BRC BANANAMAN REVIEW CENTER

MACHINE DESIGN AND SHOP PRACTICE PROBLEMS SET 1

1.

This radial distance in a gear is measured between the addendum

and dedendum circle, and is the sum of the addendum and the
dedendum? How do you call this distance?
a) Addendum
c) Working depth

5.

6.

b) 209.5 cm4
d) 205.9 cm4

3.

Solution:

This minimum distance is measured between the non-driving side of

a tooth and the adjacent side of the mating tooth. It is the amount by
which the width of a tooth space exceeds the thickness of the
engaging tooth measured on the pitch circle. What is this distance?

7.

b) Whole depth
d) Space width

8.

A helical-coil spring has a mean coil diameter of 1 inch and a wire

diameter of 1/8 inch. Determine the curve correction factor of the
spring.
a) 1.144
c) 1.1144

b) 4.4 mm
d) 8.8 mm

b) 1.44
d) 1.1414

Answer: Curve Correction Factor, Kc = 1.1144

Answer: b) Thickness, t = 4.4 mm

Solution:

b) Upper deviation
d) Tolerance

Answer: c) Lower Deviation

With the water interruptions prevailing in your town, you have been
asked to design an upright cylindrical water tank 6 meters in
diameter and 6 meters high, vented, and to be filled completely with
water. Determine the minimum thickness of the tank plate if the
stress is limited to 40 Mpa.
a) 3.3 mm
c) 5.5 mm

What is the algebraic difference between the minimum limit and the
corresponding basic size?
a) Fundamental deviation
c) Lower deviation

Answer: c) Backlash
4.

b) 0.0037
d) 0.00013

63 000 Hp
63000 40
32
32

T
32T
n

1800 0.00013 radian 0.0073

4
4
L JG D G
D4 G
1.75 12 x 106

J 2J 3
Zj

D 10.16 3 205.9 cm 3
c D 16
16

a) Circular pitch
c) Backlash

A steel shaft 1.75 inches in diameter transmits 40 Hp at 1800 rpm.

Assuming a modulus of rigidity of 12 x 10 6 psi, find the torsional
deflection of the shaft in degrees per foot length.
a) 0.0073
c) 0.0063

Answer: c) 205.9 cm3

Solution:

b) Upper deviation
d) Tolerance

Answer: b) Upper Deviation

What is the polar section modulus of a solid shaft with a diameter of

101.6 mm?
a) 209.5 cm3
c) 205.9 cm3

What is the algebraic difference between the maximum limit and the
corresponding basic size?
a) Fundamental deviation
c) Lower deviation

b) Whole depth
d) Space width

Answer: b) Whole depth

2.

pD 58 .8396 6

0.00441 m 4.41 mm
2s t
2 40 000

p gh 1000 9.8066 6 58 839 .6 Pa 58 .8396 kPa

1

4C 1 0.615

Kw
C 1.184 1.1144
Kc
4C 4
2
C

1
Ks
1.0625
2
C
Solution:

1 p
L
0.25
1
1
o
tan
tan
tan 0.09095 5.197

D
0
.
875

tan 1

Solving for the torque required to overcome the collar friction,

9.

This is either the upper or the lower deviation, depending on which is

closer to the basic size. How do you call this deviation?
a) Fundamental deviation
c) Lower deviation

Tc

b) Upper deviation
d) Tolerance

fFD c 0.2 200 0.5

20 in lb
2
2

Solving for the torque required to overcome the thread friction,

Answer: Fundamental deviation

10. A vise is equipped with a 1-inch single square thread, with 4 threads
per inch. The frictional radius of the collar is 0.5 inch. The coefficient
of friction for both the collar and threads is 0.20. How much external
torque must be applied to produce a force of 200 lb against the jaws
of the vise?
a) 39.73 in-lb
c) 37.93 in-lb

Ts

200 0.875
FD m tan f

2 1 f tan
2
Solving for the total torque,

T = Ts + Tc = 25.93 + 20 = 45.93 inches

b) 33.97 in-lb
d) 39.37 in-lb

11. What is the difference between the maximum and minimum size
limits of a part?

Answer: c) 37.93 in-lb

Vise Jaw

a) Allowance
c) Deviation

Screw
Collar

Nut

12. A helical-coil spring has a mean coil diameter of 1 inch and a wire
diameter of 1/8 inch. Determine the Wahl factor of the spring.

Solution:

p
For the thread pitch,

a) 1.148
c) 1.418

1
1
0.25 inch
Number of Threads per Inch 4

b) 1.184
d) 1.814

Answer: b) Wahl Factor, Kw = 1.184

For the minor diameter, Di = Do p = 1 0.25 = 0.75 inch

Dm

b) Tolerance
d) Basic size

Answer: b) Tolerance

Handle

F = 200 lb

For

0.09095 0.2

25.93 in lb
1 0.2 0.9095

the

mean

or

pitch

D o Di 1 0.75

0.875 inch
2
2

diameter

of

the

screw,

Solution:
Kw

For the lead angle,

Dm
1

8
1
d
8

4C 1 0.615 4 8 1 0.615

1.184
4C 4
C
4 8 8
8

Solution:
13. It is the capacity of a material to absorb energy when it is deformed
elastically and then, upon unloading, to increase this energy. What is
this capacity of a material?
a) Resilience
c) Rigidity

1.5708 1.5708

0.31416 inch
pd
5

17. How do you call a structural member designed to support loads

perpendicular to its longitudinal axis?

b) Toughness
d) Ductility

a) Cantilever beam
c) Overhanging beam

Answer: a) Resilience

b) Beam
d) Column

Answer: b) Beam

14. A helical-coil spring has a mean coil diameter of 1 inch and a wire
diameter of 1/8 inch. Determine the value of Bergstrassar factor of
the spring.
a) 1.172
c) 1.217

18. Compute the speed of the gear mounted on a 52.5 mm diameter

shaft receiving power from a driving motor with 250 Hp.
a) 2 182 rpm
c) 2 265 rpm

b) 1.712
d) 1.271

b) 2 071 rpm
d) 2 341 rpm

Answer: c) The speed, N = 2265 rpm

Answer: a) Bergstrassar Factor, KB = 1.1724

Solution:

D
1
C m
8
1
d
8
Solution:

KB

4C 2 4 8 2

1.1724
4C 3 4 8 3

From PSME Code:

15. How do you call the strain energy per unit volume required to stress a
material from an unloaded state to the point of yielding?

80 250
52 .5

25 .4

2 264 .92 rpm

19. It is a load applied transversely to longitudinal axis of member. How

do you call this load?

a) Modulus of roughness
b) Modulus of elasticity
c) Modulus of rigidity
d) Modulus of resilience

a) Bending load
c) Distributed load

b) Combined load
d) Cyclic load

Answer: a) Bending load

Answer: d) Modulus of Resilience

16. Compute the tooth thickness of a 14.5o spur gear with diametral pitch
of 5.
a) 0.23140 inch
c) 0.43140 inch

80 P

20. What is a load distributed over an entire area?

a) Bending load
c) Distributed load

b) 0.31416 inch
d) 0.03140 inch

b) Combined load
d) Cyclic load

Answer: c) Distributed load

Answer: b) Tooth thickness, t = 0.31416 inch

25. How do you call a statistical data used to identify the most likely
failure modes?
21. Compute the working strength of 1 inch bolt which is screwed up
tightly in packed joint when the allowable working stress is 13000 psi.
a) 3 600 lb
c) 3 900 lb

a) Finite element analysis

b) Fault free analysis
c) Failure analysis
d) Random analysis

b) 3 950 lb
d) 3 800 lb

Answer c) The working strength, W = 3 900 lb

Solution:

From

machinerys

Handbook,

Answer: b) Fault free analysis

page

W s t 0.55 d 0.25 d 13 000 0.55 1 0.25 1 3 900 lb

2

1149:

26. A hollow iron pipe to be designed as a column has an outside

diameter of 240 mm and is subjected to a force of 80 KN. Find the
pipe thickness if the compressive stress is limited to 16 MPa.
a. 5.85 mm
c. 7.85 mm

22. It is a design approach where no catastrophic loss can occur as a

result of a component failure. What is this design approach?

Answer: b) Pipe thickness, t = 6.85 mm

a) Fail-safe design approach

b) Fault free analysis approach
c) Manifest danger approach
d) Redundancy approach

Solution:
Inside Diameter,

Answer: a) Fail-safe design approach

Di

23. It is the condition of a machine element when it is completely

inoperable, cannot perform its intended function adequately, or is
unreliable for continued safe use. What do you call this condition?
a) Fail-safe condition
c) Critical condition

0.24 2

4 80
0.2263 m 226.3 mm
16 000

D o D i 240 226 .3

6.85 mm
2
2

27. It is a computational method used for solving complex shapes, such

as those found in machinery; replaces the complex shape with a set
of simple elements interconnected at a finite set of a specific
purpose. What is this computational method?

Answer: Shear Stress, ss = 19.56 MPa

Solution:

4F

Thickness of the Pipe,

b) 21.65
d) 25.12

ss

Do2

b) Failure condition
d) Salvage condition

24. Compute the nominal shear stress at the surface, in MPa, for a 50
mm diameter shaft that is subjected to a torque of 0.48 kN-m.
a) 16.95
c) 19.56

b. 6.85 mm
d. 8.85 mm

16 T
16 0.48

19 556 .96 kPa 19.56 MPa

3
3
D
0.050

a) Finite element analysis

b) Numerical method of analysis
c) Fault free analysis
d) Synthesis

Answer: a) Finite element analysis

a) 18.4o
c) 14.5o

b) 20o
d) 20.5o

Answer: a) Pitch angle of the pinion = 18.4o

Tp

tan 1
Solution:

28. A uniform beam 12 meters long is fixed at one end. It has a uniform
weight of 50 kg/m along its length. A load of 20 kgs. is suspended on
the beam 4 m from the free end. The moment at the fixed end is
a. 3760 kg-m
c. 60 kg-m

tan 1 14 18 .4 o
42

Tg

31. How do you call the diameter of the imaginary cylinder that bounds
the crest of an external thread and the roots of an internal thread?

b. 0.0 kg-m
d. 4800 kg-m

a) Mean diameter
c) Minor diameter

Answer: a) 3760 kg-m

b) Stress diameter
d) Major diameter

Answer: d) Major diameter

Solution: Bending Moment,

32. A 20o straight-tooth bevel pinion having 14 teeth and a diametral
pitch of 6 teeth/inch drives a 32-tooth gear. The two shafts are at
right angles and in the same plane. The pinion is to transmit 1800
rpm and transmitting 50 hp. Determine the pitch diameters of the
gears.

M 6 600 8 20 3 760 kg m
W = 50 (12) = 600 kg
F = 20 kgs

a) 2.33 inches and 5.36 inches

b) 3.23 inches and 3.56 inches
c) 5.36 inches and 6.36 inches
d) 2.33 inches and 2.33 inches

6m

Answer: a) 2.33 inches and 5.36 inches

8m

Solution:

D1

29. When a hot part is cooled suddenly by quenching, there is

momentarily a high temperature gradient that induces a stress
gradient. Some metal parts under certain conditions crack as a result.
How do you call this phenomenon?
a) Thermal-shock failure
c) Honing

T1 14

2.33 inches
Pd
6
T2
32
2.33 5.36 inches
T
14
1

D 2 D1

b) Thermal fatigue
d) Quenching

33. It is a measure of the change in length of a material subjected to a

change in temperature. How do you call this property of the material?

Answer: a) Thermal-shock failure

30. A 20o straight-tooth bevel pinion having 14 teeth and a diametral
pitch of 6 teeth/inch drives a 42-tooth gear. The two shafts are at
right angles and in the same plane. Find the pitch angle of the pinion.

a) Toughness
b) Coefficient of thermal expansion
c) Thermal conductivity

d) Electric Resistivity

35. What is a condition where one surface is comparatively free of stress?

Answer: b) Coefficient of thermal expansion

a) Octahedral plane
c) Strain plane

b) Biaxial or Plane stress

d) Principal normal stress

Answer: b) Biaxial or Plane stress

34. A 1-inch diameter shaft has a single disc weighing 75 lb mounted

midway between two bearings 20 apart. Find the lowest critical
speed in rpm. Neglect the weight of the shaft. Assume that the
modulus of elasticity is 30 x 106 psi.
a) 2038 rpm
c) 2380 rpm

36. A flywheel weighing 457 kg has a radius of 375 mm. How much
energy, in N-m, does the flywheel loss from 3 rps to 2.8 rps?
a) 368
c) 1474

b) 2308 rpm
d) 2803 rpm

b) 150
d) 38

Answer: c) Flywheel Energy =1474

Solution:
Solution:

W = 75 lb

10

D = 1 inch

V1 2 0.375 3 7.069 m / s

V2 2 0.375 2.8 6.597 m / s

10

E = 30 x 106 psiL = 20 inches

KE

D 4 1

0.0491 in.4
64
64
4

Moment of Inertia,

m V12 V22
457 7.069 2 6.597 2

1 473 .91 N m
2
2

Solving for the lowest critical speed,

cr

576 E I g

W L3

576 30 x 106 0.0491 32.2

3
75 20
N cr

213.39 rad / s
37. How do you call the circle on a gear that corresponds to the contact
surface of the friction wheel?

30 cr 30 213.39

2 037.68 rpm

a) Addendum circle
c) Pitch circle
Answer: c) Pitch circle

b) Root circle
d) Base circle

steels and for use where fatigue resistance and long endurance are
needed; this is also good for shock and impact loads.
a) Chrome silicon
c) hard-drawn wire

b) Chrome vanadium
d) Oil-tempered wire

Answer: b) Chrome Vanadium

38. A triple threaded worm has a pitch diameter of 3 inches. The wheel
has 25 teeth and a pitch diameter of 5 inches. Material for both the
wheel and the wheel is phosphor bronze. Determine the helix angle
of the gear.
a) 11.31o
c) 11.13o

40. What is the largest roller chain size that can be used for power
transmission at a sprocket speed of 1000 rpm?
a) RC 35
c) RC 80

b) 13.11o
d) 10.13o

b) RC 50
d) RC 60

Answer: d) RC 60

Answer: Gear Helix angle = 11.31o

p max
Note: Max. Chain Pitch in Practice:

Solution:

Circular pitch of the worm gear,

Pc

Dg
Tg

5
25

0.6283 inch

p max

Solving for the lead, L = Nt Pa = 3(0.6283) = 1.8849 inches

0.932 in

41. These are gears with teeth formed on conical surfaces and are used
mostly for transmitting motion between intersecting shafts. How do
you call these gears?

Solving for the lead angle of the worm,

L
1 1.8849
o
tan
11.31
3
D w

tan 1

a) Spur gears
c) Bevel gears

For the helix angle, and considering that the shafts angle
is 90o,
g = = 11.31

2
3

2
3

Since RC 80, p = 1 inch exceeds the maximum and RC 70 does not

exist, and then use RC 60.

Where, Pc = Pa = pitch of the worm

900

1000

900

b) Helical gears
d) Worm gearings

Answer: c) Bevel gears

ans.
42. A single square thread power screw is to raise a load of 70 kN. The
screw has a major diameter of 36 mm and a pitch of 6 mm. The
coefficient of thread friction and collar friction are 0.13 and 0.10

39. This material is the most popular alloy spring steel for conditions
involving higher stresses than can be used with the high-carbon

respectively. If the collar mean diameter is 90 mm and the screw

turns at 60 rpm, find the axial linear speed of the screw.
a) 5 mm/s
c) 7 mm/s

Solution:

b) 6 mm/s
d) 5.5 mm/s

D3 N 1 380

10 Hp
38
38
3

45. A spur pinion rotates at 600 rpm and transmits 25 kW to a mating

gear. The pitch diameter of the pinion is 100 mm, and the pressure
angle is 20o. Determine the tangential load, in N.

Answer: b) 6 mm/s
Solution: For the linear speed of the screw,

a) 7660
c) 3900

Vn = n (L) = (60 rpm)(6 mm/rev) = 360 mm/min = 6 mm/s

b) 6790
d) 3098

Ft
Solution:
43. A double thread ACME screw driven by a motor at 400 rpm raises the
attached load of 900 kg at a speed of 10 m/min. The screw has a
pitch diameter of 36 mm; the coefficient of friction on threads is 0.15.
The friction torque on the thrust bearing of the motor is taken as 20
% of the total input. Determine the lead angle.

30 P 2 30 25 000

7 957 .75 N
n 0.10 600

46. A bearing that primarily guides the motion of a machine member

without specific regard to the direction of load application.

Answer: a) 12.465o

a) Journal bearing
b) Clearance bearing
c) Guide bearing
d) Thrust bearing

Solution:

Answer: c) Guide bearing

a) 12.465o
c) 15.462o

For the lead,

b) 14.265o
d) 16.452o

V 10

0.025 m 25 mm
n 400

L
tan 1
D m
For the lead angle,

47. A multiple-disk clutch, composed of three plates with a small

diameter of 150 mm and large diameter of 200 mm, is designed to
transmit 100 kW at 3000 rpm at a coefficient of friction of 0.5.
Determine the spring force needed to engage the clutch.

25
o
12 .465
36

tan 1

a) 2820 N
c) 5460 N
Answer: 3638 N

44. What Hp can a 1-inch diameter short shaft transmit at 380 rpm?
a) 3 Hp
c) 10 Hp

b) 2428 N
d) 3638 N

Solution:

b) 18 Hp
d) 7.1 Hp

Answer: c) 10 Hp

30 P 30 100

0.3183 kN m 318 .3 N m
n 3000

 D d
N fs
4

T f P rf N fs f P

49. What is the bursting steam pressure of a hemispherical steel shell

with a diameter of 100 inches and made of 0.0635-m thick steel
plate, if the joint efficiency is 70 % and the tensile strength is 60 000
psi?

4T
4 318 300

3 637 .71 N
f D d N fs 0.5 200 150 2

a) 4 020 psi
c) 2 400 psi

b) 4 200 psi
d) 2 040 psi

Answer: b) 4200 psi

p
Solution:

4 t sl E j
D

63 .5
4
in 60 000 lb / in 2 0.70
25 .4

4 200 psi
100 in .

Where, p = bursting pressure, psi

sl = shell stress, psi
t = shell thickness, inches
D = shell diameter, inches
Ej = joint efficiency
48. A wire rope lifts a load of 10 kips at a maximum speed of 1000 feet
per minute, attained in 5 seconds starting from rest. The rope has a
metallic cross sectional area of 0.4 in 2. Determine the maximum
tensile stress on the rope in ksi.
a) 26.2
b) 25.0
c) 27.6
d) 32.4

Note: For the longitudinal stress of the thin-walled cylinder, and the stress
for spherical tank:

sL

pD
4t E j

Answer: c) maximum tensile stress = 27.6 MPa

50. A cylinder having an internal diameter if 508 mm and external
diameter if 914.4 mm is subjected to an internal pressure of 69 MPa
and an external pressure of 14 MPa. Determine the hoop stress at the
inner surface of the cylinder.

Solution:

sti

pi ro2 ri 2 2 po ro2

ro2 ri2

2
2
914.4

508

914.4

mm
mm 214 MPa
mm

2

2

2
2
2
914.4

508

mm
mm

69 MPa

a) 90.11 MPa
c) 911.0 MPa

V1 Vo 1000 / 60 0

3.33 fps 2
t
5

b) 91.10 MPa
d) 19.10 Mpa

Answer: a) 90.11 MPaa

Solution:

a
3.33

F WL 1 10 000 1
11 034 .16 lb
g
32
.2

St

sti = 90.11 Mpa

Where,
sti = maximum tangential or hoop stress at the inside
= inside radius, mm
pi = internal pressure, Mpa

11,034 .16
27 585.4 psi 27.6 ksi
0.4

ri

ro = outside radius, mm
po = external pressure, Mpa

L
Key length based on shear,

Note: For the maximum tangential or hoop stress at the outside,

2 pi ri 2 po ro2 ri 2
sto
ro2 ri 2

2T
2 63 000

2.1 inches
s s bD 15 000 1 4
4T
4 63 000

2.1
s c t D 30 000 1 4

Key length based on compression,

Therefore, use L = 2.1 inches

52. Which of the following are the compositions of stainless steel 302?
a) 18 % chromium and 8 % nickel
b) 18 % nickel and 8 % chromium
c) 18 % chromium and 8 % phosphor bronze
d) 18 % bronze and 8 % vanadium
Answer: a) 18 % chromium and 8 % nickel

51. What length of a square key is required for a 4-in diameter shaft
transmitting 1000 hp at 1000 rpm? The allowable shear and
compressive stresses in the key are 15 ksi and 30 ksi, respectively.
a) 2.1 inches
c) 3.2 inches

b) 2.8 inches
d) 4.2 inches
53. The root diameter of a double square thread is 0.55 inch. The screw
has a pitch of 0.2 inch. Find the number of thread per inch.

Solution:

a) 0.2 threads/inch
c) 5 threads/inch

63000 Hp 63000 1000

T

63 000 in lb
n
1000
Transmitted torque,

Key width,

Answer: a) 2.1 inches

tan 3.3125 1 0.13 tan 3.3125 100 % 12.53 %

0.10 90
tan 3.3125 0.10
1 0.13 tan 3.3125
33

b) 10 threads/inch
d) 2.5 threads/inch

Answer: TPI = 5 threads per inch

Solution:

D
, for good proportion
4

TPI
The number of threads per inch,

10

1
1

5 threads / inch
p 0.2

54. A single square thread power screw is to raise a load of 70 kN. The
screw has a major diameter of 36 mm and a pitch of 6 mm. The
coefficient of thread friction and collar friction are 0.13 and 0.10
respectively. If the collar mean diameter is 90 mm and the screw
turns at 60 rpm, find the combined efficiency of the screw and collar.
a) 15.32 %
c) 13.52 %

Solution:

rf
Friction radius,

b) 12.53 %
d) 15.97 %

3
3
2 ro ri
3 ro2 ri2

2
3

125 3 100 3

Surface Area of contact,

Answer: b) 12.53 %

A f 2rf b 2 0.11296 0.125 0.0887 m 2

Solution:

W normal
= 70 N to the surface of contact,
Force

1
1
h p 6 3 mm
2

2
For the depth of the thread,

Fn pA f 70 0.0887 6.209 kN
Power Capacity,

For the mean diameter of the screw,

D m D o h 36 3 33 mm

L
D m

p
D m

tan 1

e
Solving for the Efficiency,

6
3.3123 o
33

tan 1

n Tf
n

f Fn rf 870 0.30 6.209 0.11296 19 .2 kW 25 .74 Hp

30
30
30

Dm

a) 1.71 kN/m
Do kN/m
c) 2.71

tan 1 f tan 100 %

f D
tan f c c
Dm

56. Three extension springs are hooked in series that support a single
weight of 100 kg. The first spring is rated at 4 kN/m and the other
two springs are rated 6 kN/m each. Determine the equivalent
stiffness
of the three springs.
Di

For the lead angle,

tan 1

112 .96 mm

2
2
125 100

1 f tan

b) 5 kN/m
d) 3.71 kN/m

Answer: a) 1.71 kN/m

Solution:

1
1
1
1
1 1 1 1 1 34 7

k e k1 k 2 k 3 4 6 6 4 3
12
12
ke

55. Determine the power capacity of a cone clutch under uniform

pressure and assuming the following conditions: major diameter =
250 mm; minor diameter = 200 mm; length of conical elements in
contact = 125 mm; rotational speed = 870 rpm; coefficient of friction
= 0.30; and allowable pressure = 70 kPa.
a) 25.74 Hp
c) 27.45 Hp

12
1.71 kN / m
7

57. These springs are made from one or more flat strips of brass, bronze,
steel or other materials loaded as cantilevers or simple beam.
a) Torsion springs
c) Garter springs

b) 24.75 Hp
d) 24.57 Hp

Answer: b) Leaf Springs

Answer: a) 25.74 Hp

11

b) Leaf springs
d) Drawbar springs

58. A flat belt is 6 inches wide and 1/3 inch thick and transmits 20 Hp.
The center distance is 8 ft. The driving pulley is 6 inches in diameter
and rotates at 2 000 rpm such that the loose side of the belt is on
top. The driven pulley is 18 inches in diameter. The belt material is
0.035 lb/in3 and the coefficient of friction is 0.30. Determine the belt
net tension.
Answer: a) 2.578
a) 201 lb
c) 102 lb

b) 210 lb
d) 120 lb

60. This refers to the space between adjacent coils when the spring is
compressed to its operating length.

Answer: b) 210 lb
Solution:

F F1 F2

a) Coil clearance
c) Lead

2 T 2 63 000 Hp 2 63 000 20


210 lb
D
D
n
2 000
6

d) Deflection

Answer: a) Coil clearance

Other Solution:

61. Select a deep-groove ball bearing to carry a radial load F x = 800 lb

and a thrust load Fz = 700 lb at 1750 rpm. The service is 8 hr/day,
but it is not continuous; design for 20 000 hr. The operation is smooth
with little vibration; the outer ring rotates. Determine the design life
in mr with no more than 10 % failure.

6
Vm D n
2 000 3141 .59 fpm
12

F F1 F2

b) Pitch

33 000 Hp 33 000 20

210 lb
Vm
3141 .59

a) 20100 mr
c) 2001 mr

b) 2100 mr
d) 1200 mr

Answer: b) 2100 mr

AE 2
1.3
2
D E
0.025 207 000 000 000 52 837.66 N

L
L 4
2.5 1000 4

Solution:

B10 Hrs 60 min s / hr rpm

59. A pulley 600 mm in diameter transmits 40 kW at 500 rpm. The arc of

contact between the belt and pulley is 155 o, the coefficient of friction
between belt and pulley is 0.35 and the safe working stress of the
belt is 2.1 MPa. Determine the belt tensions ratio, neglecting the
effect of centrifugal force.
a) 2.578
c) 5.287

10 6

b) 2.857
d) 5.782
62. Determine the Hp lost when a collar is loaded with 2000 lb, rotates at
50 rpm, and has a coefficient of friction of 0.15. The outside diameter
of the collar is 4 inches and the inside diameter is 2 inches.

Solution:

F1
0.35 155
e f e

F2

20 000 60 1750 2100 mr

180

2.578

a) 0.7314 Hp

12

b) 0.3714 Hp

c) 0.4713 Hp

d) 0.4371 Hp

Answer: a) Clearance

Answer: b) 0.3714 Hp

66. A 50-mm diameter shaft is to transmit 12 kW power at a speed of 500

rpm, determine the mean diameter of the pin, under double shear,
for a material having a safe unit stress of 40 N/mm2.

Solution:

fHp

Tf n
f W rf n 0.15 2000 lb 1.56 inches 50 rpm

0.3714
63000
63000
63000

rf
Where,

3
3
2 ro ri
3 ro2 ri2

a) 11.08 mm
c) 13.08 mm

3
3

2 2 1 1.56 inches

3 3 2 1 2

Answer: b) Diameter of the pin = 12.08 mm

Solution:
Transmitted Torque,

63. In a lathe machine, it is the diameter of the largest workpiece it can

rotate in a chuck or between centers without hitting the bed.

s bLD
2 s

D
2T
2
14 000 28.13 175
Fp

ss bL

Dp
Dp
25.4 25.4
Dp
30 P 30 12 000
T

229 .183 N m 229 183 N mm

n
500

a) Chuck diameter
b) Swing
c) Distance between centers
d) Spindle diameter
Answer: b) Swing
64. What load in N must be applied to a 25 mm round steel bar 2.5 m
long (E = 207 Gpa) to stretch the bar 1.3 mm?
a) 42 000 N
c) 53 000 N

b) 12.08 mm
d) 10.08 mm

b) 52 840 N
d) 60 000 N

Pin Shearing Force,

Answer: b) The load, 52 840 N

Solution:

Pin Mean Diameter,

The load,

65. This is a general term that refers to the mating of cylindrical parts
such as bolt or a hole; it is used only when the internal member is
smaller that the external member. How do you call this?
a) Clearance
c) Allowance

b) Interference
d) Tolerance

13

2 Fs

ss

Fs

2 T 2 229 183

9167 .32 N
D
50

ss

Fs
4 Fs
2 Fs

2
2 As 2 d
d2

2 9 167 .32
12 .08 mm
40

112.5

10 014.74 lb
1 200

67. This is a lubrication condition where non-conformal surfaces are

completely separated by lubricant film and no asperities are in
contact. How do you call this lubrication condition?

required diameter of the bolts circle based on an average shearing

stress of 27.5 MPa.
a) 245 mm
c) 452 mm

a) Elastohydrodynamic lubrication
b) Boundary lubrication
c) Hydrodynamic lubrication
d) Hydrostatic lubrication

Answer: a) Bolt Circle diameter = 245 mm

Solution:

DB

Answer: a) Elastohydodynamic lubrication

68. A 1200 mm cast iron pulley is fastened to 112.5 mm shaft by means
of a 28.13 mm square key 175 mm long. The key and shaft have a
shearing stress of 14 000 psi. Determine the force acting at the
pulley that will shear the key.
a) 10 015 lb
c) 11 050 lb

Where,

s s bLD
2

ssd n B

8 30 P
2

d ssn n B

8 30 350

0.018 2 27 500 650 6

2

0.245 m 245 mm

s s d 2 D B n n B 30 P

8
n

70. How do you call the flattened end of a shank, and intended to fit into
a driving slot in the socket?
a) Handle
c) Relief

Pin

b) Tang
d) Tip

Answer: b) Tang
71. If a sleeve bearing has an outside diameter of 38.1 mm and a length
of 50.8 mm, the wall thickness is 3/16 inch. The bearing is subjected
to a radial load of 500 kg. What is the bearing pressure, in psi?

Note: Torque Based on Shear,

Answer: a) The force acting on the pulley = 10 015 lb

Shaft

8T

b) 11 005 lb
d) 10 501 lb

Solution:

b) 254 mm
d) 425 mm

a) 904 psi
c) 490 psi

Torque based on shear, in lb

b) 409 psi
d) 940 psi

Answer: c) Bearing pressure = 490 psi

Solution:
For bearing or projected area,

50 .8
38 .1

in .
in . 2 3
in 2.25 in 2
16
25 .4
25 .4

AB L D

p
Bearing pressure,
69. A 75-mm diameter shaft is transmitting 350 kW at 650 rpm. A flange
coupling is used and has 6 bolts, each 18 mm in diameter. Find the

14

500 kg 2.205 lb / kg 490 psi

W

AB
2.25 in 2

72. This material is the most popular alloy spring steel for conditions
involving higher stresses than can be used with the high-carbon
steels and for use where fatigue resistance and long endurance are
needed; this is also good for shock and impact loads.
a) Chrome silicon
c) hard-drawn wire

75. For an American Standard Screw Threads, what does 6-32 UNC
designate?
a) Size 6, 32 threads per inch, coarse thread
b) 6 inches basic diameter, 32 threads per inch, coarse thread
c) Size 6, 32 threads per inch, fine thread
d) 32 inches basic diameter, 6 threads per inch, coarse
thread

b) Chrome vanadium
d) Oil-tempered wire

Answer: b) Chrome Vanadium

Answer: a) Size 6, 32 threads per inch, coarse thread

73. Determine the minimum whole depth of spur gear of 14.5 o involute
type with diametral pitch of 24 and circular pitch of 0.1309 inch.
a) 0.09000 inch
c) 0.0899 inch

b) 0.08900 inch
d) 0.089758 inch

76. Determine the Poissons ratio of a material whose modulus of

elasticity is 200 GPa and whose modulus of rigidity is 80 GPa.

Answer: c) Whole depth = 0.0899 inch

a) 0.33
c) 0.38

Solution:

h
From Vallance, page 262:

G
Solution:

Solution:

0.25

a) 300 ksi
c) 75 ksi

Pcn
0.62832

0.72552 inch / tooth

cos cos30o
Pa

E
2(1 )

E = 200GPa,

G = 80GPa:

77. A steel has a BHN = 300. What is its approximate ultimate strength in
ksi?

b) 1.6625 inches/tooth
d) 1.6256 inches/tooth

Answer: a) Axial circular pitch = 1.2566 inches/tooth

Pc

b) 0.25
d) 0.22

Answer: b) Poissons ratio = 0.25

2.157 2.157

0.089875 inch
pd
24

74. A parallel helical gear set was a 17-tooth pinion driving a 34-tooth
gear. The pinion has a right-hand helix angle of 30 o, a normal
pressure angle of 20o, and a normal diametral pitch of 5 teeth/in. Find
the axial circular pitches.
a) 1.2566 inches/tooth
c) 1.6526 inches/tooth

Note: 6 stands for the designated size, 32 stands for the

number of threads per inch, UNC stands for Coarse threads

b) 150 ksi
d) 200 ksi

Answer: b) Ultimate Strength = 150 ksi

Solution: Su 0.5(BHN), ksi

Pc
0.72552

1.2566 inches / tooth

tan tan 30o

15

78. If the angular deformation of a solid shaft should not to exceed 1 o in a

length of 1.8 m and the allowable shearing stress is 83 MMa, what is
the diameter of the shaft? Assume that the shaft material has G = 77
x 106 kPa.
a) 222.34 mm
c) 23.42 cm

rf
Where,

b) 234.22 mm
d) 24.22 cm

a) Nitriding
c) Peening

D3ss
L
32
16
TL 32T L

2 ss L

JG D 4G
DG
D 4G

2 ss L

3
3
2 2 1 1.56 inches
2
2

3 3 1

b) Shot blasting
d) Tempering

Answer: c) Peening
82. Two shafts 3.6 m between centers carry pulleys 1.2 m in diameter
and 0.91 m in diameter respectively, connected by a crossed belt. It
is desired to put the belt on as an open belt. How long a piece must
be cut of it?

2 83 000 1.8
222.34 mm

6
1
77
x
10
o
180
o

81. It is a process that produces residual compressive stress on the

machine part, which uses a series of hammer blows on the surface.

Answer: a) Shaft diameter = 222.34 mm

Solution:

3
3
2 ro ri
3 ro2 ri2

a) 303.3 mm
c) 333.0 mm

b) 330 mm
d) 330.3 mm

Answer: Length to be cut off = 303.3 mm

Solution: For the length of an open belt connection,
79. How do you call the process of producing the residual compressive
stress of machine parts, which is performed by directing the a high
velocity stream of hardened balls or pellets at the surface to be
treated.
a) Nitriding
c) Peening

Lo

For the length of belt for crossed belt connection,

b) Shot blasting
d) Tempering

Lc

Answer: b) Shot blasting

80. Determine the Hp lost when a collar is loaded with 2000 lb, rotates at
50 rpm, and has a coefficient of friction of 0.15. The outside diameter
of the collar is 4 inches and the inside diameter is 2 inches.
a) 0.7314 Hp
c) 0.4713 Hp

2
2

D1 D 2 2C D 2 D1 1200 910 2 3600 1200 910 10 520 .22 mm

2
4C
2
4

3600

D1 D 2 2C D 2 D1 1200 910 2 3600 1200 910

2
4C
4 3600
2
2

Solving for the difference of lengths,

L L c L o 10 823 .55 10 520 .22 303 .33 mm

b) 0.3714 Hp
d) 0.4371 Hp

83. It is a surface-hardening process for alloy steels in which the material

is heated to 950 oF in a nitrogen atmosphere, typically ammonia gas,
followed by slow cooling.

Answer: b) Frictional Horsepower = 0.3714 Hp

Solution:
T n
f W rf n 0.15 2000 lb 1.56 inches 50 rpm
fHp f

0.3714
63000
63000
63000

a) Quenching
c) Shot blasting
Answer: b) Nitriding

16

b) Nitriding
d) Peening

84. A 20-tooth motor sprocket, running at 1200 rpm, drives a blower at a

speed ratio of 4:1. Using the largest permissible chain size and the
largest permissible center distance of 80 pitches, what length of
chain in pitches is required to connect the sprockets?
a) 200 pitches
c) 216 pitches

87. A right-handed single-thread hardened-steel worm has a catalog

rating of 2.25 kW at 650 rpm when meshed with a 48-tooth cast-steel
gear. The axial pitch of the worm is 25 mm, normal pressure angle is
14.5o, and the pitch diameter of the worm is 100 mm. The coefficient
of friction is 0.085. Determine the shafts center distance.

b) 212 pitches
d) 220 pitches

a) 241 mm
c) 412 mm

b) 142 mm
d) 124 mm

Answer: b) Chain length = 21 pitches

Answer: a) Center distance = 241 mm

N N t1 212 .pitches
N Nt2
L c t1
2C p t 2
2
40 C p
2

Solution:

Solution:
Speed Ratio, SR

85. Which of the following gases is typically used in nitriding process of

surface hardening?
a) Nitrogen gas
c) Ammonia gas

Tan

b) Carbon dioxide
d) Hydrogen gas

Tg

Dg

86. A 20-kW motor, running at 1200 rpm, drives a 400 mm diameter

pulley at a belt tension ratio of 2.4. If the belts tight side tension is
only 1200 N, determine the transmission efficiency.
b) 84.58 %
d) 86.55 %

Center Distance,

Pinput

Dw p
D
w

T
w

Dw Dg
2

Tg p 48 25

381.97 mm
T 1
w

100 381.97
241 mm
2

88. Which of the following is the benefit in using nitriding as a surfacehardening process for alloy steels?

Solution:

4.55 o

Tg

D w tan

T
w

Answer: a) Transmission Efficiency = 87.97 %

Poutput

p
L
25

0.07958
D w D w 100

Pitch diameter of the gear,

Answer: c) Ammonia gas

a) 87.97 %
c) 85.66 %

Tg
D g cos
Dg
w n w

g
ng
Tw D w sin D w tan

a) Improvement of endurance strength, 50 % or more

b) Improvement of endurance strength, less than 50 %
c) Improvement of endurance strength, more than 50 %
d) 80 % improvement on the endurance strength

1200
n D
1200 0.40
Tout n n D F

net
F1 F2

1200

30 2
30 2
30 2
2.4

30

0.8797
Pinput
Pinput
Pinput
20 000

Answer: a) Improvement of endurance strength, 50 % or more

17

 T Dg

tan 1 2 5 9.46 o
tan 1 w
Tg D w
20 3

89. A 20o straight-tooth bevel pinion having 14 teeth and a diametral

pitch of 6 teeth/inch drives a 42-tooth gear. The two shafts are at
right angles and in the same plane. Find the pitch angle of the pinion.
a) 18.4o
c) 14.5o

92. A 36-tooth pinion turning at 300 rpm drives 120-tooth gear of 14.5 o
involute full depth pressure angle. Determine the rpm of the driven
gear.

b) 20o
d) 20.5o

a) 60 rpm
c) 75 rpm

Answer: a) Pitch angle = 18.4o

Tp
tan 1
Tg

Solution:

b) 45 rpm
d) 90 rpm

Answer: d) 90 rpm

tan 1 14 18.4 o

42

Solution:
Tp

ng np

90. A triple-thread worm has a lead angle of 17 and a pitch diameter of

2.2802 inches. Find the center distance when the worm is mated with
a wheel of 48 teeth.
a) 6.72 inches
c) 6.27 inches

93. If two parallel shafts are connected by cylinders in pure rolling

contact and turning in the same direction, and having a speed ratio of
2.75, what is the Center distance of the two shafts assuming that the
diameter of the smaller cylinder is 22 cm?

b) 7.26 inches
d) 7.62 inches

Answer: a) Center Distance = 6.72 inches

a) 18.25 cm
c) 20.25 cm

Solution:

D tan 48 2.2802 tan 17 o 11.154 inches

T w
3
w

D w Dg
2

Solution:

2.2802 11.154
6.72 inches
2

Diameter of the bigger cylinder,

91. A double-thread worm has a pitch diameter of 3 inches. The wheel

has 20 teeth and a pitch diameter of 5 inches. Find the gear helix
angle.
a) 4.69o
c) 6.49o

b) 19.25 cm
d) 17.25 cm

Answer: b) Center Distance = 19.25 cm

Tg

Dg

300 36 90 rpm
120

Tg

Center distance,

D 2 SR D1 2.75 22 60.5 cm

D 2 D1 60.5 22

19.25 cm
2
2

94. In estimating the actual endurance strength of steel parts, one of the
factors to be considered is the material factor, which of the following
is the recommended material factor for cast steel?

b) 9.46o
d) 6.94o

Answer: b) Gear helix angle = 9.46o

a) 0.70
c) 0.75

Solution:

18

b) 0.80
d) 1.0

Answer: a) Material factor for cast steel = 0.70

95. How do you call the level of stress that the part will be permitted to
see under operating conditions?
a) Yield stress
c) Design stress

98. Two extension coil springs are hooked in series that support a single
weight of 100 kg. The first spring is rated at 4 kN/m and the other
spring is rated at 6 kN/m. Determine the total deflection of the
springs.

b) Endurance stress
d) Ultimate stress

Answer; c) Design Stress

a) 408.6 mm
c) 480.6 mm

96. Which of the following column formulas is applicable to cast iron

columns?
a) Eulers formula
C) Secant formula

Answer: a) Spring Deflection = 408.6 mm

b) J.B.Johnsons formula
d) Straight line formula

Solution:

t 1 2

Answer: d) Straight line formula

o

Ans. D. Straight line formula. Cast iron columns are usually

designed on the basis of
P
L
9000 40 e
a Straight line formula
A
k

Where the slenderness ratio Le/k should not exceed 70.

b) 486.0 mm
d) 460.8 mm

k k2
4 6
F F
100 kg 9.8066 N / kg

F 1
408 .6 mm
k1 k 2
4 6
k1k 2

99. If the ultimate shear strength of a steel plates is 42 000 psi, what
force is necessary to punch a 0.75 inch diameter hole in a 0.625 inch
thick plate?
a) 61 850 lb
c) 61 580 lb

b) 65 810 lb
d) 60 185 lb

Answer: a) Punching force = 61 850 lb

97. Which of the following ferrous metals has the lowest carbon content?
a) Carbon steel
c) Cast iron

Solution:

Answer: b) Wrought iron

o

F s u A s s u d t 42000 lb / in 2 0.75 in 0.625 in 61850 .1 lb

b) Wrought iron
d) SAE 4140

100.
If stiffness is the main criterion in selecting a material, which of
the following is the most economical choice?

Wrought iron usually contains less than 0.04% C; steel usually

has less than 2.5% C; cast iron has more than 1.7% C; SAE 4140
has approximately 0.4% C.

a) SAE 3130
b) SAE 1020
c) SAE 6150
d) AISI 301, hard stainless steel
o

19

Ans. B. SAE 1020- plain carbon steel.

Note: All of the above materials are steel with practically equal
modulus of elasticity. The three other materials are alloy steels
that are relatively more expensive.
Solving for the maximum induced shear stress,

ss max k ts ss 1.25 36.84 46.05 MPa

101.

Which of the following materials can easily be machined?

a) AISI C1020
c) AISI C1030

104.
A steam engine that has a stroke of 12 inches has an overhung
crank of 11 inches. The maximum tangential force, P, on the crank
may be assumed as 75000 lb. Assuming an allowable stress in shear
as 4400 psi, determine the crankshaft diameter.

b) AISI C1112
d) AISI C1010

Answer: b) AISI CIII2

o

a) 4.77 inches
c) 2.77 inches

Ans. b. C1112. This is a free-cutting steel with a higher sulfur

content for ease in machining

Answer: a) Crankshaft Diameter = 4.77 inches

102.
Wood is an ______ material; that is, its mechanical properties are
unique and independent in three mutually perpendicular directions
longitudinal, radial, and tangential.
a) Isotopic
c) Orthotropic

b) 3.77 inches
d) 1.77 inches

Solution:
B

b) Anisotropic
d) Any of these

Crankpin

Answer: c) Orthotropic material

103.
A stepped torsion shaft has diameters of 16 mm and 12 mm and
a fillet radius of 2 mm. The shaft is subjected to a torque of 12.5 N-m.
Find the maximum induced stress caused by the fillet. Consider a
stress concentration factor of 1.25.
a) 36.84 MPaa
c) 38.64 MPa

11

b) 46.05 MPa
d) 45.06 MPa

Solving for the torque,

Solving for the bending moment,

Solution:

Solving for the shaft diameter,

ss

16

D
ss

16 T 16 12.5

36841422.01 Pa 36.84 MPa

d 3 0.012 3
r = 2 mm

D = 16 mm

d = 12 mm
20

1
3

M 2 T 2

Crankshaft

T P R 7500 6 45 000 in lb

Answer: b) 46.05 MPa

Solving for the average induced shear stress in the shaft

16

4400

M 7500 11 82 500 in lb

45 000 2 82 500

1
3

4.77"

105.
The principal raw materials used in steelmaking are iron ore, coal,
and __________.
a) Coke
c) Slag

Answer: b) At high cutting speeds

b) Limestone
d) Flux

Answer: b) Limestone

106.
The steel part is heated to a temperature of 9001150 degrees F
in an atmosphere of ammonia gas and dissociated ammonia for an
extended period of time that depends on the case depth desired.
a) Nitriding
c) Case hardening

109.
A parallel helical gear-set consists of a 19-tooth pinion driving a
57-teeth gear. The pinion has a left-hand helix angle of 20 o, a normal
pressure angle of 14o, and a normal diametal pitch of 10 teeth/inch.
If the pinion is to transmit 50 Hp at a speed of 1750 rpm. Determine
the center distance of the two gears.

b) Carburizing
d) Cyaniding

Answer: a) Nitriding

a) 2.02 inches
c) 4.04 inches

107.
Determine the Hp lost when a collar is loaded with 2000 lb,
rotates at 50 rpm, and has a coefficient of friction of 0.15. The
outside diameter of the collar is 4 inches and the inside diameter is 2
inches.
a) 0.7314 Hp
c) 0.4713 Hp

b) 6.06 inches
d) 2.06 inches

Answer: c) 4.04 inches

Solution:

b) 0.3714 Hp
d) 0.4371 Hp

Pdn

Tp
Tg
Pd

cos D p cos D g cos

Answer: b) 0.3714 Hp

Pitch diameter of the pinion,

Solution:

Dp

T n
f W rf n 0.15 2000 lb 1.56 inches 50 rpm
fHp f

0.3714
63000
63000
63000

Where,

3
3
2 r r
rf o2 i2
3 ro ri

Pdn cos

19
10 cos 20 o

2.02 inches

Tg

Dg Dp

3
3

2 2 1 1.56 inches

3 3 2 1 2

Pitch Diameter of the gear,

b) at high cutting speeds

d) at slow cutting speeds

21

D p Dg
2

2.02 57 6.06 inches

19

Tp

Center-to-center distance,

108.
The primary application of high-speed steels is to tools used for
the working of metals __________.
a) That are too hard
c) That are too soft

Tp

2.02 6.06
4.04 inches
2

110.
In gearing, this is the ratio of the arc of action to the circular
pitch.
a) Speed ratio
c) Contact ratio

a) Elinvar
c) Inconel

b) Arc ratio
d) Gear ratio

b) Monel
d) Dynavar

Ans. Dynavar; source: Machinerys handbook

Answer: c) Contact ratio

114.
To ensure an adequate factor of safety in the design of a shaft
with standard keyway, the key width should be about:

111.
A single square thread power screw is to raise a load of 70 kN.
The screw has a major diameter of 36 mm and a pitch of 6 mm. The
coefficient of thread friction and collar friction are 0.13 and 0.10
respectively. If the collar mean diameter is 90 mm and the screw
turns at 60 rpm, find the axial linear speed of the screw.
a) 5 mm/s
c) 7 mm/s

a) One half of the shaft diameter

b) One fourth of the shaft diameter
c) One eighth of the shaft diameter
d) One third of the shaft diameter

b) 6 mm/s
d) 5.5 mm/s

Answer: b) One-fourth of the shaft diameter

Note: One-fourth of shaft diameter, as a guide in key selection for
both square and flat rectangular keys.

Answer: b) 6 mm/s

115.
What is the property of matter that causes it to resist any change
in its motion or state of rest?

Solution: For the linear speed of the screw,

Vn = n (L) = (60 rpm)(6 mm/rev) = 360 mm/min = 6 mm/s

a) Momentum
c) Inertia

112.
Flywheel arms are usually of elliptical cross-section, the strength
of the arms should equal _________the strength of the shaft in torsion.
a) Three-fourths
c) Two-thirds

b) Kinetic Energy
d) Section modulus

Answer: c) Inertia
116.
This is defined as the cutting time to reach a predetermined
wear, called the tool wear criterion.

b) One-half
d) One-fourth

a) Wear duration
c) Tool life

Answer: a) Three-fourth

b) Cycle time
d) Life cycle

Answer: c) Tool life

113.
This alloy (nickel, iron, chromium, cobalt is a non-magnetic,
corrosion resistant material suitable for sub-zero temperatures and
temperatures up to about 750 degrees F., provided that torsional
stresses are kept below 75,000 pounds per square inch. It is
precipitation-hardened to produce hardnesses of 48 to 50 Rockwell C
and is used in watch and instrument springs.

117.
Which of the following G-codes refers to rapid traverse in CNC
machining?
a) G00
c) G02

22

b) G01
d) G03

Answer: a) G00

a) 18
c) 12

118.
An acronym in CNC machining which means access of the
machine operator to insert machining instructions directly into the NC
machine control system via push buttons, pressure pads, knobs, or
other arrangements.
a) FMS
c) CIM

Answer: d) 10 percent
123.
What grades of stainless steels are nonmagnetic in the annealed
condition, although some may become slightly magnetic after cold
working?

b) FMC
d) MDI

a) Ferritic grades
c) Martensitic grades

Answer: d) MDI
Note: MDI = manual data input

b) Copper
d) Aluminum

a) Strength
c) Ductility

Answer: d) Aluminum
120.

b) Cold formability
d) Durability

Answer: b) Cold formability

Which of the following statements is NOT true?

125.
Steel is heated to a temperature above the critical range, after
which it is cooled in still air to produce a generally fine pearlite
structure. The purpose is to promote uniformity of structure and
properties after a hot-working operation such as forging or extrusion.
What was the heat treatment involved?

a) The terms polishing and buffing are sometimes applied to

similar classes of work in different plants.
b) Polishing is any operation performed with wheels having abrasive
glued to the working surfaces
c) Buffing is done with wheels having the abrasive applied loosely
d) Polishing is not so harsh an operation as buffing, and it is
commonly utilized to obtain very fine surfaces having a grainless
finish.

a) Annealing
c) Tempering

b) Normalizing
d) Stress relieving

Answer: b) Normalizing

Answer: d)

126.
At certain speeds called the critical speeds, a rotating shaft will
become dynamically unstable and the resulting vibrations and
deflections can result in damage not only to the shaft but to the
machine of which it is a part. At what percentage of the critical speed
should a shaft be safely operated?

Note: Polishing is harsher than buffing.

121.
If the steel is strongly deoxidized by the addition of deoxidizing
elements, no gas is evolved, and the steel is technically called
_______because it lies quietly in the molds.
a) Quenched
c) Killed

b) Austenitic grades
d) Any of these

Answer: b) Austenitic grades

124.
These steels (SAE Steels 1006, 1008, 1010, 1015) are the lowest
carbon steels of the plain carbon type, and are selected where ________ is the primary requisite of the user.

119.
The variable polarity plasma arc (VPPA) process was developed
for welding metals that form an oxide skin, such as ___________.
a) Steel
c) Cast iron

b) 16
d) 10

a) Plus or minus 20%

c) Plus or minus 10 %

b) Annealed
d) Tempered

b) Plus or minus 5 %
d) Any of these

Answer: a) Plus or minus 20 %

Answer: c) Killed steel

127.
This is the most widely used of all spring materials for small
springs operating at temperatures up to about 250 degrees F. It is
tough, has a high tensile strength, and can withstand high stresses
under repeated loading.

122.
Stainless steels generally contain at least __ per cent chromium,
with or without other elements.

23

a) Music wire
b) Hard drawn spring wire
c) Oil tempered spring wire
d) Stainless steel spring wire

continuous flow of oil inside the chain loop evenly across the chain
width and directly at the slack strand.

Answer:

Answer: a) Oil stream lubrication

a) Oil stream lubrication

c) Drip lubrication

128.
It is an acronym in machining. This process uses an electrode to
remove metal from a workpiece by generating electric sparks
between conducting surfaces.
a) MIG
c) EDM

133.
In manufacturing, this is the operation of cutting out flat area to
some desired shape and is usually the first step in a series of
operation.

b) GMAW
d) CNC

a) Turning
c) Blanking

Ans. Electro-Discharge Machining (Source: Machinerys

Handbook)

b) Facing
d) Finishing

Answer: c) Blanking
134.
An M-code which generally refers to start spindle rotation in a
clockwise direction.

129.
In die casting accurate parts made of steel, what shrinkage
allowance in inches per inch is recommended?
a) 0.011
c) 0.033

b) Bath lubrication
d) Recirculated lubrication

a) M03
c) M05

b) 0.022
d) 0.044

b) M04
d) M06

Ans. M03-spindle start in a clockwise rotation

Ans. 0.022. (Source: Machinerys Handbook)
135.
A final operation to improve the polish of a metal and to bring out
the maximum luster

130.
This are gears used to connect shafts that are non-intersecting
and non-parallel. They are a cross between spriral bevel gears and
worm gears.
a) Helical gears
c) Planetary gears

a) Finishing
c) Broaching

b) Hypoid gears
d) Bevel gears

b) Surface grinding
d) Buffing

Answer: d) Buffing

Answer: b) Hypoid gears

136.
Machining operations with the proper application of a cutting fluid
generally has the following attributes except:

131.
This is a type of seal used where some form of relative motion
occurs between rigid parts of an assembly.
a) Gasket
c) Vibratory seal

a) Higher cutting speeds

b) Higher feed rates
c) Lengthened tool life
d) Higher cutting accuracy

b) Distorted seal
d) Dynamic seal

Answer: d) Dynamic seal

Ans. D. The use of cutting fluids does not increase cutting
accuracy.

132.
It is a lubrication for roller chains wherein the lubricant is supplied
by a circulating pump capable of supplying the chain drive with a

24

137.
A material of construction (only developed commercially in the
late 1940s concurrently with zirconium) offers the unique
combination of wide ranging corrosion resistance, low density, and
high strength.
a) Tungsten
c) Vanadium

a) Soldering
c) Brazing

b) Welding
d) Any of these

Answer: c) Brazing

b) Titanium
d) Molybdenum

Answer: b) Titanium

138.

Which of the following is the lightest of all structural metals?

a) Aluminum
c) Magnesium

143.

b) Copper
d) Manganese

a) Self locking in one direction

b) Self energizing
c) Self locking in both directions
d) Any of these

Answer: c) Magnesium
139.
This process reduces internal stresses, caused by machining, cold
working, or welding, by heating the steel to a temperature below the
critical range and holding it there long enough to equalize the
temperature throughout the piece.
a) Annealing
c) Tempering

Ans. Self-locking in one direction only

144.
How do you call a fixed crane consisting of a supported vertical
member from which extends a horizontal swinging arm carrying a
trolley hoist or other hoisting mechanism?

b) Normalizing
d) Stress Relieving

a) Jib crane
c) Overhead crane

Answer: d) Stress Relieving

140.
A free-cutting steel has a higher ______ content than comparable
carbon steels.
a) Sulfur
c) Nickel

b) Gantry crane
d) Tower crane

Ans. a) Jib crane

145.
This iron is also known as a ductile cast iron. How do you call this
iron?

b) Cobalt
d) Chromium

a) Malleable iron
c) White cast iron

Answer: a) Sulfur
141.
This property designates the steels resistance to the softening
effect of elevated temperature.
a) Hot hardness
c) Toughness

In braking, the term backstop refers to a brake that is:

b) Nodular cast iron

d) Gray cast iron

Ans. b) Nodular cast iron is a ductile cast iron.

146.
It is the ability to deform plastically to compensate for
irregularities in bearing assembly. How do you call this?

b) Machinability
d) Elasticity

a) Plasticity
c) Embeddability

Answer: a) Hot hardness

142.
Use of hard solders, silver solders and smelter solders which have
silver, copper, or nickel bases and have melting points above 800
degrees F is known as_______

Ans. b) Conformability

25

b) Conformability
d) Elasticity

Free machining or free cutting carbon contains more sulfur than other
steels.

147.
A material of construction (only developed commercially in the
late 1940s concurrently with zirconium) offers the unique
combination of wide ranging corrosion resistance, low density, and
high strength.
a) Titanium
c) Vanadium

152.
Which of the following information is FALSE regarding steel that
has increased carbon content?

b) Tungsten
d) Molybdenum

a) Its strength is increased

b) Its BHN becomes greater
c) Its ductility is improved
d) Its % reduction or elongation is reduced

Ans. b) Conformability

Ans. c) Its ductility is improved

The ductility of steel is reduced if its carbon content is increased.
153.
In manufacturing, what is the operation of cutting out flat area to
some desired shape and is usually the first step in a series of
operation?

148.
Newtons law of motion that describes that if a force acts to
change the state of motion of the body, the body offers a resistance
equal and directly opposite to the force.
a) Second law
c) First law

a) Turning
c) Facing

b) Third law
d) Universal gravitation

b) Blanking
d) Finishing

Ans. b) Blanking
Ans. b) Newtons third law of motion: Action = Reaction
154.
This is a metal joining process which uses a non-ferrous filler
metal with a melting point below that of the base metals but above
800F. How do you call this process?

149.
These are steels most widely used of engineering materials. No
other material offers comparable versatility for product design.
a) Wrought steels
c) Medium carbon steels

b) Low carbon steels

d) Tool steels

a) Brazing
c) Soldering

Ans. a) Wrought steels

Ans. b) Blanking

150.
Which of the following steels does not readily respond to heat
treatment?
a) SAE 1045
c) SAE 1020

155.
Rivet holes are made usually ____ inch larger in diameter than the
nominal diameter of the rivet.

b) AISI 6150
d) SAE 1095

a) 1/8
c)

Ans. Low carbon steels (0.3% C and lower) do not readily

respond to heat treatment.
151.

b) 1/16
d) 1/32

Ans. b) 1/16
156.
Which of the following equations/formulas does not belong to the
group?

What is an element added to steel to improve its machinability?

a) Carbon
c) Cobalt

b) Arc welding
d) Riveting

b) Sulfur
d) Chromium

a) Lames equation
b) Eulers formula
c) J. B. Johnsons equation d) Secant formula

Ans. b) Sulfur

Ans. a) Lames equation

26

Lames equation is an equation for a thick-walled pressure

cylinder. The other 3 are for columns.

157.
In CNC programming, which of the following G code commands is
for dwell or rest?
a) G01
c) G03

161.
This is a hardening treatment for steels having low carbon
content.

b) G04
d) G02

a) Tempering
c) Normalizing

Ans. b) G04
o

158.
In CNC programming, which of the following M code commands is
for a tool change?

162.
What is a manufacturing process used for the production of
aluminum?

b) M04
d) M10

a) Forging
c) Blow molding

Ans. a) M06
o

b) Extrusion
d) Injection molding

Ans. b) Extrusion

M06 is for a tool change; M03 is for spindle start CW; M04 is for
spindle start CCW; M10 is for chuck open.

163.
This refers to a loss of material from the interface of two metal
surfaces that are in intimate contact. How do you call this?

159.
Which of the following is a material description referring to
unique properties in three mutually perpendicular planes?
a) Isotropy
c) Orthotropy

b) Case hardening
d) Anodizing

Ans. b) Case hardening

G04 is for dwell or rest; G01 is for linear interpolation; G02 is for
circular interpolation CW; G03 is for circular interpolation CCW.

a) M06
c) M03

The true stress-strain curve uses the actual area of the specimen
and is therefore higher than the engineering curve which is based
on a constant (original) area of the specimen.

a) Interfacing
c) Wear

b) Anisotropy
d) Isometry

b) Interference
d) Fretting corrosion

Ans. d) Fretting corrosion

164.
This is a type of fit that requires heating the hub to expand its
inside diameter. What do you call this type of fit?

Ans. c) Orthotropy
Ans. Example is wood which shows unique properties in the three
mutually perpendicular planes.

a) Expansion fit
c) Shrink fit

160.
The true stress-strain curve in a stress-stress diagram appears to
be:

b) Force fit
d) Any of these

Ans. c) Shrink fit

a) Lower than the engineering stress-strain curve

b) Higher than the engineering stress-strain curve
c) The same as the engineering stress strain curve
d) Symmetrical with the engineering stress-strain curve

165.
AFBMA is an acronym for an association involved in what
machine elements?
a) Ball and roller bearings
b) Journal bearings
c) Flat belts and other belt types
d) Any type of gears

Ans. b) Higher than the engineering stress-strain curve

27

d) Elastic material bonded coupling

Ans. a) Ball and roller bearings
Ans. c) Flexible Oldham coupling
o

166.

AFBMA means Anti-Friction Bearing Manufacturers Association

and is concerned with rolling element bearings such as ball,
roller, and needle bearings.

171.
It is a machine member that supports another part that rotates,
slides, or oscillates in or on it.

What is the general description for mild steel?

a) Medium carbon steel

c) High carbon steel

a) Pulley
c) Bearing

b) Low carbon steel

d) Cold rolled steel

b) Key
d) Shaft

Ans. c) Bearing
Ans. Mild carbon steels are low carbon steels.

167.

Von Mises theory is the other term used for

172.
It is a bearing that permits constrained relative motion of rigid
parts; lubricant is generally inserted or supplied between the mating
surfaces to reduce friction and wear, and to carry away the heat
generated.

a) Maximum principal stress theory

b) Octahedral shear-stress theory
c) Maximum shear-stress theory
d) Energy distortion theory

a) Sliding Contact Bearing

b) Rolling Contact Bearing
c) Thrust Bearing
d) Journal Bearing

Ans. b) octahedral shear-stress theory

168.

A type of key in which width and thickness are equal is called as:
Ans. a) Sliding Contact Bearing

a) Flat key
c) Pin key

b) Square key
d) Barth key
173.
These are surfaces that do not conform to each other very well as
in the rolling-element bearings.

Ans. b) Square key

169.
In the design of key, the typical hub lengths are in accordance
with the following relation where D is shaft diameter.
a) 1.25D to 2.4D
c) 2.4D to 3.5D

a) Conformal surfaces
c) Sliding surfaces

b) 0.5D to 1.25D
d) Depends on shaft diameter

b) Non-conformal surfaces
d) Rolling surfaces

Ans. b) Non-conformal surfaces

Ans. a) 1.25D to 2.4D

174.
The study of lubrication, friction, and wear of moving or
stationary parts is known as:

170.
A coupling that allows axial flexibility/movement in the operation.
Made of alternate bolting of steel, leather, fabric and/or plastic
material into two flanges.

a) Lubrication
c) Hydrodynamics
Ans. b) Tribology

a) Flexible disk coupling

b) Flexible toroidal spring coupling
c) Flexible Oldham coupling

28

b) Tribology
d) Hydrostatics

175.
A bearing where surfaces are non-conformed and motion is
primarily rolling; it composed of rolling elements interposed between
an outer ring and inner ring.

c) Centro is a point in one body about which another body actually

turns.
d) Centro is a point in one body about which another body tends to
turn.

a) Sliding-element bearing
b) Rolling-element bearing
c) Conformal surfaces bearing
d) Non-conformal surfaces bearing

Ans. b) Centro is a point in one body about which another

body does not rotate.

Ans. b) Rolling-element bearing

180.
This is the most common work holding device of a shaper
machine with the base graduated in degrees that make it possible to
swivel any angle. What is this working device?

176.
In a straight bevel gear, how do you call the angle between an
element on the pitch cone and an element on the face cone?
a) Face angle
c) Addendum angle

a) Shaper vise
b) Parallel bars and hold down bars
c) Lathe holder
d) Swivel head

b) Pitch angle
d) Dedendum angle

Ans. c) Addendum angle

Ans. a) Shaper vise

177.
It is a Grashof four-bar mechanism in which the shortest link is
the frame or fixed link and the other two cranks completely rotate
with their axes. How do you call this Grashof four-bar mechanism?

181.
This is a shaper operation, which is shaping the given stock and
having the excess material remain with a tolerable allowance for
finishing. How do you call this operation?

a) Drag-link mechanism
b) Crank-rocker mechanism
c) Double-rocker mechanism
d) Triple-rocker mechanism

a) Roughing
c) Angular cutting

Ans. a) Drag-link mechanism

Ans. a) Roughing
182.
How do you call a cutting tool that has two or more cutting edges
as in drill presses and milling machine cutters?

178.
For a planar four-bar linkage, the sum of the shortest and
longest lengths cannot be greater than the sum of the remaining two
link lengths if there is to be a continuous relative rotation between
two members. How do you call the preceding statement?
a) Grublers Law
c) Grashofs Law

b) Finishing
d) Contouring

a) Grinder
c) Multi-point cutting tool

b) Coriollis Law
d) Freudenteins Law

b) Single-point cutting tool

d) Two point cutting tool

Ans. c) Multi-point cutting tool

Ans. c) Grashofs Law

183.
This is the trade name for a patented alloy made up chiefly of
cobalt, chromium, and tungsten in varying proportions. What is this
trade name?

179.
Which of the following is not true for an instant center or centro
of planar linkages?
a) Centro is a point common to two bodies having the same velocity
in each.
b) Centro is a point in one body about which another body
does not rotate.

a) Stellite
c) Stainless steel

29

b) Carboloy
d) Copper

Ans. a) Stellite
Ans. c) Strain
184.
It is called as the transformation of concepts and ideas into useful
machinery. What is this?
a) Design
c) Analysis

188.
What is the combination of applied normal and shear stresses
that produces maximum principal normal stress or minimum principal
normal stress, with a third principal stress between or equivalent to
the extremes?

b) Synthesis
d) Theorem

Ans. a) Design
a) Principal shear stress
b) Principal normal stress
c) Maximum shear stress
d) Bending and shear stresses

185.
This is a combination of mechanisms and other components that
transforms, transmits, or uses energy, load, or motion for a specific
purpose. How do you call this?
a) Mechanism
c) Machine

b) Engine
d) Linkage

Ans. b) Principal normal stress

189.
How do you call a load that is applied transversely to longitudinal
axis of member?

Ans. c) Machine

a) Combined loads
c) Bending load

b) Concentrated load
d) Distributed load

Ans. c) Bending load

186.
It is defined as synergistic collection of machine elements;
synergistic because as a design it represents an idea or concept
greater than the sum of the individual pats. What is this system?

190.
What is the ability of the material to absorb energy up to
fracture?
a) Toughness
c) Resilience

a) System of mechanisms
b) Mechanical system
c) Design system
d) Expert system

Ans. a) Toughness

Ans. b) Mechanical system

191.
What is the other term for the Maximum-Shear-Stress Theory, as
a failure prediction theory?

187.
It may be defined as the displacement per length produced in a
solid and as the result of stress. How do you call this?
a) Deformation
c) Strain

b) Rigidity
d) Stiffness

a) von Mises criterion

c) Coulomb-Mohr theory

b) Elongation
d) Stress

Ans. b) Tresca yield criterion

30

b) Tresca yield criterion

d) Modified Mohr theory

192.
It is a failure prediction theory, which states that a part subjected
to any combination of loads will fail (by yielding or fracturing)
whenever the maximum shear stress exceeds a critical value. How do
you call this failure prediction theory?

195.
How do call the speed at which a rotating shaft becomes
dynamically unstable?
a) Normal speed
c) Critical speed

a) Distortion-energy theory
b) Maximum-shear-stress theory
c) Internal friction theory
d) Modified Mohr theory

b) Variable speed
d) Average speed

Ans. c) Critical speed

196.
How do you call a ball bearing with race containing pronounced
groove for rolling elements?

Ans. b) Maximum-shear-stress theory

a) Crown bearing
b) Conrad bearing
c) Angular-contact bearing d) Cylindrical bearing

193.
This is a theory in cyclic and impact loading, which states that
damage at any stress level, is proportional to number of cycles. What
is this theory commonly called?

Ans. b) Conrad bearing

a) Miners Rule
b) Paris Power Law
c) Goodman Rule
d) Manson-Coffin Relationship

197.
This is a machining process for producing internal straight
cylindrical surface or profiles, with process characteristics and tooling
similar to those for turning operations. What is this machining
process?

Ans. a) Miners Rule

a) Boring
c) Reaming

194.
This is a lubrication where the load-carrying surfaces of the
bearing are separated by a relatively thick film of lubricant, so as to
prevent metal-to-metal contact; and where the stability of the film
can be explained by the laws of fluid mechanics. How do you call this
type of lubrication?

b) Drilling
d) Milling

Ans. a) Boring
198.
What is a set of specification for parts, materials, or processes
intended to achieve uniformity, efficiency, and a specified quality?

a) Hydrostatic lubrication
b) Hydrodynamic lubrication
c) Elastohydrodynamic lubrication
d) Boundary lubrication

a) Code
c) Law

b) Standard
d) Theorem

Ans. b) Standard

Ans. b) Hydrodynamic lubrication

199.
This is a set of specifications for the analysis, design,
manufacture, and construction of something; the purpose of which is
to achieve a specified degree of safety, efficiency, and performance
or quality. How do you call this set of specifications?
a) Code
c) Law

31

b) Standard
d) Theorem

Ans. a) Code

Ans. c) Deviation
202.
What is the difference between the maximum and minimum size
limits of a part?
a) Allowance
c) Deviation

200.
How do call the size to which limits or deviations is assigned and
is the same for both members of the fit; it is the exact theoretical
size?
a) Nominal size
c) Maximum size

Ans. b) Tolerance

b) Basic size
d) Minimum size

203.
This is used either for very accurate angular measurements or for
locating work at a given angle; is used together with precision gage
blocks. What is this?

Ans. b) Basic size

201.
What is the algebraic difference between a size and the
corresponding basic size?
a) Tolerance
c) Deviation

b) Tolerance
d) Basic size

a) Protractor
c) Sine bar

b) Allowance
d) Limit

Ans. c) Sine bar

32

b) Compound rest
d) Micrometer