VALLIAMMAI ENGINEERING COLLEGE

SRM Nagar, Kattankulathur – 603 203

DEPARTMENT OF
MECHANICAL ENGINEERING

QUESTION BANK

6th SEMESTER
ME6004 UNCONVENTIONAL MACHINING PROCESSES

Regulation – 2013

Academic Year 2017 – 18

Prepared by

Mr. P.RAMU, Assistant Professor

Mr. K. VIJAYENDIRAN, Assistant Professor

Mr. P. VIJAYAN, Assistant Professor

 UNIT I - INTRODUCTION
Unconventional machining Process – Need – classification – Brief overview
PART – A (2Marks)
Q.No QUESTIONS LEVEL COMPETENCE
1 State the industrial needs for unconventional machining processes. BT1 Remember
2 Why is unconventional mechanical machining process not popular? BT1 Remember
3 Suggest a suitable unconventional machining process to cut a thin glass
plate into 2 pieces.. BT6 Create
4 List the requirements that demand the use of nontraditional machining
processes. BT1 Remember
5 Classify modern machining processes on the basis of the type of energy
employed. BT3 Apply
6 Write the importance of surface finishing in machining operations
BT3 Apply
7 What are the advantages of unconventional machining process? BT1 Remember
8 List the unconventional machining process which uses mechanical
energy. BT1 Remember
9 Distinguish traditional and non-traditional machining. BT2 Understand
10 List out the limitation of traditional machining processes BT1 Remember
11 List the important characteristics of unconventional machining processes BT1 Remember
12 What are the factors to be considered in selection of unconventional
machining process? BT3 Apply
13 List the unconventional machining processes, which used heat energy. BT1 Remember
14 List the unconventional machining processes, which used Electro
chemical energy. BT1 Remember
15 What is meant by Unconventional machining processes? BT3 Apply
16 Demonstrate that conventional machining process is not so effective on
BT5 Evaluate
soft metals like aluminium.
17 Asses the various electrical energy based process. BT5 Evaluate
18 What is meant by conventional machining processes? BT4 Analyze
.
19 Select any two demerits of UCM. BT4 Analyze
20 Name the UCM process in which power consumption is more than
BT5 Evaluate
others.

PART-B (13 Marks)

Q.No QUESTIONS LEVEL COMPETENCE
Explain the basis on selection of unconventional machining process for
1 BT4 Analyze
given job
Why electro chemical process is found to be most potential process for
2 gear finishing? Explain its principle, key process parameters and other BT4 Analyze
applications.
Elaborate the classification of modern machining process on the basic of
3 energy employed. Discuss the mechanism of material removal and BT2 Understand
energy transfer in each category
 How are the developments in the area of materials partly responsible for
4 evolution of advanced machining techniques? BT6 Create

Classify the unconventional machining process on the basis of type of

5 BT3 Apply
energy employed, MRR, Transfer medial and energy resources used.
Label the comparison between ultrasonic machining and conventional
6 BT1 Remember
grinding.
Describe and analyze the applicability or different processes with
7 different types of materials, alloys and non-metals. Presentation in the BT2 Understand
form of table is preferred
Summarize the needs for development of unconventional machining
8 BT5 Evaluate
processes? Explain with examples.
Compare the process capabilities and limitations of Mechanical,
9 Electrical, Chemical and Thermal energy based unconventional BT5 Evaluate
machining processes.
Integrate the items that can be considered with respect to the analysis of
10 economics of various non-traditional machining processes? Briefly BT4 Analyze
explain.
Summarize the physical parameters of various non-traditional machining
11 BT2 Understand
processes.
12 Describe advantages and limitation of UCM processes. BT2 Understand
Differentiate between conventional and unconventional machining
13 processes. Discuss the reasons for the development of unconventional BT5 Evaluate
machining methods.
Explain in detail about the following USM process parameters.
(i) Metal removal rate.
14 (ii) Tool Material. BT4 Analyze
(iii) Tool wear rate.
(iv) Surface finish.
PART-C (15 Marks)
What are the basic limitations of conventional manufacturing Evaluate
1 process? Justify the need of unconventional manufacturing BT5
process in today’s industries.
2 How are the developments in the area of materials partly
responsible for evaluation of advanced machining techniques? BT5 Evaluate

3 Write a note on recent development in unconventional

machining techniques. BT6 Create
Tabulate the comparison among various non-traditional
machining processes in terms of the following. Presentation in
4 the form of table is preferred. BT6 Create
(i) Pocketing operation (ii) Contouring a surface.
 UNIT II - MECHANICAL ENERGY BASED PROCESSES
Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining - Ultrasonic Machining.(AJM,
WJM, AWJM and USM). Working Principles – equipment used – Process parameters – MRR- Applications.
PART – A (2Marks)
Q.No QUESTIONS LEVEL COMPETENCE
1 Why abrasive jet machining is not recommended to machine ductile
materials? BT2 Understand
2 Reuse of abrasives is not recommended in abrasive jet machining process.
Why? BT6 Create
3 List the different type of abrasives used in AJM. BT1 Remember
4 List the applications of WJM BT1 Remember
5 Name any four process variables that control the material removal rate in
AJM process. BT1 Remember
6 Identify the transfer medium in AJM and also abrasives used? BT1 Remember
7 Write the formula for material removal rate for ductile and brittle
BT3 Apply
materials in AJM.
8 In what way abrasive grain sizes influence the material removal rate in
AJM? BT5 Evaluate
9 Tell a few desirable properties of carrier gas in AJM BT2 Understand
10 Show two application of AJM. BT3 Apply
11 Mention the functions of a horn in ultrasonic machining. BT4 Analyze
12 What are the parameters that influence the material removal rate in
ultrasonic machining process? BT5 Evaluate
13 What is feed mechanism and state its types? BT2 Understand
14 What are the applications of USM process? BT3 Apply
15 What are the advantages of Ultrasonic machining? BT1 Remember
16 List the abrasive used in USM? What are criteria for selection of an
BT1 Remember
abrasive?
17 List the limitations in ultrasonic machining. BT1 Remember
18 Define the functions of transducers in ultrasonic machining. BT3 Apply
19 Give the range of frequency required for ultrasonic machining. BT2 Understand
20 Integrate the major elements of the USM equipments.
BT6 Create

PART-B (13 Marks)

Q.No QUESTIONS LEVEL COMPETENCE

What are the factors that affect the performance of WJM process?
1 BT2 Understand
Discuss their effect of MRR.
Discuss in detail the working principle of Abrasive jet machining
2 process and explain briefly how its various parameters influence the BT2 Understand
surface finish.
 Explain the variables that are affecting the material removal rate and
3 accuracy of the Abrasive jet machining process. BT4 Analyze

Draw the schematic layout of abrasive jet machine and explain wear rate
4 BT3 Apply
of nozzle in AJM.
5 Explain metal removal rate and wear rate of nozzle in WJM. BT1 Remember
Describe the apparatus, nozzles, process parameters, process capabilities
6 BT1 Remember
and application of Abrasive jet machining
Describe the apparatus, metal removal rate, process principles and
7 BT1 Remember
application of Water Jet Machining.
Explain the principles, equipments, transducer, tool holders, tools,
8 BT2 Understand
abrasives, applications, advantages of Ultrasonic Machining.
9 Write a brief note on Types of transducers used in USM BT5 Evaluate
10 Mechanism of material removal in USM BT5 Evaluate
Demonstrate the USM, WJM and AJM in terms of process capabilities
11 BT3 Apply
and limitations.
Briefly explain the effect of operating parameters on material removal
12 BT6 Create
rate. List of applications of USM.
Describe the methods of generating the ultrasonic and characteristics of
13 the various types of tool holders and the tool feed mechanism in USM BT6 Create
process and the process parameters.
Write short notes on the following related to Ultra Sonic Machining:
14 (i) Functions of slurry and oscillator in USM BT4 Analyze
(ii) Grain size Vs. Machining rate.
PART-C (15 Marks)
In abrasive water jet machining at what stage is the abrasive introduced
1 BT6 Create
in the water jet?
In which of the manufacturing activates in industry is the WJM and
2 BT5 Evaluate
AJW process most applicable?
Do you think it should be possible to produce spur gears by advanced
3 BT6 Create
machining processes, starting with round blank? Explain.
With appropriate sketches, describe the principles of various Fixturing
4 BT5 Evaluate
methods and devices that on be used for USM.
 UNIT III ELECTRICAL ENERGY BASED PROCESSES
Electric Discharge Machining (EDM)- working Principle-equipments-Process Parameters-Surface Finish and
MRR- electrode / Tool – Power and control Circuits-Tool Wear – Dielectric – Flushing – Wire cut EDM –
Applications.
PART – A (2Marks)
Q.No QUESTIONS LEVEL COMPETENCE
1 Name some of the most commonly used dielectric fluids in EDM. BT1 Remember
2 Sate the function servo-mechanism in Electrical discharge machining
(EDM) process BT1 Remember
3 List the desirable properties of a good dielectric fluid. BT1 Remember
4 Write down the limitation in EDM. BT2 Understand
5 What are the roles of dielectric fluid in EDM? BT2 Understand
6 Name same of the tool materials used in EDM. BT1 Remember
7 List the EDM flushing techniques. BT1 Remember
8 What are the reasons for the use of deionized water as dielectric system in
wire-EDM? BT2 Understand
9 List the applications of wire EDM. BT1 Remember
10 List out importance of EDM process. BT1 Remember
11 Define the range of pulse duration and current in EDM. BT3 Apply
12 Describe the recent development in EDM process. BT3 Apply
13 Label the difference between wire cut EDM and EDM process. BT4 Analyze
14 Describe the process capability of EDM process. BT4 Analyze
15 Assess the influence of current in MRR in EDM process. BT5 Evaluate
16 Analyze the functions of adaptive control used for EDM. BT4 Analyze
17 Assess the ways of gap-flushing used in EDM. BT5 Evaluate
18 What are the factors affecting metal removal rate? BT6 Create
19 How the tool materials are classified? BT6 Create
20 What are the drawbacks of using relaxation circuit? BT1 Remember

PART-B (13 Marks)

Q.No QUESTIONS LEVEL COMPETENCE

1 Sketch and explain of metal removal in EDM process. BT1 Remember
2 Discuss briefly the types of spark erosion generators. BT2 Understand
3 Explain the working of wire EDM. How stratified wire works? BT5 Evaluate
Explain the general arrangement of an Electrical discharge machining
4 BT5 Evaluate
process and list out its advantages, disadvantages and applications.
Describe the principle, construction and working of Wire-cut electrical
5 discharge machining process (WCEDM) and state its merits and BT2 Understand
demerits.
Discuss the process parameters that effects on the metal removal in
6 BT3 Analyze
WEDM
7 Does EDM affect the fatigue strength of cold worked metals? Explain. BT5 Evaluate
 Briefly explain various types of dielectric fluid and its functions in EDM
8 BT4 Analyze
process.
Explain the following in EDM with neat sketches:
Evaluate
9 (i) Electrode feed control system BT5
(ii)Factors to be considered for EDM machine tool selection
Explain the following on wire EDM technology
10 (i) Dielectric System BT5 Evaluate
(ii) Deionized water
Explain the following on wire EDM technology
11 (i) Positioning system BT5 Evaluate
(ii) Wire drive system
Find the condition for maximum power delivery to the discharging
12 BT6 Create
circuit in EDM
13 Explain the break down mechanism in EDM process. BT5 Evaluate
14 Discuss the types of tool wear in EDM process. BT4 Analyze
PART-C (15 Marks)
Compare EDM and Wire Cut EDM process. In what ways wire cut
1 BT5 Evaluate
EDM process is best over EDM process? Justify.
In which of the manufacturing activities in industry is the wire EDM
2 BT6 Create
process most applicable?
Why do different material-removal processes affect the fatigue strength
3 BT6 Create
of materials to different degrees?
Comment on the depth of material removed from a metal surface by
4 BT5 Evaluate
EDM processes.
 UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
Chemical machining and Electro-Chemical machining (CHM and ECM)-Etchants – Maskant techniques of
applying maskants - Process Parameters – Surface finish and MRR-Applications. Principles of ECM- equipments-
Surface Roughness and MRR Electrical circuit-Process Parameters ECG and ECH - Applications.
PART – A (2Marks)
Q.No QUESTIONS LEVEL COMPETENCE
1 State the principle of chemical machining process. BT1 Remember
2 What are the three different layers that can be identified in spark eroded
surface? BT1 Remember
3 What do you understand by charging of electrolyte? BT2 Understand
4 Define maskants in Electrochemical machining process. BT1 Remember
5 List the factors that affect MRR in ECM BT1 Remember
6 Summarize the application of ECM. BT5 Evaluate
7 Name the electrolytes which are used in electro chemical machining BT1 Remember
8 Calculate the amount of current required when iron is subjected to electro
chemical process. The material removal rate 5cm3/min. Assume weight of BT5 Evaluate
iron 58kg, valancy 2, density of iron 7.78 g/cm3.
9 What are etchant in chemical machining process? BT4 Analyze
10 List the advantages of ECM process. BT1 Remember
11 What is the advantage of ECG over conventional grinding? BT3 Apply
12 Give the application of electro chemical grinding. BT2 Understand
13 What are the parameters that affect the material removal rate in Electro
chemical Grinding? BT4 Analyze
14 Experiment the difference between electroplating and ECM BT5 Evaluate
15 State the principle of electro chemical grinding process BT2 Understand
16 State the principle of electro chemical honing process BT2 Understand
17 List the advantages of ECH process. BT1 Remember
18 Generalize techniques of applying maskant. BT6 Create
19 Explain etchant. BT3 Apply
20 List the process parameters of ECH process. BT1 Remember

PART-B (13 Marks)

Q.No QUESTIONS LEVEL COMPETENCE

With the help of a simple diagram, explain briefly the working of
1 BT5 Evaluate
Electro-chemical machining process.
2 Explain the principle of electro chemical deburring process. BT3 Apply
3 Discuss about the types of maskants used in chemical machining. BT2 Understand
Explain the followings with respect to chemical machining process:
4 (a) Characteristics of cut and peel maskants (b) Selection of maskants BT3 Apply
(c) Limitations
Explain the following on Electro Chemical Machining process with
5 BT5 Evaluate
suitable sketches:
 (a) Cathode tool
(b) Correction tool
With a neat sketch, explain the principle of electro-chemical grinding.
6 BT1 Remember
State its process capabilities and application.
7 Explain the electro-chemical Honing process with a neat sketch. BT3 Apply
Compare the Chemical Machining (CHM) with Electro-Chemical
8 BT4 Analyze
Machining (ECM) with respect to their process parameters.
9 Explain a neat sketch, explain the chemical machining process. BT3 Apply
Discuss the effect of high temperature and pressure of electrolyte of
10 BT2 Understand
ECM process.
11 Explain the process parameters MRR and surface finish in CHM. BT3 Apply
Explain the requirement of tool material for ECM process; Write the
12 BT5 Evaluate
commonly used tool materials.
Calculate amount of current required the iron is subjected to ECM
13 process. The metal removal rate of iron is 4cm3/min. assuming atomic BT6 Create
weight iron N=56 Kg, valancy n=2, density of iron ρ = 7.787 g/cm3.
Predict the MRR by ECG comprise. What are the functions of abrasive
14 BT4 Analyze
particles?
PART-C (15 Marks)
Explain the basis, why surface finish of chemically machine surface of
1 BT6 Create
an alloy is poor.
During the machining of iron (Fe) using aqueous solution of Nacl. What
2 BT5 Evaluate
are the possible reactions at electrode?
Briefly discuss about electro chemical deburring process parameters of
3 chemical machining process that influence the performance of the BT6 Create
machining?
Explain why the life of the ECG wheel is much higher than conventional
4 BT5 Evaluate
grinding.
 UNIT V THERMAL ENERGY BASED PROCESSES
Laser Beam machining and drilling (LBM), plasma Arc machining (PAM) and Electron Beam Machining (EBM).
Principles – Equipment –Types - Beam control techniques – Applications.
PART – A (2Marks)
Q.No QUESTIONS LEVEL COMPETENCE
1 What do you mean by plasma? BT2 Understand
2 What is the advantage of EBM over LBM? BT1 Remember
3 State the working principle of Plasma arc Machine Process. BT1 Remember
4 Why vacuum is needed in Electron beam machine process? BT2 Understand
5 Is it possible to machine electrically non-conductive material using EBM
process? Justify your answer. BT4 Analyze
6 Why tungsten is not used as electrode material in Plasma arc cutting? BT4 Analyze
7 What is the function of electron beam gun? BT3 Apply
8 What is abrasive flow finishing? BT3 Apply
9 Compare LBM with EBM. BT4 Analyze
10 Write the advantages of Plasma Arc Machining. BT1 Remember
11 List various types of lasers. BT1 Remember
12 List some application of magnetic abrasive finishing. BT1 Remember
13 Narrate the principle of electron beam machining. BT5 Evaluate
14 Can you machine electrically non-conductive materials by PAM? Justify
your answer. BT6 Create
15 Define transferable arc in plasma machining. What is its use? BT1 Remember
16 What is the Acronym of LASER? BT2
17 Quote deflection coil provided for EBM. BT5 Evaluate
18 Distinguish vacuum and non-vacuum EBM. BT2 Understand
19 Design the parameters of PAM BT6 Create
20 Discuss commonly used gas mixture in PAM. BT2 Understand

PART-B (13 Marks)

Q.No QUESTIONS LEVEL COMPETENCE

Explain different types of plasma arc machining process with a neat
1 BT5 Evaluate
sketch.
2 What is LASER? Explain how it is used to machine the materials. BT1 Remember
Discuss the factors that influence the quality of the cut in Plasma arc
3 BT2 Understand
Machining Process.
4 Explain the principles of EBM with neat sketch. BT3 Apply
5 Explain the production of laser beam and working principle of LBM. BT3 Apply
Compare the operation of transferred and non-transferred are mode in
6 BT5 Evaluate
plasma machining.
7 Briefly explain on under water plasma cutting. BT5 Evaluate
 Explain the control of following parameter in EBM (i) current (ii) Spot
8 diameter (iii) Focus distance of magnetic lens. BT3 Apply

Describe the process parameters of LBM and influence on machining

9 BT2 Understand
quality.
10 Demonstrate the thermal features of LBM. BT6 Create
Explain the following in LBM process (i) Advantages (ii) Disadvantages
11 BT5 Evaluate
(iii) Application.
Describe the principles, equipments, solid state laser, gas laser, thermal Understand
12 BT2
features applications and advantages of laser beam machining.
Describe the principles, equipments, solid state laser, gas laser thermal
13 BT1 Remember
features applications and advantages of Plasma Arc Machining.
14 Describe Laser beam drilling process with sketches. BT4 Analyze
PART-C (15 Marks)
Which of the advanced machining processes causes thermal damage?
1 BT5 Evaluate
What is the consequence of such damage to workpiece?
Describe your thoughts regarding the laser beam machining of
2 nonmetallic material. Give several possible applications, including their BT5 Evaluate
advantages as compared to other process.
Describe the types of surfaces produced by EBM, PAM and Laser
3 BT6 Create
cutting.
Which of the processes described are suitable for producing very small
4 BT6 Create
and deep holes? Why?