Machining

Test and identify properties of metal

SELF CHECK UNIT ONE
PART: I
TRUE OR FALSE QUESION
Write “TRUE” if the statement is correct and “FALSE” if it is wrong statement.
1. High carbon steel provides high hardness and strength.
2. A ferrous and non-ferrous metal contains iron in their chemical compounds.
3. The copper is one of the most common non-ferrous metals.
4. Nickel is an example of non-ferrous metal.
5. Tensile strength is ability of a metal to resist being pulled apart by opposing forces acting
in a straight line.

PART: II
MULTIPLE CHOOSE QUESION
Choose the correct answer for the following questions.
1. One of the following is not the classification of metals
A. Ferrous metals B. Non-ferrous metals
C. Ferrous alloys D. Non-ferrous alloys E. None
2. The basic principle raw material for all ferrous metal is
A. Pig iron B. Cast iron C. Malleable iron D. All
3. Grey pig iron contains about _______% carbon in free form
A. 4 % B. 3% C. 1% D. 2%
4. Which one of the following is correct about grey cast iron and white iron?
A. Low in cost B. Very brittle C. cannot hammer D. All
5. Which one of the following is not correct about low carbon steel is
A. Have a lower tensile strength and hardness
B. It is easy welded machined, and formed
C. It is used for most bench metal D. Non

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PART: III
MACHING QUESION
Match the following items from column “B” to “A” with their meanings and write your
answer on the space provided. (10 %
Column A Column B

1. Non-ferrous metal A. steel

2. Bronze B. an alloy of CU and Zn

3. Solder C. an alloy of lead and tin

4. Brass D. an alloy of CU and Son

5. Ferrous metal E. Aluminum

6. Elasticity F .The property of breaking without warning

7. Ductility G. A combination of high strength and medium ductility

8. Malleability H. The capacity to be rolled or hammered into thin sheets

9. Toughness I. The capacity to be drawn from a larger to a smaller

10. Brittleness J .The ability of material to return to its original size, shape

Self-Check –UNIT TWO

Part: I
MULTIPLE CHOOSE QUESION
Choose the correct answer for the following questions.
1. The last step of manufacturing process is
A. Machining B. Casting C. Deformation D. Polishing
2. Which of the following is deformation process?
A. Rolling B. Extrusion C. Forging D. All
3. __________is a process of reduction of the cross-sectional area or shaping a metal piece
through the deformation caused by a pair of rotating in opposite directions metal rolls.

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 A. Rolling B. Extrusion C. Forging D. Casting
4. _________is a metal forming process involving shaping a metal billet (hot or cold) by
forcing it through a die with\ an opening.
A. Rolling B. Extrusion C. Forging D. Casting
5. _________is a compressive metal forming process, involving shaping a metal piece by
hammer or press.
A. Rolling B. Extrusion C. Forging D. Casting
6. ________is a metal forming process involving pulling a work piece (cold or hot) through a
die providing reduction of the cross section of the work piece.
A. Rolling B. Extrusion C. Drawing D. Casting
7. ____________is manufacturing processes by which a liquid material is usually poured into a
mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
A. Rolling B. Extrusion C. Forging D. Casting

8 Which one the following is not true about the properties of aluminum
A. Good electrical conductivity B. Malleable and ductile
C. Low thermal conductivity D. Resistance to corrosion
9 Copper is mainly used in
A. Making electric cables and wires for electric machinery B. Motor winding
C. Electroplating D. All
10. Bronze is commonly an alloy of
A. Copper and Aluminum B. copper and Tin C. Copper and Zinc D. Tin and Zinc
11. Which one of the following is not correct about mechanical properties of materials?
A. Elasticity B. plasticity C. Density D. Strength
Part: II
SHORT ANSWER
Short Answer all the questions listed below.
1. State at least five properties cutting tool materials.
2. Write the process in which have proved fittest to satisfy the demands put upon them in terms
of the life of the tool
3. Briefly define the following property of metals in manufacturing process:

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 Cast ability weld ability and forge ability
4. Briefly define the following basic methods of engineering materials processing:
Rolling and Drawing

5. Briefly define the following methods of manufacturing:

. Hot working. Cold working and Thermal processes

Self-Check –UNIT THREE

Part: I
TRUE OR FALSE QUESION
Write “TRUE” if the statement is correct and “FALSE” if it is wrong statement. (%)
1. Materials are tested to determine what properties they possess and to what degree.
2. In non- destructive testing the test piece is not destroyed and can, therefore, be used in a
finished product.
3. Compression test is reverse of tensile test.
4. Hook’s law states that when a material is loaded within elastic limit (up to proportional
limit), stress is proportional to strain

PART: II
MACHING QUESION
Match the following items from column “B” to “A” with their meanings and write your
answer on the space provided. (5 %
Column A Column B

1. Tempering A. Age hardening

2. Quenching B. Strengthening
3. Annealing C. Toughening
4. Normalizing D. Hardening
5. Principle of aluminum alloys E. Softening

Part: III
Fill in the blank space
1. __________: is the act or process of storing sounds or images on tape or a disk.

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2. ___________: give a spoken or written account of something that one has observed, heard,
done, or investigated present oneself formally as having arrived at a particular place or as
ready to do something.

Part: IV
ASSAY ITEM
INSTRACTION : WRITE YOUR ANSWER FOR THE FOLLOWING QUESTION.
1. Write the purpose of metal testing?
2. What is the difference between destructive testing and non-destructive testing?
3. Mention at least three metal hardness testing machine?
4. List at least three destructive and non-destructive testing machines

Self-Check –UNIT four

Part I
TRUE OR FALSE QUESION
Write “TRUE” if the statement is correct and “FALSE” if it is wrong statement. (%)
1. The objective soaking is to hold the metal to the proper temperature until the desired
internal structural changes take place.
2. The objective of annealing is the opposite of hardening.
3. The purpose of hardening is only to harden metal(steel)
4. Tempering consists of heating the steel to a specific temperature above its hardening
temperature.
5. Harding is the process in which iron - base alloys are heated 40 to 50°c above the upper
transformation range
6. Normalizing is defined as the heat - treating process in which steel is heated at 20°c
above the transformation rang
7. Tempering is Carried Out to decrease the brittle and to increase strength

Part: II

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 MULTIPLE CHOOSE QUESION
Choose the correct answer for the following questions.
1. As percentage of carbon increase in steel its ______decrease?
A corrosion resistant B Ultimate strength C Hardness D. Ductility
2. What is the purpose of annealing process
A. To increase hardness B. To decrease machinability C To remove internal stress For surface
hardening
3. The process of reheating the martensitic steel to reduce its brittleness without any significant
loss in its hardness is
A. Normalizing B. Annealing C Quenching D. Tempering
4. The machine tool guide ways are usually hardened by
A. Induction hardening B. Flame hardening C. Vacuum hardening D. Tempering
5. Which one of the following mediums is used for the fastest cooling rates of steel quenching
A. Air B. Oil C. Water D. Brine
6. During quenching marten site is produced
A. With an appropriate cooling rate such the carbon has time to migrate
B. With low cooling rate
C. Rapid cooling rate
D. Medium cooling rate
7. ______ is a surface hardening process given maximum hardness to the surface
A. Pack hardening
B. Nitrating
C. Cyaniding
D. Induction hardening
8. Heat treatment process used for steel casting is ____
A. Normalizing
B. Annealing
C. Tempering
D. Hardening
9. The essential ingredient of any hardened steel is
A. Austenite B. Pearlite C. Marten site D. Cementite

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10. Which one of the following is not a case hardening process?
A. Normalizing B. Annealing C. Cyaniding D. Both A and B

Part III
ASSAY ITEM
INSTRACTION: WRITE YOUR ANSWER FOR THE FOLLOWING QUESTION
1. Explain the stages of heat treatment
2. List four basic types of heat treatment
3. Why normalizing is needed for metals

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Pre.By Abebe 2017 Check By Bizuayehu Tadese
 Machining
Test and identify properties of metal

SELF CHEK-UNIT ONE

ANSWER SHEET
PART: I
TRUE OR FALSE QUESION
1. TRUE
2 .FALSE
3 .TRUE
4. TRUE
5. TRUE
PART: II
MULTIPLE CHOOSE QUESTION
1. D
2. A
3. C
4. A
5. C
PART: III
MACHING QUESTION
1. E 6.J
2. D 7.I
3. C 8.H
4. B 9.G
5. A 10.F

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Self-Check –UNIT TWO
Part: I
ANSWER SHEET
MULTIPLE CHOOSE QUESTION
1. D
2. D
3. A
4. B
5. C
6. C
7. D
8. B
9. D
10. B
11. C

Part: II
SHORT ANSWER
1. State at least five properties of cutting tool materials:
- Hardness
- Wear resistance
- Hot hardness
- Toughness
- Chemical stability

2. Write the process in which materials have proved fittest to satisfy the demands put upon
them in the life of the tool:
- The process is known as selection or material selection. It involves choosing the most
suitable material based on the specific requirements and conditions of the application.

3. Briefly define the following properties of metals in the manufacturing process:

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- Cast ability: The ability of a metal to be cast into a desired shape without defects.
- Weld ability: The ability of a metal to be welded without defects.
- Forge ability: The ability of a metal to be deformed by hammering or pressing without
cracking.

4. Briefly define the following basic methods of engineering materials processing:

- Rolling: A metalworking process in which metal stock is passed through one or more
pairs of rolls to reduce the thickness and make the thickness uniform.
- Drawing: A metalworking process in which a metal wire or rod is pulled through a single
or multiple dies to reduce the diameter and increase the length.

5. Briefly define the following methods of manufacturing:

- Hot working: A metalworking process in which metal is worked at a temperature above
its recrystallization temperature, allowing for significant shape changes without defects.
- Cold working: A metalworking process in which metal is worked at a temperature below
its recrystallization temperature, leading to hardening and strengthening of the metal.

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SELF CHEK-UNIT THREE
ANSWER SHEET
TRUE OR FALSE QUESION
1. TRUE
2. FALSE
3. TRUE
4. TRUE

PART: II
MACHING QUESI ON
1. C
2. D
3. E
4. B
5. A

Fill in the blank space

1. RECORDING
2. REPORT
Part: IV
ASSAY ITEM
1.The purpose of metal testing is to determine the properties and characteristics of metals,
such as their composition, strength, hardness, and durability. This information is crucial
for ensuring the quality and safety of metal products and structures.

2. Destructive testing involves testing a material or component to the point of failure,

resulting in its destruction. This type of testing is used to determine the maximum load or

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stress a material can withstand before breaking. Non-destructive testing, on the other
hand, does not involve damaging the material or component being tested. Instead, it uses
various techniques, such as visual inspection, ultrasonic testing, or magnetic particle
testing, to detect flaws or defects without causing any damage.
3. Three examples of metal hardness testing machines are:
- Rockwell Hardness Tester
- Vickers Hardness Tester
- Brine ll Hardness Tester
4. Three examples of destructive testing machines are:
- Tensile Testing Machine
- Impact Testing Machine (Charpoy or Izard)
- Fatigue Testing Machine

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Self-Check –UNIT FOUR
Part: I
ANSWER SHEET
TRUE OR FALSE QUES
1. FALSE
2 TRUE
3. FALSE
4. FALSE
5 FALSE
6. FALSE
7. TRUE

PART: II
MULTIPLE CHOOSE QUESTION
1. D
2. C
3. D
4. A
5. C
6. C
7. D
8. B
9. C
10. C

Part III
ASSAY ITEM
1.Explain the stages of heat treatment:
The stages of heat treatment typically include:
- Heating: Raising the temperature of the metal to a specific range to alter its
microstructure.
- Holding: Maintaining the metal at a constant temperature to allow for the desired
changes in microstructure.

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- Cooling: Gradually reducing the temperature to achieve the desired hardness and
strength.

2. List four basic types of heat treatment:

- Annealing: Heating the metal to a specific temperature and then slowly cooling it to
relieve internal stresses and improve its ductility.
- Quenching: Rapidly cooling the metal from a high temperature to increase its hardness.
- Tempering: Heating the quenched metal to a lower temperature to reduce brittleness and
improve its toughness.
- Normalizing: Heating the metal to a temperature above its critical point and then air-
cooling it to produce a uniform microstructure.

3. Why normalizing is needed for metals:

Normalizing is needed for metals to:
- Eliminate internal stresses and defects caused by uneven cooling during manufacturing.
- Produce a uniform and consistent microstructure throughout the metal.
- Improve the mechanical properties, such as hardness and toughness, by refining the grain
structure.
- Enhance the metal's overall strength and durability, making it more suitable for specific
applications.

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