Free FMS Practice Questions

Question 1

A correctly specified replacement V-belt still slips under the usual load. Alignment and tension meet specification. Inspection under lockout reveals polished wear on the belt's bottom surface and concave wear on the sheave groove flanks. What repair is most likely to restore reliable power transmission?

Accepted Answer

Replace the worn sheaves and fit the specified belt.

Answer

Increase belt tension until the slipping stops under full load.

Answer

Install a shorter belt with the same cross section.

Answer

Apply belt dressing to improve traction in the existing grooves.

Question 2

An air cylinder holds a conveyor carriage above a maintenance access area. The carriage must remain raised for the task. Electrical and air supplies are locked out, but the cylinder circuit still reads 5 bar. A rated mechanical support can be engaged from outside the crush zone but is not yet in position. Before anyone enters beneath the carriage, which sequence addresses the remaining hazards?

Accepted Answer

Engage the rated mechanical support, then release and verify the trapped pressure.

Answer

Exhaust the cylinder circuit first, then engage the support beneath the carriage.

Answer

Keep the trapped air as the support and verify that the supply valve is locked.

Answer

Hold the emergency stop engaged and verify that the carriage does not move.

Question 3

A drawing permits a locating pin diameter of 19.980-19.990 mm and a mating bore diameter of 20.010-20.020 mm. For any pair manufactured within these limits, what minimum diametral clearance is guaranteed?

Accepted Answer

0.020 mm

Answer

0.010 mm

Answer

0.030 mm

Answer

0.040 mm

Question 4

With a motor locked out and its coupling disconnected, loosening one hold-down bolt allows that foot to rise 0.15 mm. A feeler gauge finds a uniform gap across the clean foot; the other three feet remain firmly seated. Before making the final shaft-alignment adjustments, the technician should:

Accepted Answer

Shim the full foot by 0.15 mm, retorque, and recheck.

Answer

Move the motor horizontally until the two coupling rims line up.

Answer

Use a tapered shim to support only the outside edge of the foot.

Answer

Tighten the hold-down bolt further to pull the foot onto the base.

Question 5

A steel bracket flexes under load but returns to its original shape when unloaded. An engineer proposes a replacement with identical geometry, twice the yield strength, and the same Young's modulus. Both grades remain in their linear elastic range under this load. How will the replacement behave?

Accepted Answer

It will have essentially the same elastic deflection under the load.

Answer

It will deflect about half as much because its yield strength is doubled.

Answer

It will not deflect until the higher yield strength is reached.

Answer

It will retain a permanent bend because higher-strength steel is less ductile.

Question 6

A vertical positioning axis uses a ball screw that can back-drive under the carriage's weight. Its motor holds position while energized. Which device is suited to keep the stationary screw from turning after electrical power is removed?

Accepted Answer

A spring-applied, electrically released holding brake.

Answer

A spring-released, electrically applied holding brake.

Answer

An electromagnetic clutch that disconnects the motor on power loss.

Answer

A torque-limiting friction clutch between the motor and screw.

Question 7

A small deep-groove ball bearing must be mounted onto a shaft with an interference fit. The housing will be installed later, and the bearing manufacturer permits cold mounting with a press. Which mounting method is appropriate?

Accepted Answer

Use a fitting sleeve to press evenly against the inner ring.

Answer

Use a fitting sleeve to press evenly against the outer ring.

Answer

Tap opposite points on the inner ring directly with a steel hammer.

Answer

Support the outer ring while pressing the shaft into the bearing bore.

Question 8

During a steady-load belt-drive test, tight-side tension is 450 N and slack-side tension is 150 N. The driven sheave has a pitch diameter of 200 mm. Neglecting losses, how much torque does the belt transmit to that sheave?

Accepted Answer

30 N·m

Answer

15 N·m

Answer

45 N·m

Answer

60 N·m

Question 9

The run-in log for a newly installed bearing shows housing temperatures of 48°C, 62°C, and then 58°C at successive checks under the same test load. The specified grease and quantity were used; noise, vibration, and motor current remain normal. The manufacturer's housing-temperature limit for this installation is 85°C. Which instruction fits these findings?

Accepted Answer

Continue the run-in with temperature and vibration monitoring.

Answer

Stop the test and dismantle the bearing before allowing further operation.

Answer

Change to a lower-viscosity lubricant before repeating the test.

Answer

Add grease to eliminate the temperature rise observed at startup.

Question 10

Three external spur gears form a simple train on parallel shafts: a 20-tooth driver, a 30-tooth idler, and a 60-tooth output gear. The driver runs clockwise at 1,200 rpm. Viewed from the same side of the gearbox, the output gear runs at:

Accepted Answer

400 rpm, clockwise.

Answer

400 rpm, counterclockwise.

Answer

800 rpm, counterclockwise.

Answer

3,600 rpm, clockwise.

Free FMS Practice Questions

Domain 1: Safety protocols and risk management strategies

Question 1

Domain 2: Mechanical system design principles

Question 2

Domain 3: Mechanical properties of materials

Question 3

Domain 4: Introduction to mechanical drive systems

Question 4

Domain 5: Belt, chains, and gear drives

Question 5

Question 6

Domain 6: Couplings and shaft alignment

Question 7

Domain 7: Bearings and linear bearings

Question 8

Domain 8: Gaskets, seals, ball screws, clutches, and brakes

Question 9

Domain 9: Laser alignment, lubrication, and vibration analysis

Question 10

That's 10 of 1,030