IDM Exam 1 UPDATED QUESTIONS AND
CORRECT ANSWERS
Machining - CORRECT ANSWER Material removal process
Types of Machining - CORRECT ANSWER Cutting (single / multipoint tools),
Abrasive (grinding), Advanced (electrical, chemical, thermal, laser)
Pros of Machining - CORRECT ANSWER High accuracy, complex shapes, small
batches
Cons of Machining - CORRECT ANSWER Material waste, energy/time intensive,
costly for mass production
Turning - CORRECT ANSWER Rotating workpiece, tool feeds linearly
Cut-off - CORRECT ANSWER Tool feeds radially inward
Slab milling - CORRECT ANSWER Rotating cutter removes surface layer
End milling - CORRECT ANSWER Cavity/profile cutting
Depth of cut - CORRECT ANSWER to
Feed rate - CORRECT ANSWER Distance/rev (mm/rev, in/rev)
Cutting speed - CORRECT ANSWER v
Chip Formation - CORRECT ANSWER Chip forms by shearing along shear plane
, Chip thickness - CORRECT ANSWER Chip thickness > depth of cut
Cutting ratio - CORRECT ANSWER r = to / tc < 1
Continuous Chips - CORRECT ANSWER Ductile materials, high speed, good surface
finish, safety hazard
Built-Up Edge (BUE) - CORRECT ANSWER Material sticks to tool edge, poor
surface finish, protects tool slightly
Serrated Chips - CORRECT ANSWER Saw-tooth appearance, low thermal
conductivity materials (e.g. Ti)
Discontinuous Chips - CORRECT ANSWER Brittle materials, low rake, poor stiffness
Chip Breakers - CORRECT ANSWER Used to break continuous chips
Orthogonal Cutting - CORRECT ANSWER Cutting edge ⟂ to motion
Oblique Cutting - CORRECT ANSWER Inclination angle forces chip sideways
Cutting Forces - CORRECT ANSWER Fc - cutting force, Ft - thrust force, R -
resultant force
Friction coefficient - CORRECT ANSWER μ = F/N
Power in Cutting - CORRECT ANSWER P = Fc ⋅ v
CORRECT ANSWERS
Machining - CORRECT ANSWER Material removal process
Types of Machining - CORRECT ANSWER Cutting (single / multipoint tools),
Abrasive (grinding), Advanced (electrical, chemical, thermal, laser)
Pros of Machining - CORRECT ANSWER High accuracy, complex shapes, small
batches
Cons of Machining - CORRECT ANSWER Material waste, energy/time intensive,
costly for mass production
Turning - CORRECT ANSWER Rotating workpiece, tool feeds linearly
Cut-off - CORRECT ANSWER Tool feeds radially inward
Slab milling - CORRECT ANSWER Rotating cutter removes surface layer
End milling - CORRECT ANSWER Cavity/profile cutting
Depth of cut - CORRECT ANSWER to
Feed rate - CORRECT ANSWER Distance/rev (mm/rev, in/rev)
Cutting speed - CORRECT ANSWER v
Chip Formation - CORRECT ANSWER Chip forms by shearing along shear plane
, Chip thickness - CORRECT ANSWER Chip thickness > depth of cut
Cutting ratio - CORRECT ANSWER r = to / tc < 1
Continuous Chips - CORRECT ANSWER Ductile materials, high speed, good surface
finish, safety hazard
Built-Up Edge (BUE) - CORRECT ANSWER Material sticks to tool edge, poor
surface finish, protects tool slightly
Serrated Chips - CORRECT ANSWER Saw-tooth appearance, low thermal
conductivity materials (e.g. Ti)
Discontinuous Chips - CORRECT ANSWER Brittle materials, low rake, poor stiffness
Chip Breakers - CORRECT ANSWER Used to break continuous chips
Orthogonal Cutting - CORRECT ANSWER Cutting edge ⟂ to motion
Oblique Cutting - CORRECT ANSWER Inclination angle forces chip sideways
Cutting Forces - CORRECT ANSWER Fc - cutting force, Ft - thrust force, R -
resultant force
Friction coefficient - CORRECT ANSWER μ = F/N
Power in Cutting - CORRECT ANSWER P = Fc ⋅ v
