Manufacturing

Question 1

You need a corrosion resistant sheet metal. What are your options?

Answer 1

Aluminum and Stainless Steel

Question 2

Rate these from easiest to hardest to form: CRS, Aluminum, Stainless Steel

Question 3

Galvanized steel is steel coated with what

Answer 3

zinc

Question 4

What is blanking

Question 5

What is bend relief

Question 6

What welding process joins sheet metal using melted filler metal?

Question 7

What is a hem in sheet metal?

Answer 7

A fold over the edge for strength and safety.

Question 8

Why should bend radii be consistent in a part?

Answer 8

To simplify tooling and reduce cost

Question 9

Why avoid placing holes too close to bends?

Answer 9

To prevent distortion and cracking during bending.

Question 10

What is a K-Factor in bending

Question 11

Why is grain direction important in sheet metal design?

Answer 11

Bending parallel to grain can cause cracking.

Question 12

How do you compensate for springback in bending?

Answer 12

Over-bend slightly past the desired angle.

Question 13

What is typically the minimum flange length?

Answer 13

4X the material thickness

Question 14

What is the advantage of fiber lasers over CO₂ lasers?

Answer 14

Higher efficiency, lower maintenance, better cutting of reflective metals.

Question 15

What’s the typical angle of a V-die for bending?

Answer 15

85–90°

Question 16

What defect is caused by excessive punch-to-die clearance?

Answer 16

Burrs on edges. Higher shear forces cause galling and accelerated edge wear

Question 17

What is the main cause of warping in welding sheet metal?

Answer 17

Uneven heat distribution

Question 18

What is the main benefit of powder coating steel

Answer 18

Corrosion prevention

Question 19

If a part requires multiple sequential bends, what’s the main reason to bend from the largest flange first?

Answer 19

Prevents collisions with tooling and ensures dimensional consistency

Question 20

In laser cutting, what’s the impact of assist gas type (oxygen vs nitrogen)?

Answer 20

Oxygen promotes oxidation, faster cutting but rougher edge; nitrogen yields clean, oxide-free edges

Question 21

Why is MIG welding less suitable than TIG welding for thin sheet metal?

Answer 21

MIG has higher heat input, increasing risk of burn-through and warping

Question 22

Why do CNC press brakes use crowning systems?

Answer 22

To compensate for machine deflection, ensuring consistent bend angle across length.

Question 23

What’s the advantage of a servo-electric press brake over hydraulic?

Answer 23

Higher precision, energy efficiency, and faster cycle times.

Question 24

What is the minimum distance recommended between a punched hole and a bend line?

Answer 24

At least 2× material thickness

Question 25

Why is nesting important in laser cutting or punching?

Answer 25

Maximizes sheet utilization, reduces scrap

Question 26

Why are nibbling operations prone to edge roughness?

Answer 26

They approximate curves with overlapping small punches

Question 27

What defect occurs when the slug is not stripped during punching?

Answer 27

Double-hits or slug pulling, damaging tool and part

Question 28

Why is copper backing often used when welding thin sheet metal?

Answer 28

It absorbs heat, reduces burn-through, and prevents weld spatter adhesion.

Question 29

What defect occurs if weld penetration is too shallow in MIG welding?

Answer 29

Lack of fusion, leading to weak joints.

Question 30

Why should bend radii be kept ≥ material thickness in aluminum?

Answer 30

To prevent cracking due to lower ductility.

Question 31

Why do tabs and slots help in sheet metal design?

Answer 31

Aid self-location, improve assembly accuracy, reduce fixturing

Question 32

What is a louver

Answer 32

To create ventilation in enclosures

Question 33

What defect occurs if press brake crowning is not used on long bends?

Answer 33

Middle bends are shallower than ends (banana bend).

Question 34

Why are carbide tools preferred over HSS in modern machining?

Answer 34

Higher hardness, wear resistance, and hot hardness → faster cutting speeds.

Question 35

Why does tool wear accelerate at higher cutting speeds?

Answer 35

Increased temperature accelerates diffusion and oxidation wear.

Question 36

What causes chatter in machining?

Answer 36

Self-excited vibrations from interaction of tool, work, and machine compliance

Question 37

Why does reaming produce better surface finish than drilling?

Answer 37

Removes small material allowance with multi-edge tool, reducing tool deflection

Question 38

A device mounted on a spindle that grips the workpiece

Answer 38

Chuck

Question 39

A slotted sleeve that grips round stock with high concentricity when tightened

Answer 39

Collet

Question 40

A shaft used to hold hollow workpieces from the inside

Answer 40

Mandrel

Question 41

Lathe component opposite the headstock used to support work or hold tools.

Answer 41

Tailstock

Question 42

Moves along lathe bed, holding cross slide and toolpost

Answer 42

Carriage

Question 43

Rotating machine component that drives tool or workpiece.

Answer 43

Spindle

Question 44

Internal diameter measuring tool with dial indicator.

Answer 44

Bore Gauge

Question 45

Inserts serrated edges to remove material aggressively. Smooth flutes for fine surface finish.

Answer 45

Roughing End Mill Finishing End Mill

Question 46

Measures deviation in rotational or linear motion.

Answer 46

Dial Indicator

Question 47

Go/No-Go tool for hole checking.

Answer 47

Pin Gauge

Question 48

Programming language used to control CNC machines.

Answer 48

G-Code

Question 49

Removing edge material to create a beveled edge

Answer 49

Chamfering

Question 50

Removing sharp edges, burrs, or roughness after machining.

Answer 50

Deburring