Chapter 1 Reviewer

1. A study of __________ will show that industry has progressed from the time when everything was
made by hand to the present fully automated manufacturing of products.

2. __________ tools have played an essential roie in all technological advances.

3. High-paying skilled jobs in manufacturing, such as tool-and-die making and precision machining,
require aptitudes comparable to those of ___________.

4. _____________ are the class of machines which, taken as a group, can reproduce themselves
(manufacture other machine tools).

5. The first machine tools, the ________ and _________, were hand-made.

6. They have been dated back to about _______ BC.

7. Until the end of the 17th Century

the lathe could only be used to turn ________ materials, such as wood, ivory, or at most, soft metals like
lead or copper.

8. Eventually the bow lathe with its reciprocating (back-and-forth) motion gave way to _________ power,
which made possible work rotation that was continuous in one direction.

9. Later, machines were powered by a ______________ turned by flowing water or by a person or

animal walking on a treadmill.

10. When inventor ____________ first experimented with his ___________ , the need for perfectly
bored cylinders soon became apparent.

11. The first true machine tool was a form of the lathe and was called a " ________ "

12. The ___________ tool was developed in 1774 by Englishman John Wilkinson.

13. Operation of the boring mill, like all metal cutting lathes at the time, was hampered by the lack of
tool control. The "________" (the first machinist) had to unbolt and reposition the cutting tool after each
cut.

14. About 1800, the first lathe capable of cutting accurate screw threads was designed and constructed
by _____________, an English mastermechanic and machine toolmaker.

15. Maudslay also devised a _________ rest and fitted it to his lathe. It allowed the cutting tool to be
accurately repositioned after each cut.

16. _____________ is considered the "granddaddy" of all modern chip making machine tools.
17.In retrospect, the Industrial Revolution could not have taken place if there had not been a cheap,
convenient source of power: the ____________ .

18. The steam engine, in turn, would not have been possible without _____________.

19. The ____________ was the next important development in machine tools. It also evolved from the
lathe.

20. In 1820, ___________ , an American inventor and manufacturer, devised a system to mass produce
muskets (guns). 21. Whitney began using a milling machine, to make interchangeable ______ parts.

23. Whitney's milling machine even had power feed, but it had one defect. There was no _________ to
raise the worktable.

As machine tools were improved, so was the way they were powered.

23 _________ . The bow lathe and bow drill are examples. Direction of rotation changed at each stroke
of the bow.

24. _________. A treadle or a treadmill made possible continuous rotation of the work in one direction.

25. _________. Treadmills were used to power early devices for boring cannon barrels. Human foot
power was not sufficiently strong for this work.

26. _________ . Not always dependable as a power source, because of lack of water during dry seasons.

27. _________ . The first real source of dependable powver. A centrally located steam engine turned
shafts and overhead pulleys that were belted to the individual machines.

28. __________ . Large electric motors simply replaced the steam engines. Power transmission to the
machines did not change.

29. ______________ . Motors were built into the individual machine tools. Overhead belting was
eliminated.

30. Almost all machine tools have evolved from the _________ .

31. The most advanced version of the lathe is the ___________ .

32. A ___________, rotates a cutting tool (drill) against the material with sufficient pressure to cause the
tool to penetrate to the material.

33. ___________ , is an operation that removes metal by rotating a grinding wheel or abrasive belt
against the work.
34. ___________ . Work that does not require great accuracy is hand-held and manipulated until ground
to the desired shape.

35. ___________ . Only a small amount of material is removed with each pass of the grinding wheel, so
that a smooth, accurate Surface is generated.

36. ___________ is a finishing operation.

37. ___________ , is a widely employed technique that makes use of a continuous saw blade.

38. A ___________ rotates a multitoothed cutter into the work.

39. ____________ are designed to push or pull a multitoothed cutter across the work.

40. There are a number of machining operations that have not evolved from the lathe. They are
classified as ___________ processes.

These processes include:

41. ____________ An advanced machining process that uses a fine, accurately controlled electrical spark
to erode metal.

42. ____________ A method of material removal that shapes a workpiece by removing electrons from
its surface atoms. In effect, it is exactly the opposite of electroplating.

43. _____________ A process in which chemicals are employed to etch away selected portions of metal.

44. _____________ A material removal

method in which chemicals are employed to produce small, intricate, ultrathin parts by etching away
unwanted material.

45. _____________ A computer-controlled technique that uses a 55,000 psi water jet to cut complex
shapes with minimum waste. The work can be accomplished with or without abrasives added to the jet.

46. ______________ A method that uses ultrasonic sound waves and an abrasive slurry to remove
metal.

47. _______________ A thermoelectric process that focuses a high-speed beam of electrons on the
workpiece. The heat that is generated vaporizes the metal.

48. _______________The laser produces an intense beam of light that can be focused onto an area only
a few microns in diameter. It is useful for cutting and drilling.

49. ____________ CNC has made possible unconventional machine tools that use new work positioning
and tool-positioning concepts.These tools, already available to industry, utilize the same movement
principles developed for the flight simulators that train aircraft pilots. They offer basic advantages in
stiffness, accuracy, speed, dexterity and scaling (making larger or smaller versions of the same part).
50-54.

The Parsons Corporation, a manufacturer of aircraft parts, had developed a __________ technique for
generating data to check helicopter blade airfoil patterns. This system used _________ tabulating
equipment. To determine the accuracy of the data, a pattern was mounted on a ___________. With a
dial indicator in place, the X and Y points were called out to a machinist operating the machine's ______
handwheel and another machinist who controlled the _________ handwheel. With enough reference
points established, the generated data proved accurate to 0.0015" (0.038 mm).

55. Parsons realized that the technique might also be developed into a two-axis, or even three-axis,
machining system. With an Air Force contract to manufacture a contoured integrally stiffened air-craft
wing section, the Parsons Corporation subcontracted with the Servomechanism Laboratory at the
______________ to design a three-axis machining system. MIT eventually took over the entire NC
development project.

56-60

By 1952, MIT had designed a control system and mounted it on a vertical _________ machine tool. The
system operated on instructions coded in the binary number system on punched (perforated) tape.
Programming required the use of an early __________ upon which MIT was also experimenting. Later in
that year, MIT demonstrated the first machine tool capable of executing _____________ cutting tool
movement on three axes. Since mathematical information was the basis of the concept, MIT coined the
term _____________ . This machines became available to industry by late _________ .

61-62. In the mid-1970s, with the introduction of the __________ , the use of onboard computers on
individual machine tools became possible. This led to the introduction of ___________.

63. ____________ are much easier to use than manuaily controlled machines. They have menu-
selectable displays, advanced graphics (the multi-function screen displays the full operational data as

a part is being machined), and a word address format for programming.

64. The program is made up of __________ commands.

65. Programs on _____________ are rarely used.

66. A modern CNC is called _____________.

ACNC machine tool offers:

67. __________ It is capable of producing consistent and accurate workpieces.

68. __________ It is able to produoce any number of identical workpieces once a program is verified.

69. ___________ Changeover to running another type of part requires only a short period of
nonproductive machine downtime.
70.The use of ___________ for loading and unloading permits some machine tools to operate
unattended during the entire machining cycle.

71. A _______ is a prograrmmable, muiltifunctional manipulator designed to move maternial, tooks, or

specializod devices through programmed motions for the performmance of a variety of tasks.

Robots also have many other industrial applications. They can:

72. Operate in ________ and ________ environments.

73. Perform operations that would be _______ for a human operator.

74. Handle ________ materials.

75. Position parts with great repetitive __________.

76. The __________ industry makes extensive use of robots in the manufacture and assembly of motor
vehicles.

The machinist must:

77. Make a thorough _______ of the print.

78. Determine the _________ that must be done.

79. Ascertain _________ requirements.

80. Plan the machining _________.

81. Determine how the _________ will be made.

82. _________ the machine tool, cutter(s), and other tools and equipment that will be needed.

83. __________ cutting speeds and feeds.

84. Select a proper __________ for the material being machined.

85. A machinist is able to _________ the machining program.

86. The National Tooling and Machining Association, with the aid of the metalworking industry, has
developed ________ of skill standards reflecting industry skill requirements.

87. A major goal of the Metalworking Skills Standards program is __________ .

TEST YOUR KNOWLEDGE

1. One of the first machine tools, the bow lathe:

a. Could only turn softer materials.

. Has been dated back to about 1200 BC.

c. Eventually gave way to treadle power.

d. None of the above.

e. All of the above.

2. The Industrial Revolution could not have taken place without the cheap, convenient power of the
____________ .

3. List seven power sources in the order they have evolved over the last 150 years or so.

4. Almost all machine tools have evolved from the __________ .

5. Jobs such as tool-and-diemaking and precision machining require aptitudes comparable to those of :

a. High school graduates.

b. College graduates.

c. High school equivalency graduates.

d. All of the above

e None of the above.

6. Eli Whitney's mass-production system for muskets had a major problem because __________.

a. There were no skilled workers

b. There was no good source of power

c. There was no standard of measurement.

d.All of the above.

e. None of the above.

7. What occurred in the mid-1860s that was very important to the development of machining
technology in the United States?

8. List four types of nontraditional machining processes and briefly describe their operation.

9. The introduction of the microchip in the midmachine 1970s led to the introduction of _________
tools.
10. List four industrial applications of robots.