounted in the spindle. How should you secure the drill in the spindle? - ANSWER Use a drill socket To remove a tapered shank twist drill from the drill press spindle, use a: - ANSWER drill drift When using a sensitive drill press, what should you do as the drill breaks through the workpiece? - ANSWER Ease up on the pressure The included point angle of a countersunk hole for most flathead screws is: - ANSWER 82 degrees Which type of machine tap pushes the hip out ahead of the tap? - ANSWER Spiral pint (gun) tap The lip relief (clearance) angle of a drill should be: - ANSWER 8-12 degrees A general-purpose drill bit for drilling most metals has an included point angle of: - ANSWER 118 degrees The hand drill is quicker and more versatile than any drill press for: - ANSWER drilling small non-vertical holes Electric hand drills are limited by: - ANSWER the amount of feed pressure (and 16 rpm) that can apply to large-diameter drills How are step drills used? - ANSWER Used to drill and then countersink You must used the correct RPM when using a center drill or you will dull/break the bit - ANSWER True What speed should a countersink and counterbore be set at? - ANSWER Approximately 1/4 of what you would use for a drill What are the drill point included angles for soft, general and hard material? - ANSWER 60-90 degrees for soft, 118 degrees for general and 150 degrees for hard material What are 2 dial reading styles? - ANSWER Balanced and continuous What are 3 types of dial indicators? - ANSWER Bottom plunger, test indicators and back plunger What are dial bore gauges? - ANSWER Comparison measurement tool What is the advantage of a dial bore gauge? - ANSWER You can move it to various positions with making any adjustments Copper sulphate layout solution should be used on: - ANSWER Ferrous metals When angles are laid out with a bevel protractor, the accuracy attainable is: - 17 ANSWER +/- 0.5 degrees (30mins) The surface gauge is used: - ANSWER to layout lines parallel to an edge For maximum reliability when setting dividers to a dimension on a steel rule: - ANSWER set one point to the 1 inch or 10 MM graduation Trammels are used for scribing when: - ANSWER the circle to be scribe is beyond the range of the dividers When a radius is being laid out on a corner? - ANSWER the centre of the radius is located equidistant from the two adjacent sides before using a vernier height gauge it is important to: - ANSWER zero the vernier to the reference surface If the lines are scribed onto a workpiece it is considered to be: - ANSWER temporary layout The grade of surface plate which would be used in the shop is the: - ANSWER Grade B Which part of the combination set would be used to find the centre on the end of a shaft? - ANSWER a centre head and rule Precision layout with a vernier height gauge is accurate to: - ANSWER 0.001" or 0.02MM 20 What type of taper is used in the tailstock? - ANSWER Morse taper How are metric tapers designated? - ANSWER As a ratio 1:25 What is the amount of taper on taper pins? - ANSWER 1/4" per foot Cutting a taper with a compound rest has what major disadvantage? - ANSWER There is no power feed What is affected when drill bit tapers get damaged? - ANSWER Alignment and locking capability Once you have set a taper attachment to a desired angle, what important step must you follow? - ANSWER Take a trial cut and measure the taper The most common lathe operation is: - ANSWER turning Cutting speed refers to: - ANSWER How fast the workpiece travels past the tool Turning is usually done: - ANSWER with a right-hand tool An infeed of 0.050 on a direct reading cross-slide results in a diameter reduction of: - ANSWER 0.050 You are machining a 4.5 inch diameter steel shaft with a carbide tool. To machine it at 290 surface feet per minute, what should the approximate rpm of the spindle 21 be? - ANSWER RPM = (CS x 4)/ D (290 x 4)/4.5= 257.7777 or 255 The boring operation on a lathe: - ANSWER increases the diameter of a hole in a workpiece A reamer is used to: - ANSWER produce smooth accurate holes How does the speed and feed of a reamer compare to a drill? - ANSWER RPM is slower and feed is faster The pitch of a thread cut on a lathe is controlled y: - ANSWER The lead screw The finish on a thread can be enhanced by using: - ANSWER Coolant The thread-chasing dial: - ANSWER tells you when to engage the split nut When finishing with an emery cloth, the end held in your left hand passes under the workpiece and the end coming over the top it held in your right right hand - ANSWER True The result of knurling is: - ANSWER a workpiece slightly larger in diameter To achieve a good knurl, you should: - ANSWER flood the workpiece with coolant When grinding a workpiece between centres, you feed: - ANSWER with the 22 carriage feed What is a negative result of using a tool post grinder on a lathe? - ANSWER The dust can destroy the ways Cutting fluids are mainly used for: - ANSWER decreasing heat and friction What feed rate is used for finishing? - ANSWER 0.002-0.005 inches per revolution A high feed rate cuts metal quickly but: - ANSWER decreases tool life How much material should you leave for finishing? - ANSWER 0.030" What angle would the point angle of a cold chisel be ground to when splitting nuts? - ANSWER 40-50 degrees What are the removable serrated jaws on a bench vise made from? - ANSWER Hardened steel What type of chisel would be used to cut a narrow square shaped groove in a piece of mild steel? - ANSWER Cape chisel Where is the datum line on a micrometer? - ANSWER Sleeve When tapping a hole with a pipe tap, how many threads of the nipple should be able to turn into the hole before the use of a wrench becomes necessary? - ANSWER 2-3 threads 25 What is the minimum safe distance from which an electric arc should be seen with the naked eye? - ANSWER 12M (40ft) What is Voltage responsible for in arc welding? - ANSWER Starting arc Welding tip sizes are 000,00,0 and 1-10 - ANSWER True What type of electrode is used in the CAC-A process - ANSWER Carbon-graphite Which type of rod is best suite for high carbon steel in overhead postion? - ANSWER 7018 What type of flame is used to fusion weld low carbon steel? - ANSWER Neutral What gas is most efficient for welding purposes? - ANSWER Acetylene Carbon arc cutting can trim or cut parts made of ferrous and some non-ferrous metals - ANSWER True What is a worker responsible for? - ANSWER For own safety Wear proper PPE Not remove any safeties Have proper instruction of a piece of equipment Use tools properly 26 What are the four classes of fire? (Colour, letter and shape) - ANSWER Green Triangle (A) = Ordinary combustibles Red Square (B) = Vapours Blue Circle (C) = Electrical Yellow Star (D) = Combustible metals What is the ratio of height to distance from the foot of a ladder to the support structure? - ANSWER 4:1 or 75.5 degrees L/4=S What is the highest safe standing level on a step ladder? - ANSWER Second form the top What are the 2 styles of ladders? - ANSWER Access and working What are the 4 CSA ratings for ladders and application? - ANSWER 1. Extra heavy duty (industrial construction) 2. Heavy duty (building maintenance) 3. Medium duty (light commercial) 4. Light duty (household) Overreaching will cause the ladder to tip over - ANSWER True Side rails should extend a minimum of 1M above platform - ANSWER True Toe boards can't be less than 3.5" in height from surface work area - ANSWER True 27 Wet wood can conduct electricity - ANSWER True What does the fire triangle consist of? - ANSWER Heat, fuel and oxygen What are the differences between acute an chronic toxic effects? - ANSWER Acute is short term exposure but in high concentrations and chronic is long term exposure but in low concentrations What are the types of hazardous energy? - ANSWER Kinetic, chemical, potential, thermal, electrical and radiation What is ZMS in terms of lockout? - ANSWER Zero mechanical state You must bleed all residual pressure when locking out - ANSWER True What is the difference between fall arrest and fall restraint? - ANSWER Fall arrest stops someones free fall and fall restraint stops someone from reaching a fall hazard What is the taper per foot for an arbor? - ANSWER 0.006-0.008" per foot What is the taper per foot for a jacobs taper? - ANSWER 0.591-0.979" per foot What pitch of a hacksaw blade is for general shop use? - ANSWER 18-pitch A high pitch blade number is generally used for: - ANSWER Harder and thinner material 30 What characteristics does propane have? - ANSWER Colourless, odourless and non-toxic Is propane heavier or lighter than air? - ANSWER Heavier How much does propane expand when changed into gas? - ANSWER 270 times its volume Constant current maintains and varies - ANSWER amperage, voltage Constant voltage maintains and varies - ANSWER voltage, amperage Alternating current (AC) is: - ANSWER Positive and negative values that flow in 1 direction for the first half of the cycle and then flows in reverse in the next half of the cyle Direct current (DC) is: - ANSWER Flows 1 way and either has a positive or negative value What is voltage responsible for? - ANSWER Starting and maintaining arc, puddle fluidity, and flow What is amperage responsible for? - ANSWER Metal deposition rate and penetration What is straight polarity and what does it effect? - ANSWER Electrode negative 31 (EN) work positive. Burns hotter, faster welding speed, wide metal flow, shallow penetration and hard to control when position welding What is reverse polarity and what does it effect? - ANSWER Electrode positive (EP) work negative. Cooler burning, slower weld speed, narrow metal flow, deeper penetration and better control when position welding What increases as hardness of a metal increases? - ANSWER Brittleness Anything over 1.7% of carbon is considered: - ANSWER Cast iron What is maraging steel? - ANSWER Carbon is considered an impurity. Made up of nickel, cobalt and molybdenum Ferrite is: - ANSWER Pure iron Pearlite is: - ANSWER Iron and carbon Cementite is: - ANSWER Iron and carbon where iron is dominant Martensite is: - ANSWER Rapid cooling of austenite Austenite is: - ANSWER Ferrite but heated to red hot Only steel with a carbon content of .10 and higher percent can be hardened - ANSWER False. Only steel with a carbon content of 0.20 percent and higher can be hardened 32 What is full annealing? - ANSWER Opposite of hardening What is limestone? - ANSWER A flux that is added when forging steel to remove impurities What does C mean in AISI manufacturing process of steel? - ANSWER C= Basic open hearth carbon steel What are 3 types of technical drawings? - ANSWER 1. Orthographic 2. Pictorial 3. Schematic What are the 2 angles of orthographic drawings? - ANSWER 1. First angle (Europe) 2. Third (North America) What are the 2 types of pictorial drawings? - ANSWER 1. Orthographic 2. Oblique Isometric has angle: - ANSWER 30 degree Oblique has angle: - ANSWER 45 degree What are the 3 types of tolerances? - ANSWER 1. Unilateral 2. Bilateral