MAE 183A: Introduction to Manufacturing Processes
University of California, Los Angeles (UCLA)
Winter 2026 Instructor: CJ Kim
Examination II
February 18: 12:30–1:20 PM (50 minutes)
Name: ____Solutions____, ___________________________
Last First
SCORE: __55__55
Write within the given spaces. More than enough spaces are given.
Prob. 1 (15 pts) Multiple choice questions. Circle the correct answer(s).
(1) Which one of the four types of chip would be expected in a turning operation conducted at low cutting
speed on a brittle work material: (a) continuous, (b) continuous with built-up edge, (c) discontinuous, or (d)
serrated?
(2) Which of the following manufacturing processes are classified as material removal processes (two
correct answers): (a) spinning, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g)
molding, (h) pressworking, and (i) casting? (Need both to receive 1 pt.)
(3) A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b)
drilling, (c) lapping, (d) milling, or (e) turning?
(4) Which of the following are alternative names for indirect extrusion (two correct answers): (a) backward
extrusion, (b) direct extrusion, (c) forward extrusion, (d) impact extrusion, and (e) reverse extrusion? (Need
both to receive 1 pt.)
(5) Which of the following rolling mill types are associated with relatively small diameter rolls in contact
with the work (two correct answers): (a) cluster mill, (b) continuous rolling mill, (c) four-high mill, (d)
reversing mill, and (e) three-high configuration? (Need both to receive 1 pt.)
(6) Compared with forging hammers, forging presses apply the load (pressure) against workpart (a) more
gradually, (b) more impactfully, (c) more strongly, (d) less strongly. Choose one best answer.
(7) The coefficient of friction between the part and the tool in hot working tends to be (a) higher, (b) lower,
or (c) no different relative to its value in cold working?
(8) Stresses applied in most metal forming operations are which one of the following: (a) compressive, (b)
shear, or (c) tensile?
, Write your last name: Solutions
(9) (2 pts) A polymer melt exhibits which of the following typical properties and characteristics (two correct
answers): (a) becomes less resistant to flow at high shear rates, (b) becomes more resistant to flow at high
shear rates, (c) Newtonian fluid, and (d) viscoelasticity?
(10) Extrusion is a tensile process in which material is forced to flow through a die orifice to provide long
continuous product whose cross-sectional shape is determined by the shape of the orifice: (a) true or (b)
false? (Don't glance through the problem statement; please read every single word in it.)
(11) In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an
external melting container, and a piston is used to inject the metal under high pressure into the die cavity:
(a) true or (b) false?
(12) A misrun is which one of the following defects in casting: (a) globules of metal becoming entrapped in
the casting, (b) metal is not properly poured into the downsprue, (c) metal solidifies before filling the cavity,
(d) microporosity, and (e) "pipe" formation?
(13) Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more
rapidly than the surrounding sand are called which one of the following: (a) external chills, (b) internal
chills, (c) pipes, or (d) sprues?
(14) A riser in casting is described by which of the following (two correct answers): (a) an insert in the
casting that inhibits buoyancy of the core, (b) gating system in which the sprue feeds directly into the cavity,
(c) metal that is not part of the casting, and (d) source of molten metal to feed the casting and compensate
for shrinkage during solidification? (Need both to receive 1 pt.)
Prob. 2 (20 pts) Short answer questions. Write within the given spaces.
(1) What is vacuum molding?
Answer. Vacuum molding forms a mold by holding sand together with vacuum pressure (rather
than with moisture or binder).
(2) What is the difference between a pattern and a core in sand molding?
Answer. The pattern determines the external shape of the cast part, while a core determines its
internal geometry if the casting includes a cavity.
(3) What is a meant by the term mushy zone during solidification of a metal alloy?
Answer. The mushy zone is a mixture of solid and liquid metal that occurs while the temperature
of the metal is between the liquidus and solidus for the alloy.
2
University of California, Los Angeles (UCLA)
Winter 2026 Instructor: CJ Kim
Examination II
February 18: 12:30–1:20 PM (50 minutes)
Name: ____Solutions____, ___________________________
Last First
SCORE: __55__55
Write within the given spaces. More than enough spaces are given.
Prob. 1 (15 pts) Multiple choice questions. Circle the correct answer(s).
(1) Which one of the four types of chip would be expected in a turning operation conducted at low cutting
speed on a brittle work material: (a) continuous, (b) continuous with built-up edge, (c) discontinuous, or (d)
serrated?
(2) Which of the following manufacturing processes are classified as material removal processes (two
correct answers): (a) spinning, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g)
molding, (h) pressworking, and (i) casting? (Need both to receive 1 pt.)
(3) A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b)
drilling, (c) lapping, (d) milling, or (e) turning?
(4) Which of the following are alternative names for indirect extrusion (two correct answers): (a) backward
extrusion, (b) direct extrusion, (c) forward extrusion, (d) impact extrusion, and (e) reverse extrusion? (Need
both to receive 1 pt.)
(5) Which of the following rolling mill types are associated with relatively small diameter rolls in contact
with the work (two correct answers): (a) cluster mill, (b) continuous rolling mill, (c) four-high mill, (d)
reversing mill, and (e) three-high configuration? (Need both to receive 1 pt.)
(6) Compared with forging hammers, forging presses apply the load (pressure) against workpart (a) more
gradually, (b) more impactfully, (c) more strongly, (d) less strongly. Choose one best answer.
(7) The coefficient of friction between the part and the tool in hot working tends to be (a) higher, (b) lower,
or (c) no different relative to its value in cold working?
(8) Stresses applied in most metal forming operations are which one of the following: (a) compressive, (b)
shear, or (c) tensile?
, Write your last name: Solutions
(9) (2 pts) A polymer melt exhibits which of the following typical properties and characteristics (two correct
answers): (a) becomes less resistant to flow at high shear rates, (b) becomes more resistant to flow at high
shear rates, (c) Newtonian fluid, and (d) viscoelasticity?
(10) Extrusion is a tensile process in which material is forced to flow through a die orifice to provide long
continuous product whose cross-sectional shape is determined by the shape of the orifice: (a) true or (b)
false? (Don't glance through the problem statement; please read every single word in it.)
(11) In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an
external melting container, and a piston is used to inject the metal under high pressure into the die cavity:
(a) true or (b) false?
(12) A misrun is which one of the following defects in casting: (a) globules of metal becoming entrapped in
the casting, (b) metal is not properly poured into the downsprue, (c) metal solidifies before filling the cavity,
(d) microporosity, and (e) "pipe" formation?
(13) Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more
rapidly than the surrounding sand are called which one of the following: (a) external chills, (b) internal
chills, (c) pipes, or (d) sprues?
(14) A riser in casting is described by which of the following (two correct answers): (a) an insert in the
casting that inhibits buoyancy of the core, (b) gating system in which the sprue feeds directly into the cavity,
(c) metal that is not part of the casting, and (d) source of molten metal to feed the casting and compensate
for shrinkage during solidification? (Need both to receive 1 pt.)
Prob. 2 (20 pts) Short answer questions. Write within the given spaces.
(1) What is vacuum molding?
Answer. Vacuum molding forms a mold by holding sand together with vacuum pressure (rather
than with moisture or binder).
(2) What is the difference between a pattern and a core in sand molding?
Answer. The pattern determines the external shape of the cast part, while a core determines its
internal geometry if the casting includes a cavity.
(3) What is a meant by the term mushy zone during solidification of a metal alloy?
Answer. The mushy zone is a mixture of solid and liquid metal that occurs while the temperature
of the metal is between the liquidus and solidus for the alloy.
2
