Non Conventional Machining Processes

Objective Type Questions
UNIT-1
Ultrasonic Machining
1. Which of the following is an unconventional process of machining?
a) Milling
b) USM
c) Drilling
d) None of the mentioned
Answer: b
Explanation: USM stands for ultrasonic machining process and it is an unconventional process of
machining.
2. Ultrasonic machining process can be used for
a) Conductors
b) Insulators
c) Metals
d) All of the mentioned
Answer: d
Explanation: Ultrasonic machining is more versatile and can be used for the metal as well as non
metal.
3. Which of the following is a conventional process of machining?
a) Electro chemical machining
b) Electron beam machining
c) Ultrasonic machining
Answer: d
Explanation: All of the mentioned are unconventional process of machining
4. For machining of plastic material which of the unconventional process can be used effectively?
a) Electro chemical machining
b) Electron beam machining
c) Ultrasonic machining
Answer: c
Explanation: Ultrasonic machining is more versatile and can be used for the metal as well as non
metal.
5. Material removal rate in USM increases with
a) Decrease in volume of work material per impact
b) Increase in volume of work material per impact
c) Decrease in frequency
d) Decrease in number of particle making impact per cycle
Answer: b
Explanation: Material removal rate in USM is proportional to the volume of work material per
impact.
b) Decrease in volume of work material per impact
d) Increase in number of particle making impact per cycle
Answer: d
Explanation: Material removal rate in USM is proportional to the number of particle making
impact per cycle
b) Decrease in volume of work material per impact
c) Increases in frequency
d) Decreases in the number of particle making impact per cycle
Answer: c
Explanation: Material removal rate in Ultrasonic machining is proportional to frequency.
8. Element of machine which is used to convert high frequency electrical impulse into mechanical
vibration in USM is known as
a) Tool
b) Feeding unit
c) Transducer
Answer: c
Explanation: Transducer is a device which is used to convert one form of energy to other.
9. Which of the following elements of USM is used to apply working force during machining
operation?
a) Tool
b) Feeding unit
c) Transducer
Answer: b
Explanation: Feeding unit is used to apply working force during a machining operation.
a) Decrease in amplitude
b) Decrease in grain size of abrasives
d) Increase in amplitude
Answer: d
Explanation: Material removal rate in ultrasonic machining is proportional to amplitude
Ultrasonic Machining – 1
1. Ultrasonic machining (USM) can be classified as which of the following type of non-traditional
machining process?
a) electrical
b) optical
c) mechanical
d) chemical
Answer: c
Explanation: Ultrasonic machining is a non-traditional machining process. USM is grouped under
the mechanical group NTM processes. In ultrasonic machining, a tool of the desired shape vibrates
at an ultrasonic frequency.
2. Which of the following material is not generally machined by USM?
a) Copper
b) Glass
c) Silicon
d) Germanium
Answer: a
Explanation: USM is mainly used for machining brittle materials which are poor conductors of
electricity and thus cannot be processed by Electrochemical and Electro-discharge machining
3. Tool in USM is generally made from which of the following materials?
a) Glass
b) Ceramic
c) Carbides
d) Steel
Answer: d
Explanation: The tool material should be such that indentation by the abrasive grits does not lead
to brittle failure. Thus the tools are made of tough, strong and ductile materials like steel, stainless
steel and other ductile metallic alloys.
4. Under what frequency ultrasonic machining is done?
a) 5—10 Hz
b) 5—10 kHz
c) 12—19 Hz
d) 19—25 kHz
Answer: d
Explanation: Ultrasonic machining is a mechanical type non-traditional machining process. In
ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency of around 19—25
kHz with an amplitude of around 15 – 50 μm over the workpiece.
5. In ultrasonic machining (USM), the tool is pressed downward.
a) True
b) False
Answer: a
Explanation: Generally the tool is pressed downward with a feed force. Between the tool and
workpiece, the machining zone is flooded with hard abrasive particles generally in the form of
water based slurry.
6. In ultrasonic machining, the abrasive particles act as the __________
a) chip carriers
b) intenders
c) finishing particles
d) thickening agent for the slurry
Answer: b
Explanation: During ultrasonic machining, as the tool vibrates over the workpiece, the abrasive
particles act as the indenters and indent both the work material and the tool.
7. In case of brittle materials, the material is removed by crack initiation.
a) True
b) False
Answer: a
Explanation: The abrasive particles, as they indent, the work material, would remove the same,
particularly if the work material is brittle, due to crack initiation, propagation and brittle fracture
of the material.
8. During USM, cracks are produced due to _____
a) von-mises stresses
b) hertzian stresses
c) principal stresses
d) episodic acute stresses
Answer: b
Explanation: During USM, as the tool vibrates, it leads to the indentation of the abrasive grits.
During indentation, due to hertzian contact stresses, cracks would develop just below the contact
site then as indentation progresses the cracks would propagate due to increase in stress and
ultimately lead to brittle fracture of the work material under each individual interaction site
between the abrasive grits and the workpiece.
9. In USM, material removal may occur due to _____
a) fatigue failure
b) fouling failure
c) free flowing impact of the abrasive
d) creep
Answer: c
Explanation: Other than brittle failure of the work material due to indentation some material
removal may occur due to free flowing impact of the abrasives against the work material and
related solid-solid impact erosion, but it is estimated to be rather insignificant.
10. Increasing volume concentration of abrasive in slurry would affect MRR in which of the
following manner?
a) increase MRR
b) decrease MRR
c) would not change MRR
d) initially decrease and then increase MRR
Answer: a
Explanation: The concentration of abrasive grits in the slurry is related as follow
n = (6AC)/ πdg2,
where n= number of grits
A= total surface area of the tool facing the workpiece
C= concentration of abrasive grits in the slurry
dg= diameter of a grit
Thus above relation shows that any increase in ‘C’ will increase ‘n’ and hence material removal
rate (MRR).
1. The machining system of USM contains which of the following components?

a) Magnetostrictor
b) Concentrator
c) Tools and slurry
Answer: d
Explanation: In machining system of USM, the above mentioned components have to be present.
2. State whether following statement is true or false.
“In Ultrasonic Machining, Magnetostrictor is energized at ultrasonic frequency.”
a) True
b) False
Answer: a
Explanation: To oscillate, magnetostrictor must be energized to ultrasonic frequency in USM.
3. Of the following scientists, who discovered magnetostrictor effect?
a) Balamuth
b) Steve O Flawer
c) Joule
d) Turing
Answer: c
Explanation: This effect was discovered by Joule in 1874 at Manchester
4. In Ultrasonic Machining, magnetostrictor converts magnetic energy into which type of energy?
a) Mechanical energy
b) Electrical energy
c) Thermal energy
Answer: a
Explanation: Oscillation of magnetostrictor takes place by converting magnetic energy to
mechanical energy.
5. What is the value of the amplitude obtained without mechanical amplifier?
a) 0.0001 – 0.001 µm
b) 0.001 – 0.1 µm
c) 1 – 10 µm
d) 10 – 100 µm
Answer: b
Explanation: Relatively very small amplitudes are obtained without amplifier.
6. What is the value of the amplitude obtained when we use mechanical amplifier?
a) 1 – 10 µm
b) 10 – 40 µm
c) 40 – 50 µm
d) 50 – 100 µm
Answer: c
Explanation: Relatively larger amplitudes are obtained
Answer: b when amplifier is used.
7. State whether the following statement is true or false.
“In USM, tool tips must have low resistance and fatigue strength.”
a) True
b) False
Answer: b
Explanation: In USM, tool tips should must have high wear resistance and fatigue strength
8. At what rate slurry is pumped through nozzle in USM?
a) 10 L/min
b) 25 L/min
c) 50 L/min
d) 75 L/min
Explanation: Slurry is pumped through nozzle at the rate of 25 L/min, L- litres.

UNIT-2
Abrasive Jet Machining – Introduction and Machining system

1. In advanced machining processes, what is the full form of AJM?
a) Automatic Jet Manufacturing
b) Abrasive Jet Machining
c) Automated Jet Machining
d) Abrasive Jet Manufacturing
Answer: b
Explanation: In advanced machining processes, full form of AJM is Abrasive jet machining
2. In AJM, which of the following materials are used as abrasive grains?
a) Al2O3
b) SiC
c) Glass beads
Answer: d
Explanation: In Abrasive jet machining, any of the particles mentioned above can be used as
abrasive grains.
3. In Abrasive jet machining, work piece material of removed by which of the following means?
a) Vaporization
b) Electro plating
c) Mechanical abrasion
d) Corrosion
Answer: c
Explanation: Abrasive particles hit the surface with high pressure and high velocities, which
removes the material.
4. Which type of materials can be machined using Abrasive jet machining?
a) Glass
b) Ceramics
c) Hard materials
Answer: d
Explanation: Materials like ceramics, glass, hard and super hard materials can be machined using
Abrasive jet machining.
5. In machining system of AJM, which is the medium of carrying the abrasive grains for
machining?
a) Liquids
b) Gases
c) Any fluids
Answer: b
Explanation: In AJM, different types of gases are used as the medium for carrying abrasives
6. In machining system of AJM, what is/are the gas/es used for carrying the abrasives?
a) CO2
b) Air
c) Nitrogen
Answer: d
Explanation: In AJM, gases like CO2, air or nitrogen are used to carry the abrasives
7. What is the pressure of gas that is to be supplied, for carrying the abrasives?
a) 0.1 to 1.0 kg/cm2
b) 2.0 to 8.0 kg /cm2
c) 10.0 to 18.0 kg/cm2
d) 25.0 to 35.5 kg/cm2
Answer: b
Explanation: The pressure of the carrying gas should range between 2 to 8 kg/cm 2.
8. Which of the following gas, should never be used as the carrier of abrasives?
a) Nitrogen
b) CO2
c) Oxygen
d) Air
Answer: c
Explanation: Oxygen should not be used as carrier because it causes a violent chemical reaction
with abrasives or work piece.
9. What is the frequency of mixing chamber, consisting of gas and abrasives?
a) 10 Hz
b) 30 Hz
c) 50 Hz
d) 70 Hz
Answer: c
Explanation: Mixing chamber consisting of carrier gas and the abrasive grains, vibrates at a
frequency of 50 Hz.
10. In Abrasive jet machining, what may be the size of the abrasive grains used?
a) 10 – 40 µm
b) 50 – 100 µm
c) 100 – 150 µm
d) 200 – 300 µm
Answer: a
Explanation: Abrasive grains of size, between 10 – 40 µm can be used for machining.
AJM – Material Removal Rate and Process parameters
1. In AJM, what is the mechanism of removal of material from the work piece?
a) Corrosion
b) Abrasion
c) Electron transfer
d) Vaporization
Answer: b
Explanation: In Abrasive jet machining, the removal of material takes places by mechanical
abrasion, using abrasive grains.
2. In AJM, abrasive jet from the nozzle follows, which type of path for a short distance?
a) Parallel
b) Inclined
c) Perpendicular
Answer: a
Explanation: Abrasive particles follow a parallel path for short distance and then flare outward
3. Which of the following components, influence the material removal rate in Abrasive jet
machining?
a) Nozzle
b) Carrier gas
c) Abrasive grains
Answer: d
Explanation: All the components mentioned above, influence the rate of material removal, directly
or indirectly
4. Of the following properties of nozzle, which of them does not influence the MRR?
a) Size
b) Wear
c) Outside temperature
d) Distance from work piece
Answer: c
Explanation: The outside temperature of nozzle has no influence on the material removal rate.
5. Of the following properties of abrasive grains, which of them changes rate of material removal?
a) Size
b) Strength
c) Shape
Answer: d
Explanation: The above mentioned properties of abrasive grains influence the material removal
rate
6. As the abrasive flow rate increases, what happens to the volumetric removal rate?
a) Increases
b) Decreases
c) Increase and then decrease
d) Decrease and then increase
Answer: c
Explanation: In AJM, volumetric removal rate increases up to a level and then decreases
7. What is the value of abrasive grain flow rate in Abrasive jet machining?
a) 0.1 – 2 g/min
b) 3 – 20 g/min
c) 30 – 56 g/min
d) 68 – 85 g/min
Answer: b
Explanation: Abrasive grain flow rate is between 3 – 20 g/min, in AJM.
8. What must be the velocity of the carrier gas that carries the abrasive particles?
a) 10 – 50 m/sec
b) 50 – 150 m/sec
c) 150 –300 m/sec
d) 300 – 500 m/sec
Answer: c
Explanation: Velocity of abrasive carrier gas must be between 150 – 300 m/sec
9. What is the value of carrier gas flow rate in Abrasive jet machining?
a) 6 L/min
b) 17 L/min
c) 28 L/min
d) 39 L/min
Answer: c
Explanation: In Abrasive jet machining, the flow rate of abrasive carrier gas is around 28 L/min
10. Which of the following material/s cannot be used for making of nozzle in Abrasive jet
machining?
a) Tungsten Carbide
b) Steel alloy
c) Sapphire
d) Synthetic sapphire
Answer: b
Explanation: Nozzle in Abrasive jet machining is made up of sapphire or WC.
11. Between which of the following values, does the diameter of the nozzle lies?
a) 0.01 – 0.10 mm
b) 0.30 – 0.50 mm
c) 0.70 – 0.90 mm
d) 1.10 – 1.50 mm
Answer: b
Explanation: In AJM, Diameter of the nozzle ranges between 0.30 – 0.50 mm.
12. What is the life of Tungsten carbide material nozzle?
a) 1 – 8 hrs
b) 2 – 5 hrs
c) 10 – 15 hrs
d) 25 – 40 hrs
Answer: c
Explanation: Nozzle made up of WC material has a life period which range between 10 – 15 hrs.
WJM – Applications
1. In the following materials, Water jet machining can be used on which type of material?
a) Metals
b) Plastics
c) Ceramics
Answer: d
Explanation: WJM can be used on metals, cloth, paper, plastics, food, leather and ceramics.
2. What are the processes and applications, where Water jet machining can be used?
a) Cutting
b) Drilling
c) Deburring
Answer: d
Explanation: Water jet machining can be used for drilling, cutting, deburring, surface treatment
and many more applications.
3. What are the tolerance limits range of thin materials in WJM?
a) ± 0.1 mm
b) ± 10 mm
c) ± 25 mm
d) ± 50 mm
Answer: c
Explanation: In Water jet machining, the range of tolerance is ± 25 mm.
4. In cutting of rocks using water jet machining, which type of pressure is needed?
a) Low pressure
b) Medium pressure
c) High pressure
Answer: c
Explanation: In WJM, very high pressures and velocities are needed while cutting rocks
5. In deburring, which combination removes the material from non-metallic materials?
a) High pressure and low flow rate
b) High pressure and high flow rate
c) Low pressure and low flow rate
d) Low pressure and high flow rate
Answer: a
Explanation: For non-metallic materials high pressure and lower flow rates are used in deburring.
6. Which of the following materials has some drawbacks of cutting WJM?
a) Food
b) Rocks
c) Fibre-reinforced plastics
Answer: c
Explanation: Water gets deflected due to the fibre embedded in the matrix of fibre-reinforced
plastics, when we use WJM
7. What is the accuracy level obtained when PCB’s are cut by WJM?
a) ± 0.05 mm
b) ± 0.13 mm
c) ± 0.26 mm
d) ± 0.33 mm
Answer: b
Explanation: In WJM, accuracy obtained in cutting of PCB’s is ± 0.13 mm.
8. In WJM, surface treatment includes which type of processes?
a) Removing deposits
b) Removing chemicals
c) Degreasing
Answer: d
Explanation: Surface treatment is done using WJM to clean the surface from many toxic chemical,
deposits, residues etc.
AJM – Applications, Advantages and limitations
1. Which of the following, are the processes and applications in which Abrasive jet machining can
be applied?
a) Drilling
b) Cutting
c) Deburring
Answer: d
Explanation: Abrasive jet machining can be used for cutting, drilling, deburring and cleaning
processes.
“Using abrasive jet machining, wire cleaning and insulation stripping takes places without affecting
the conductor.”
a) True
b) False
Answer: a
Explanation: Without affecting the conductor, both stripping and cleaning are done, by using
Abrasive jet machining.
3. In Abrasive jet machining, intricate shapes and holes are machined on which type of materials?
a) Brittle
b) Thin
c) Difficult to machine
Answer: d
Explanation: Abrasive jet machining is used to machine, intricate shapes and holes in brittle, thin
and difficult to machine materials.
4. State whether the following statement is true or false, about Abrasive jet machining.
“Using Abrasive jet machining, micro deburring of hypodermic needles can take place.”
a) True
b) False
Answer: a
Explanation: Abrasive jet machining can be used for micro deburring of hypodermic needles
5. What are the type of materials that can be machined using Abrasive jet machining?
a) Glass
b) Sapphire
c) Quartz
Answer: d
Explanation: In Abrasive jet machining, the above mentioned materials can be machined, which
are heat sensitive and brittle.
6. What is the amount of material utilizes when we machine parts using Abrasive jet machining?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Abrasive jet machining, material utilization is very high since it removes material
by using abrasives.
7. After how much time tool has to be changed in AJM?
a) 1 hr
b) 2 hrs
c) 5 hrs
d) No tool change required
Answer: d
Explanation: In Abrasive jet machining, tool changes are not required
8. By using Abrasive jet machining, how much amount of hardening does the materials experience?
a) No hardening
b) Very less hardening
c) Average hardening
d) High hardening
Answer: a
Explanation: In Abrasive jet machining, hardening is not experienced by the machined materials.
9. Which type of materials cannot be machined using Abrasive jet machining?
a) Soft materials
b) Hard materials
c) Difficult to machine materials
Answer: a
Explanation: Soft materials such as candy bars, thin softwood etc.., cannot be machined using
AJM.
10. Which of the following materials in Abrasive jet machining can be a health hazard?
a) Abrasive grains
b) Air carrier
c) Silica dust
Answer: c
Explanation: Silica dust, that occurs after machining can be a health hazard in AJM.
Abrasive Water Jet Machining – Introduction
1. In advanced machining processes, what is the full form of AWJM?
a) Automated Water Jet Machining
b) Automated Water Jet Manufacturing
c) Abrasive Water Jet Machining
d) Abrasive Water Jet Manufacturing
Answer: c
Explanation: Full form of AWJM is Abrasive Water Jet Machining.
2. What are all the types of materials, which can be machined using AWJM?
a) Glass
b) Ceramics
c) Concrete
Answer: d
Explanation: Hard to cut materials, which are mentioned above, can be machined using Abrasive
water jet machining.
3. When was Abrasive water jet machining developed first?
a) 1942
b) 1958
c) 1974
d) 1980
Answer: c
Explanation: Abrasive water jet machining was first developed in the year 1974.
4. When compared to the conventional machining, how much times faster, is the Abrasive water jet
machining?
a) 5 times
b) 10 times
c) 15 times
d) 20 times
Answer: b
Explanation: Abrasive water jet machining is 10 times faster than the conventional machining.
5. What is the percentage of the abrasives and water in the mixture?
a) 20% water and 80% abrasives
b) 80% water and 20% abrasives
c) 30% water and 70% abrasives
d) 70% water and 30% abrasives
Answer: d
Explanation: Abrasive mixture consists of 70 percent water and 30 percent abrasives.
6. What are the materials used for abrasives in Abrasive water jet machining?
a) SiC
b) Corundum
c) Glass beads
Answer: d
Explanation: All of the materials mentioned above can be used for making abrasives in Abrasive
water jet machining.
7. In the machining system of AWJM, which one accelerates the abrasives to remove material?
a) Water only
b) Water jet stream
c) Feeder
Answer: b
Explanation: Water jet stream accelerates abrasives but not the water only, to remove material.
“Introduction of compressed air to the water jet enhances the deburring action.”
a) True
b) False
Answer: a
Explanation: Compressed air increases the pressure energy of the jet stream, which enhances the
material removal rate.
9. What is the grain size of abrasive particles, which are often used for Abrasive water jet
machining?
a) 0.01 – 0.50 µm
b) 10 – 150 µm
c) 200 – 500 µm
d) 500 – 1000 µm
Answer: b
Explanation: Grain size of the abrasive particles range between 10 – 150 µm in Abrasive water jet
machining.
10. How is the material removed in Abrasive water jet machining?
a) Vaporization
b) Electron transfer
c) Corrosion
d) Erosion
Answer: d
Explanation: In Abrasive water jet machining, material removal takes place by erosion of the work
piece material using abrasives accelerated by jet stream.
AWJM – Machining System
1. Which of the following is not the feed mechanism of the abrasives in AWJM?
a) Side feed
b) Cross feed
c) Central feed
Answer: b
Explanation: Only side feed and central feed are used in Abrasive water jet machining.
2. In Abrasive water jet machining, how are the abrasives fed into the water jet stream?
a) Suspension
b) Injection
c) All of the mentioned
Answer: c
Explanation: Abrasives are fed into the water jet stream through suspension or injection.
3. What is the use of delivery system in the machining system of AWJM?
a) To deliver colloidal solution
b) To pump water
c) To fed abrasives
Answer: b
Explanation: In Abrasive water jet machining, water delivery system is used
4. Of the following components, which one does not come under the machining system of AWJM?
a) Water delivery system
b) Transducer
c) Cutting nozzles
d) Mixing chambers
Answer: b
Explanation: Transducer is the component which does not come under the machining system of
AWJM.
5. In Abrasive water jet machining, intensifier is used to deliver which type of pressure?
a) Very low pressure
b) Low pressure
c) Medium pressure
d) High pressure
Answer: d
Explanation: In AWJM, intensifier is used to deliver high pressure water using pistons with it.
6. In mixing chamber of AWJM, which of the following are mixed?
a) Abrasives and colloidal solution
b) Abrasives and water jet
c) Colloidal and water jet
Answer: b
Explanation: In mixing chamber, abrasives and water jet stream are mixed.
7. Of the following, which one is a type of suspension in AWJM?
a) Direct pumping
b) Indirect pumping
c) Bypass pumping
Answer: d
Explanation: There are three different types of suspension AWJ formed by indirect, direct and
bypass pumping
8. In machining system of AWJM, mixing chamber is immediately followed by which of the
following component?
a) Focusing tube
b) Cutting Nozzle
c) Intensifier
d) Water delivery
Answer: a
Explanation: In Abrasive water jet machining, mixing chamber is immediately followed by the
focusing tube.
9. Which of the following energies are absorbed using the catchers in Abrasive water jet
machining?
a) Pressure energy
b) Kinetic energy of abrasives
c) Residual energy
Answer: c
Explanation: In AWJM, catchers are used to absorb the residual energy.
10. Which of the following are different types of catchers used in AWJM?
a) Water basin type
b) Submerged steel balls type
c) TiB2 type
Answer: d
Explanation: The above mentioned types are the types of catchers used in AWJM.
AWJM – Process Capabilities
1. Which of the following is not a process parameter of Abrasive water jet machining?
a) Frequency of vibration
b) Orifice diameter
c) Pressure
d) Stand-off distance
Answer: a
Explanation: Frequency of the vibrations does not belong to the parameters of Abrasive water jet
machining
2. Which of the following come under the process parameters of the Abrasive water jet machining?
a) Abrasive size
b) Machine impact angle
c) Traverse speed
Answer: d
Explanation: All the parameters mentioned above come under Abrasive water jet machining.
3. What is the value of orifice diameter in Abrasive water jet machining?
a) 0.01 – 0.03 mm
b) 0.03 – 0.09 mm
c) 0.10 – 0.30 mm
d) 0.30 – 0.90 mm
Answer: c
Explanation: The value of diameter of the orifice should range between 0.10 – 0.30 mm.
4. Of the following values, between which of them pressure value will range?
a) 1000 – 1500 bar
b) 1500 – 2500 bar
c) 2500 – 4000 bar
d) 4000 – 10000 bar
Answer: c
Explanation: In Abrasive water jet machining, pressure value will range between 2500 – 4000 bar.
5. When compared to sand, how much effective is garnet as abrasive material in AWJM?
a) 20%
b) 30%
c) 40%
d) 50%
Answer: b
Explanation: Garnet, which is commonly used abrasive material is nearly 30% more effective than
sand in Abrasive water jet machining.
6. State whether following statement is true or false about Abrasive water jet machining.
“A material, whose material removal rate is higher, produces larger surface roughness.”
a) True
b) False
Answer: a
Explanation: As rate of material removal increases in AWJM, large surface roughness are
produced
7. Surface roughness depends on which of the following parameters in Abrasive water jet
machining?
a) Work piece material
b) Grit size
c) Abrasive type
Answer: d
Explanation: All the parameters mentioned above, are responsible for variation in surface
roughness.
8. What is the value of focusing diameter in Abrasive water jet machining?
a) 0.1 – 0.6 mm
b) 0.8 – 1.4 mm
c) 1.6 – 2.8 mm
d) 3.2 – 5.2 mm
Answer: b
Explanation: Diameter value of WC focusing tube in AWJM varies between 0.8 – 1.4 mm
9. Abrasive flow value in Abrasive water jet machining will range between which of the following
values?
a) 0.01 – 0.1 kg/min
b) 0.1 – 1.0 kg/min
c) 1.0 – 10 kg/min
d) 10 – 100 kg/min
Answer: b
Explanation: In AWJM, abrasive flow ranges between 0.1 – 1.0 kg/min.
10. What is the value of stand-off distance in Abrasive water jet machining?
a) 1.0 – 2.0 mm
b) 2.0 – 4.0 mm
c) 4.0 – 6.0 mm
d) 6.0 – 10.0 mm
Answer: a
Explanation: Stand-off distance in Abrasive water jet machining will vary between 1 – 2 mm.
11. Impact angle in Abrasive water jet machining range between which of the following values?
a) 0&#176 to 10&#176
b) 10&#176 to 30&#176
c) 30&#176 to 90&#176
d) 90&#176 to 100&#176
Answer: c
Explanation: Machine impact angle in AWJM will range between 30&#176 to 90&#176
12. Of the following values, between which values traverse speed will range?
a) 0.1 to 5 m/min
b) 5 to 100 m/min
c) 100 to 500 m/min
d) 500 to 1000 m/min
Answer: b
Explanation: Value of traverse speed ranges between 5 to 100 m/min
13. Depth of cut values in Abrasive water jet machining ranges between which values?
a) 0.01 to 2 mm
b) 2 to 250 mm
c) 300 to 500 mm
d) 650 to 900 mm
Answer: b
Explanation: Value of depth of cut in AWJM ranges between 2 to 250 mm.
Electro Chemical Machining-Introduction and Principle of electrolysis
1. In advanced machining processes, what is the full form of ECM?
a) Electrochemical manufacturing
b) Electrochemical milling
c) Electrochemical machining
d) Electrochemical masking
Answer: b
Explanation: In advanced machining processes, full form of ECM is Electrochemical machining
2. Of the following scientists, who was the one to introduce first patent on ECM?
a) Balamuth
b) Steve O Flawer
c) Gusseff
d) McGeough
Answer: c
Explanation: Gusseff was the one, who introduced the first patent on ECM in 1929
3. When was the first significant development of ECM occurred?
a) 1920s
b) 1930s
c) 1950s
d) 1960s
Answer: c
Explanation: After the first patent in 1929, the first development of ECM was done in 1950s
4. Which of the following material removal mechanisms is implemented by ECM?
a) Mechanical abrasion
b) Electrochemical dissolution
c) Chemical corrosion
d) Mechanical erosion
Answer: b
Explanation: In ECM, material is removed by electrochemical dissolution.
5. Electrolysis occur when which of the following takes place between electrodes?
a) Electric current flow
b) Electron flow
Answer: c
Explanation: When there is an electron flow there is current flow in the opposite direction. For
electrolysis to take place there should be flow of current between electrodes.
6. The system which consists of electrolytic solution and electrodes can be referred as ____.
a) Electrolytic cell
b) Electrode system
c) Electrolytic system
d) Electrode cell
Answer: a
Explanation: The system of electrodes and electrolytic solution is referred as electrolytic cell.
7. The chemical reactions occurring at electrodes are called with, which of the following names?
a) Anodic reactions
b) Cathode reactions
Answer: c
Explanation: Chemical reactions occurring at electrodes are called as anodic or cathodic reactions
8. Amount of mass dissolved is directly proportional to which of the following quantities?
a) Amount of electricity
b) Frequency of vibrations
c) Amplitude of oscillations
Answer: a
Explanation: Amount of mass dissolved is directly proportional to amount of electricity and also
substances’ chemical equivalent.
9. Chemical equivalent is the ratio of which of the following factors?
a) Work piece valence to atomic weight
b) Atomic weight to work piece valence
c) Tool valence to molecular weight
d) Molecular weight to tool valence
Answer: b
Explanation: Chemical equivalent is the ratio of atomic weight to work piece valence
ECM-Theory of ECM
1. What is the value of current density used in Electrochemical machining?
a) 0.01 – 0.4 A/mm2
b) 0.5 – 5 A/mm2
c) 6 – 15 A/mm2
d) 20 – 50 A/mm2
Answer: b
Explanation: High current densities, which range between 0.5 – 5 A/mm 2 are used in ECM.
2. What are the values of voltages used in ECM?
a) 1 to 8 V
b) 10 to 30 V
c) 40 to 80 V
d) 90 to 110 V
Answer: b
Explanation: Low voltages, ranging between 10 to 30 V are used in Electrochemical machining
3. How does the current pass between the two electrodes in ECM?
a) Electrolytic solution
b) Direct contact of electrodes
Answer: a
Explanation: Current passes through the solution of electrolyte, which fills the gap between the
electrodes.
4. What is the value of velocity with which, electrolyte flows in the inter electrode gap?
a) >1 m/s
b) >3 m/s
c) >5 m/s
d) >10 m/s
Answer: c
Explanation: The velocity of the electrolytic solution must be greater than 5 m/s, in order to
intensify the mass and charge transfer
5. Of the following, electrolyte removes which of the dissolution products?
a) Metal hydroxides
b) Heat
c) Gas bubbles
Answer: d
Explanation: Electrolyte removes the dissolution products such as metal hydroxides, heat and gas
bubbles formed in the inter electrode gap.
6. State whether following statement is true or false regarding the theory of ECM.
“Application of P.D (potential difference) lead to occurrence of several reactions.”
a) True
b) False
Answer: a
Explanation: When P.D (potential difference) is applied, different reactions occur at anode and
cathode.
7. Which of the following reactions takes place at the electrodes?
a) Generation of hydrogen
b) Dissolution of iron
c) Dissolution of NaCl
Answer: d
Explanation: All the reactions mentioned above, take place at different electrodes in ECM
8. Which of the following reaction takes place at anode?
c) Generation of hydroxyl ions
Answer: b
Explanation: At anode, dissolution of Fe takes place in the process of ECM.
9. Which of the following reactions take place at cathode?
c) Dissolution of NaCl
Answer: a
Explanation: At cathode, generation of hydrogen takes place in the process of ECM.
10. Positively charged particles (cations) move towards which electrode?
a) Anode
b) Cathode
Answer: b
Explanation: Positively charge particles are directed towards cathode, which is negatively charged.
11. Negatively charged particles (anions) move towards which electrode?
a) Anode
b) Cathode
Answer: a
Explanation: Negatively charged particles are directed towards anode, which is positively charged
ECM – Equipment – 1
1. Which of the following come under the main components of ECM?
a) Feed control system
b) Work piece holding devices
c) Electrolyte supply system
Answer: d
Explanation: The main components of Electro chemical machining include feed control system,
electrolyte supply system, power supply unit, work piece holding devices.
2. Feed control system is responsible for which action in ECM?
a) Giving feed to tool
b) Electrolyte supply
c) Power supply
Answer: a
Explanation: Feed control system is used for feeding the tool at constant rate during equilibrium
machining
3. In ECM equipment, what is the role of electrolyte supply system?
c) Power supply
Answer: b
Explanation: As the name itself indicates, electrolyte supply system is used to supply the electrolyte
required for anodic dissolution
4. What is the role of power supply unit in ECM equipment?
c) Power supply
Answer: c
Explanation: In ECM, power supply unit is used to supply the machine current at constant dc
voltage
5. For large size machining, which type of facilities are used in ECM?
a) Semi-automated facilities
b) Automated facilities
Answer: c
Explanation: Automated and semi-automated facilities are used for large size machining.
6. Electrolyte supply system should concentrate on which of the following factors?
a) Pressure
b) Supply rate
c) Temperature
Answer: d
Explanation: Electrolyte supply system should supply electrolyte at a given rate, temperature and
pressure.
7. For high strength or rigidity, which type of coatings are recommended for metals?
a) Other metal coatings
b) Non-metallic coatings
Answer: b
Explanation: For high strength and rigidity, non-metallic coatings are recommended for metals.
8. What is the value of voltage that the power supply unit supplies for ECM?
a) 0.01 to 1 V
b) 2 to 30 V
c) 50 to 80 V
d) 100 to 160 V
Answer: b
Explanation: Voltage supply required for ECM range between 2 to 30 V.
9. Between which of the following values, does the current range?
a) 0.002 to 0.01 A
b) 0.01 to 10 A
c) 50 to 10000 A
d) 105 to 106 A
Answer: c
Explanation: In Electrochemical machining, current value ranges between 50 to 10000 A.
10. What are the values of current densities used in ECM?
a) 0.1 to 2 A/cm2
b) 5 to 500 A/cm2
c) 600 to 1000 A/cm2
d) 1200 to 2800 A/cm2
Answer: b
Explanation: Current density values in ECM range between 5 to 500 A/cm 2.
11. Which type of adjustment is to be done for gap voltages?
a) Continuous adjustment
b) Discontinuous adjustment
c) Periodic adjustment
Answer: a
Explanation: In ECM, usually continuous adjustment of gap voltage is required.
12. Compared to the tool used in ECM, how should be the work piece size?
a) Greater than
b) Smaller than
c) Same as tool
Answer: a
Explanation: By an oversize, work piece size is expected to be greater than tool size
13. Which of the following factors are used to determine the tool geometry?
a) Required shape
b) Electrical conductivity
c) Tool feed rate
Answer: d
Explanation: For determining a tool geometry we must specify some factors such as required shape
of surface, tool feed rate, gap voltage, electrochemical machinability of the work material,
electrolyte conductivity, and both electrodes’ polarization voltages.
14. Which of the following are the simplest methods for applying the insulation on tools?
a) Spraying
b) Dipping
Answer: c
Explanation: In ECM, dipping or spraying are the simplest methods for insulating the tools
15. State whether following statement is true or false regarding the tools of ECM.
“With computer integrated manufacturing (CIM), cathodes are produced at high costs and less
accurately.”
a) True
b) False
Answer: b
Explanation: Using CIM, cathodes are produced at low costs and more accurately
ECM – Equipment – 2
1. What are the main functions of electrolyte in Electrochemical machining?
a) Conduct machining current
b) Removal of debris
c) Maintaining constant temperature
Answer: d
Explanation: Main functions of electrolyte are conducting machine current, removing the debris,
carrying away the heat, maintaining constant temperature.
2. Electrolytic solution should ensure which type of anodic dissolution?
a) Uniform
b) Non-uniform
c) Low speed
d) None of the mentioned.
Answer: a
Explanation: Uniform and high speed anodic dissolution must be ensured by the electrolyte.
3. State whether following statement is true or false regarding the electrolytic solution.
“In ECM, formation of passive film is recommended.”
a) True
b) False
Answer: b
Explanation: Electrolytic solution should avoid formation of passive layers on anode.
4. Which type of electrical conductivity is necessary for electrolytic solution?
a) Low
b) Medium
c) High
Answer: c
Explanation: High electrical conductivity is needed for electrolytic solution in ECM.
5. What are the other features of electrolytic solution in ECM?
a) Non toxic
b) Less erosive
c) Less viscous
Answer: d
Explanation: Electrolytic solution should be nontoxic, less viscous and less erosive.
6. How much should be the electrolytic solution?
a) Highly expensive
b) Inexpensive
Answer: b
Explanation: Electrolyte must be inexpensive and available at ease.
7. What the most common electrolytes used in Electrochemical machining?
a) Sodium chloride
b) Sodium nitride
c) Sodium hydroxide
Answer: d
Explanation: Electrolytes such as sodium chloride, sodium nitride, sodium hydroxide are some of
the electrolytes used in ECM.
8. Selection of electrolyte does not depend on which of the following factors?
b) Dimensional tolerance
c) Heat affected zones
d) Machining productivity
Answer: c
Explanation: Selection of electrolyte depend up on work piece material, dimensional tolerance,
machining productivity and surface finish required
9. What must be the value of electrolytic temperature in ECM?
a) 2 to 14oC
b) 22 to 45oC
c) 46 to 57oC
d) 62 to 76oC
Answer: b
Explanation: Temperature of electrolyte should range between 22 to 45 oC.
10. What must be the value of the pressure of electrolytic solution used in ECM?
a) 1 to 10 kPa
b) 10 to 80 kPa
c) 100 to 200 kPa
d) 300 to 400 kPa
Answer: c
Explanation: Value of pressure of electrolytic solution must range between 100 to 200 kPa.
11. What must be the value of velocity of the electrolytic solution?
a) 10 to 15 m/s
b) 25 to 50 m/s
c) 60 to 100 m/s
d) 120 to 200 m/s
Answer: b
Explanation: Typical velocity of the electrolytic solution must range between 25 to 50 m/sec.
12. Local metal removal rates are high at which gap locations mentioned below?
a) Small gap
b) Medium gap
c) Large gap
Answer: a
Explanation: Local metal removal rates are high at small gap locations in ECM.
13. When local metal removal rates are high, how will be the current density and current
efficiency?
a) High
b) Medium
c) Low
d) Very low
Answer: a
Explanation: When the local metal removal rates are high then current density and efficiency are
also high.
14. Current efficiency depends on which of the following in ECM?
a) Anodic material
b) Electrolyte
Answer: c
Explanation: Current efficiency in ECM depend on electrolyte and anodic material used.
15. State whether following statement is true or false regarding the electrolytes in ECM.
“In Electrochemical machining, electrolytes should deposit on cathode electrodes.”
a) True
b) False
Answer: b
Explanation: In ECM, electrolytes should not deposit on cathode, so that shape of electrode
remains unchanged.
ECM-Basic Working Principles
1. What is the approximate value of faraday’s constant?
a) 65,200 C
b) 53,800 C
c) 96,500 C
d) 85,600 C
Answer: c
Explanation: 1 faraday equals to approximately 96500 C.
2. Of the following ratios of metal dissolved amounts, which one represent the current efficiency?
a) Observed to theoretical
b) Theoretical to observed
Answer: a
Explanation: In electrochemical machining, current efficiency is the ratio of observed amount of
metal dissolved to the theoretical amount of metal dissolved.
3. Apparent current efficiency is due to which of the following factors?
a) Choice of wrong valence
b) Passivation of anodic surface
c) Gas evolution at anode
Answer: d
Explanation: Current efficiency may be apparent because of choice of wrong valence, passivation of
anodic surface or gas evolution at anodic surface
4. State whether following statement is true or false regarding the working principles.
“In ECM, grain boundary attacks remove the grains through electrolytic forces.”
a) True
b) False
Answer: a
Explanation: In ECM, grain boundary attacks are the cause for removal of grains by electrolytic
forces.
5. In ECM, gap increase proportional to which relation of time below?
a) Square of time
b) Square root of time
c) Cube of time
d) Cube root of time
Answer: b
Explanation: In Electrochemical machining, gap increases proportional to the square root of time.
6. At constant feed rates what happens to gap thickness?
a) Increases
b) Decreases
c) Becomes constant
Answer: c
Explanation: At constant feed rate, work piece becomes stationary and thus the gap thickness
becomes constant.
7. At constant gap thickness material removal becomes equal to feed rate. What is this gap called?
a) Equal gap
b) Equilibrium gap
c) Unique gap
d) Narrow gap
Answer: b
Explanation: When rate of material removal per unit area is same as feed rate, then corresponding
thickness is called as equilibrium thickness indicated by ‘ye’.
8. If the gap thickness is greater than equilibrium thickness what will be MRR?
a) MRR is less than feed rate
b) MRR is greater than feed rate
c) MRR is equal to feed rate
Answer: a
Explanation: When gap thickness is greater than equilibrium thickness, MRR will be less than feed
rate.
9. During ECM drilling, decrease in feed rates lead to which type of machining gaps?
a) Wider
b) Narrow
c) Small
Answer: a
Explanation: Decrease in feed rate lead to wider gap thickness in ECM drilling
10. Too small gap causes which of the following effects?
a) Sparking
b) Short circuit
Answer: c
Explanation: Sparking or short circuit occurs when gap is too small.
ECM-Process Characteristics – 1
1. Electro chemical dissolution phase starts with the movement of ions between which two
components?
a) Cathode and anode
b) Cathode and power source
c) Power source and anode
d) Power source and electrolyte
Answer: a
Explanation: ECD phase occurs by the movement of ions between the two electrodes.
2. Better surface finish and higher accuracy depend on which of the factors below?
a) Chemical composition of electrolyte
b) Current density
Answer: c
Explanation: Proper chemical composition of electrolyte and proper current density are
responsible for better surface finish and accuracy.
3. For alloys, which type of electrolyte is used in ECM?
a) Single component
b) Double component
c) Multi component
d) Triple component
Answer: c
Explanation: Depending up on the elements in an alloy multi component electrolytes are used
4. Nickel can be machined with 100% current efficiency, when current density value is _____.
a) 10 A/cm2
b) 25 A/cm2
c) 45 A/cm2
d) 80 A/cm2
Answer: b
Explanation: Nickel is a metal suggested by Khayry, which can be machined at 100% current
efficiency, if current density is 25 A/cm2
5. When the electrolyte flow is low, what happens to the current efficiency?
a) Increases
b) Decreases
c) Remains same
d) Increase and then decrease
Answer: b
Explanation: In ECM, if the electrolyte flow is low, current efficiency is reduced due to the
accumulation of machining products within the gap.
6. When machining Ti, in Nacl electrolyte, what values of current efficiencies are obtained?
a) 10 – 20 %
b) 20 – 30 %
c) 30 – 50 %
d) 50 – 80 %
Answer: a
Explanation: While machining Ti using NaCl electrolyte, current efficiencies of 10 – 20 percent are
obtained.
7. State whether following statement is true or false about electrolyte in ECM.
“Machinability in ECM is enhanced, when electrolyte is heated.”
a) True
b) False
Answer: a
Explanation: Machinability is increased, when electrolyte is heated, as heating increases the specific
conductivity of the electrolyte.
8. In practice, what must be the temperature of electrolyte used in ECM?
a) 10 – 20oC
b) 20 – 40oC
c) 60 – 80oC
d) 80 – 100oC
Answer: c
Explanation: Temperature of electrolyte used in ECM must not exceed 60 – 70 oC.
9. What is the value of moderate level of pH of electrolyte used?
a) 1 – 2
b) 2 – 4
c) 4 – 10
Answer: c
Explanation: Moderate level of pH of electrolyte used in ECM range between 4 – 10.
10. What must be the working voltage in Electrochemical machining?
a) 10 V
b) 20 V
c) 30 V
d) 40 V
Answer: b
Explanation: The electrolytes in ECM employ a working voltage up to 20 V.
11. Surface roughness depend on which of the following quantities?
a) Crystallographic irregularities
b) Alloy composition
c) Distribution of current density
Answer: d
Explanation: Surface roughness of machined surface in ECM depend on crystallographic
irregularities, alloy composition, current density distribution, dislocations and grain boundaries.
12. For a better surface finish, which type of current distribution is required?
a) Even
b) Uneven
Answer: a
Explanation: More even distribution of the current density leads to a better surface finish
13. Between which values does the frontal gap’s surface roughness vary?
a) 0.02 to 0.13 µm
b) 0.30 to 1.90 µm
c) 1.93 to 2.64 µm
d) 2.73 to 4.26 µm
Answer: b
Explanation: Surface roughness varies between 0.30 to 1.9 µm for frontal gap area
14. Between which values does the side gap’s surface roughness vary?
a) >1 µm
b) >3 µm
c) >5 µm
d) >7 µm
Answer: c
Explanation: Surface roughness value is 5 µm or more for side gap areas.
15. In Electrochemical machining, larger grain size causes which type of finish?
a) Smoother
b) Rougher
c) Finer
Answer: b
Explanation: In ECM, larger grains cause rougher finish than finer grains.
ECM-Process Characteristics – 2
1. Which type of gap width is necessary for higher degree of accuracy?
a) Very small
b) Small
c) Medium
d) High
Answer: b
Explanation: A small gap width represents a high level of accuracy. Very small gap width results in
sparks and short circuits.
2. Accuracy of machining is affected by, which of the following factors?
a) Material
b) Gap voltage
c) Feed rate
Answer: d
Explanation: Accuracy of the process is affected by material equivalent, gap voltage, feed rate etc.
3. Which properties of electrolyte does not affect the accuracy of the process?
a) Temperature
b) Concentration
c) Non-reactive
d) Pressure
Answer: c
Explanation: Electrolyte must be reactive in order to carry on the reactions that occur at the
electrodes.
4. For high process accuracy, which of the following factors are needed?
a) High feed rate
b) High conductivity
Answer: c
Explanation: For higher degree of accuracy, there must be high feed rates and highly conductive
electrolytes.
5. Tool insulation that _____ the side machining action is needed in the process of ECM.
a) Limits
b) Enhances
c) Maintains
Answer: a
Explanation: Tool insulation is needed, which limits the machining of other sides of work piece.
6. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
Answer: b
Explanation: When current density is relatively high as required, then polishing occurs.
7. What happens when current density is low in ECM?
a) Pitting occurs
b) Etching occurs
Answer: c
Explanation: When current density is lower than optimum, then etching and pitting occurs which
are undesired.
8. Fine dimensional control can be obtained if throwing power of electrolyte is ____.
a) Low
b) Medium
c) High
d) Very high
Answer: a
Explanation: Throwing power of electrolyte must be less in order to obtain a fine dimensional
control.
9. Passivation is done on electrolytes in order to form which of the following?
a) Passive layer on machined parts
b) Passive layer on cathode
Answer: a
Explanation: Passivation is done on the electrolytes in order to form a passive film on machined
parts.
10. If there is an increase in the electrolyte flow, what happens to the rate of film formation?
a) Increases
b) Decreases
c) Remains same
Answer: b
Explanation: An increase in electrolytic solution flow decreases the anodic product formation,
which reduces the rate of film formation
11. What are the typical dimensional tolerances for frontal gaps in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
Answer: c
Explanation: The dimensional tolerances obtained for frontal gaps are ± 0.130 mm.
12. What are the tolerance values for the side gap in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
Answer: d
Explanation: The dimensional tolerances obtained for side gaps are ± 0.25 mm
13. What are the typical dimensional tolerances obtained in ECM when there is proper control of
machining?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
Answer: b
Explanation: The dimensional tolerances obtained by proper machining are ± 0.025 mm
14. It is difficult to machine inner radii smaller than ______ and outer radii less than ____ in ECM.
a) 0.1 mm, 0.2 mm
b) 0.5 mm, 0.8 mm
c) 0.8 mm, 0.5 mm
d) 0.2 mm, 0.1 mm
Answer: c
Explanation: It is difficult to machine inner radii < 0.8mm and outer radii < 0.5mm.
15. What is the value of overcut that is obtained using ECM?
a) 0.3 mm
b) 0.5 mm
c) 0.7 mm
d) 0.9 mm
Answer: b
Explanation: An overcut of 0.5 mm is obtained when machined using ECM.
ECM-Process Control
1. If there is a change in the selected machining conditions, it will have impact on which of the
following?
a) Process accuracy
b) Surface finish
Answer: c
Explanation: Selected machining conditions should remain unchanged, because, it will have a direct
impact on accuracy and surface finish.
2. Surface roughness depends on current density, which is affected by which of the following?
a) Tool feed rate
b) Gap voltage
c) Work piece material
Answer: d
Explanation: Roughness depend on current density, which is affected by tool feed rate, gap voltage,
work material, pH number, temperature, conductivity and pressure
3. Machining conditions leading to high accuracy are associated with ____ surface roughness and
____ productivity.
a) Greater, greater
b) Smaller, greater
c) Greater, smaller
d) Smaller, smaller
Answer: b
Explanation: Accuracy is associated with smaller surface roughness and greater machining
productivity.
4. Non stationary behaviour of ECM is due to, which of the factors below?
a) Gas generation
b) Heating
c) Passivation
Answer: d
Explanation: Non stationary behaviour of ECM is due to the inter electrode gap conditions such as
gas generation, passivation, heating and other electrode reaction
5. For large components, actual machining time constitutes to how much percentage of the total
machining time?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: Actual machining time of large components constitutes to a high percentage of total
machining time
6. What happens to the product cycle time, if the machining performance is improved?
a) Increases
b) Decreases
c) Remains same
Answer: b
Explanation: As the machining performance is improved, the time take for a product to complete
its production cycle, decreases
7. The cost of additional control hardware remain a _____ fraction of total machining cost.
a) Small
b) Large
c) Equal
Answer: a
Explanation: Cost of additional control hardware is very less, which constitutes to a small fraction
in total machining cost
8. With an increase in unmanned machining hours, what happens to the efficiency of ECM?
a) Increases
b) Reduces
c) Decreases
d) Increase and then decrease
Answer: a
Explanation: Increase in unmanned machining hours lead to a raise in efficiency of ECM.
9. State whether following statement is true or false regarding the process control of ECM.
“In Electrochemical machining, increase in unmanned machining hours reduces the possibility of
integration of process with CAD/CAM systems.”
a) True
b) False
Answer: b
Explanation: An increase in unmanned machining hours, enhances the process integration with
CAD/CAM systems.
10. Which type of damage is caused by deterioration which is caused by spark?
a) Reparable
b) Irreparable
Answer: b
Explanation: Deterioration by sparking may cause irreparable damage to the work pieces.
ECM-Applications and Micro-ECM
1. Which of the following use ECM for different applications?
a) Gas turbines
b) Jet engines
c) Bio medical implants
Answer: d
Explanation: ECM has its applications in industries such as gas turbines, jet engines, automobiles,
medical etc.
2. Which of the following processes can be done using ECM?
a) Die sinking
b) Profiling and contouring
c) Drilling and trepanning
Answer: d
Explanation: ECM can be used for die sinking, trepanning, drilling, contouring, grinding and
profiling.
3. Which of the following material cannot be machined using ECM?
a) High strength alloys
b) Hardened steels
c) Nonconductive materials
Answer: c
Explanation: ECM can be used for machining high strength alloys and hardened steels which led to
many cost-saving applications
4. ECM is used to _____ the sharp edges produced after rough cuts?
a) Enhance
b) Dull
c) Improve
Answer: b
Explanation: Using deburring process through ECM, sharp edges are dulled, which are produced
after rough cuts.
5. ECM is usually characterized as low accuracy machining, for which of the following reason?
a) Narrow gap width
b) Wider gap width
c) High current densities
Answer: b
Explanation: ECM is usually characterized as low accuracy machining because of its wider
machining gap.
6. In micro ECM, which of the following is used as micro tool?
a) Electrolyte jet
b) Electrodes
c) Power supply
Answer: a
Explanation: Electrolyte jet in micro ECM acts as the micro tool for machining.
7. Micro ECM is used to machine which type of parts?
a) Large parts
b) Micro parts
c) Normal sized parts
Answer: b
Explanation: Micro ECM is used to machine micro parts which can be from micro scale to
mesoscale in size.
8. Which of the following produces small indents and cavities using micro ECM?
a) Moving the work piece
b) Switching the pulse current
Answer: c
Explanation: Indentation and cavitation can be done using micro ECM by moving the work piece
or switching the pulse current.
ECM-Advantages and Disadvantages
1. What fraction of tool will always be in contact with the work piece?
a) Half
b) Full
c) No contact
d) Quarter
Answer: c
Explanation: Tool does not have any contact with the work piece in Electro chemical machining
2. How much amount of wear is present in the tool used in Electrochemical machining?
a) No wear
b) Low
c) Medium
d) High
Answer: a
Explanation: The tool wear is absent in the tool used in ECM, since tool has no contact with the
work piece.
3. Compared to other processes, machining is done at _____ voltages for high rates of material
removal.
a) Low
b) Medium
c) High
d) very low
Answer: c
Explanation: In ECM, machining is done at low voltages, when compared to other processes
4. Very small dimensions, up to which value can be controlled using ECM?
a) 0.01 mm
b) 0.05 mm
c) 0.07 mm
d) 0.12 mm
Answer: b
Explanation: Due to less electrode gap very small dimensions up to 0.05 mm can be controlled
5. Complicated profiles can be machined in how many operations in Electrochemical machining?
a) Single
b) Double
c) Triple
d) Multiple
Answer: a
Explanation: One of the main advantage of ECM is, complicated profiles can be machined in a
single operation itself.
6. How much amount of thermal damage occurs to the work piece?
a) Small
b) Large
c) No thermal damage
d) Negligible amount
Answer: c
Explanation: As the temperatures are very low, no thermal damage occurs to the work piece
material.
7. Which of the following materials can be machined using ECM?
a) Hard nonconductive materials
b) Hard conductive materials
c) All nonconductive materials
Answer: b
Explanation: Hard conductive materials can be machined and nonconductive materials cannot be
machined using ECM
8. What are the requirements of labour for machining purpose in Electrochemical machining?
a) Low
b) Medium
c) High
d) Very high
Answer: a
Explanation: In electrochemical machining, labour requirements are low compared to conventional
or traditional machining practices.
9. How much amount of energy is consumed in Electro chemical machining?
a) Very small
b) Small
c) Medium
d) Large
Answer: d
Explanation: Very huge amount of energy is required for ECM, which is nearly 100 times required
for turning or drilling of steel.
10. How are material removal rates of ECM, when compared to that of conventional methods?
a) Slower
b) Faster
c) Same
Answer: a
Explanation: In ECM, rates of material removal are slow compared to conventional methods.
11. State whether following statement is true or false regarding the limitations of ECM.
“In ECM, cleaning and oiling of work piece need not be done after machining.”
a) True
b) False
Answer: b
Explanation: Work piece needs to be cleaned and oiled just after the machining is done
12. Which of the following are the limitations of electro chemical machining?
a) Removal of hydrogen
b) Handling the electrolyte
c) Energy consumption
Answer: d
Explanation: Removal of hydrogen, handling and containing the electrolyte and energy
consumption are some of the limitations of ECM.
13. State whether following statement is true or false regarding the limitations of ECM.
“In electrochemical machining, duplicating the tool is easier.”
a) True
b) False
Answer: b
Explanation: Duplication of tool is difficult in ECM, since it has side machining effects.
14. Electro chemical machining process cannot produce which of the following mentioned below?
a) Drilled holes
b) Deburred edges
c) Sharp edges
Answer: c
Explanation: Electro chemical machining cannot produce sharp internal or external edges.
15. Pumping of electrolyte through the narrow gaps causes, which type of forces on tool and work
piece?
a) Large
b) Small
c) Negligible
d) No force
Answer: a
Explanation: Electrolyte pumping through the narrow gaps gives rise to a large amount of forces
on tool and work pieces.
ECM-Environmental Impact
1. If electro chemical machining is applied under appropriate conditions, how much amount of
health dangers can occur?
a) Small amount
b) Limited amount
c) Large amount
d) Very large amount
Answer: b
Explanation: Occupational health dangers are limited if ECM is done at appropriate conditions.
2. Which of the following are some of the bad impacts on environment while using ECM?
a) Electrolyte splashing
b) Toxic gases release
c) Precipitation of solid matters
Answer: d
Explanation: Electrolyte splashing, precipitation of solid matter, and toxic gas release is very
harmful to the environment.
3. Which of the following parts of the body can be contaminated while using ECM?
a) Skin
b) Eyes
Answer: c
Explanation: Contamination of skin and eyes may occur due to electrolyte splashing and toxic gas
release.
4. During deburring and die sinking which of the following electrolyte gives high surface quality
and accuracy?
a) NaNO3
b) HNO3
c) NaCl
Answer: a
Explanation: By using NaNO3, deburring and die sinking can be done with more accuracy and high
qualities are obtained.
5. Dissolution of metal containing chrome results in which of the toxic compounds?
a) Toxic chromate
b) Ammonia
Answer: c
Explanation: Dissolution of metal containing chromate results nitrate reduction at cathode tool,
which in turn produces toxic chromate and ammonia
6. Slurries mixing with toxic compounds produce, which of the following?
a) Solid precipitates
b) Liquid solutions
Answer: a
Explanation: Slurries which mix with toxic compounds such as chromate and ammonia precipitates
solid matter in the electrolyte solution.
7. What should be done to the electrolyte with solid matter?
a) Can be reused
b) Disposed off
c) No disposing is necessary
Answer: b
Explanation: The electrolyte which contain the solid precipitates needs to be disposed immediately,
in order to avoid any damage to the environment.
8. State whether following statement is true or false regarding the environmental impacts of ECM.
“In ECM, accumulation of toxic compounds is due to nitrate reduction at tool cathode.”
a) True
b) False
Answer: a
Explanation: When chromate containing metals dissolute, nitrate accumulate at cathode tool, which
result in toxic chromate and ammonia compounds.
Electrochemical Grinding-Introduction
1. What is the full form of ECG in the advanced machining processes?
a) Electro cardio graph
b) Electro chemical grinding
c) Electro chemical grooving
d) Electric cathode grinding
Answer: b
Explanation: The full form of ECG in the advanced machining processes is Electro chemical
grinding.
2. The grinding wheel used in the ECG process is of which charge given below?
a) Positive charge
b) Negative charge
c) Neutral charge
Answer: c
Explanation: The abrasive grinding wheel used in the Electro chemical grinding process is
negatively charged.
3. Which of the following mentioned below are utilized in the ECG process?
a) Electrolytic solution
b) Abrasive grinding wheel
c) Work piece
Answer: d
Explanation: Electro chemical grinding utilizes the abrasive grinding wheel, the electrolytic
solution and the work piece.
4. Electro chemical grinding is _______ Electro chemical machining.
a) Superior to
b) Inferior to
c) Similar to
Answer: c
Explanation: The process of Electro chemical grinding is similar to that of ECM except the cathode
is a constructed grinding wheel.
5. What is the value of inter electrode gap maintained in ECG process?
a) <0.015 mm
b) <0.025 mm
c) <0.035 mm
d) <0.045 mm
Answer: b
Explanation: The value of the inter electrode gap maintained in Electro chemical grinding is 0.025
mm or less.
6. What is the value of the grit number of the abrasives used in ECG?
a) 1 – 20
b) 20 – 60
c) 60 – 320
d) 350 – 640
Answer: c
Explanation: The value of the grit number of abrasive particles used in the ECG process are about
60 – 320.
7. Which of the following electrolytes are used for machining purpose in ECG?
a) Sodium nitrate
b) Hydro chloric acid
c) Nitric acid
d) Potassium permanganate
Answer: a
Explanation: Generally sodium nitrate is the electrolyte that is used for machining purpose in
Electro chemical grinding.
8. What are the values of surface speeds at which the wheel rotates?
a) 5 to 15 m/s
b) 10 to 20 m/s
c) 20 to 35 m/s
d) 40 to 60 m/s
Answer: c
Explanation: The speeds used in ECG will range from 20 to 35 m/sec
9. What are the values of current used in ECG?
a) 1 to 50 A
b) 50 to 300 A
c) 300 to 600 A
d) 600 to 1000 A
Answer: c
Explanation: The values of current in Electro chemical grinding range from 50 to 300 A.
10. State whether following statement is true or false regarding the material removal in ECG.
“In ECG, material removal is not continuous using abrasive.”
a) True
b) False
Answer: b
Explanation: Abrasive particles continuously remove the material products from the working area
in Electro chemical grinding.
ECG-Material Removal Rate
1. What is the value of gap voltage maintained in ECG process?
a) 1 to 10 V
b) 4 to 40 V
c) 40 to 400 V
d) 500 to 5000 V
Answer: b
Explanation: The value of the gap voltage in ECG process is 4 to 40 V.
2. What are the values of current densities used in the ECG process?
a) 1 to 60 A/cm2
b) 60 to 120 A/cm2
c) 120 to 240 A/cm2
d) 240 to 480 A/cm2
Answer: c
Explanation: The values of current densities range from 120 to 240 A/cm 2.
3. Current density depends on which of the following factors?
a) Machined material
b) Gap width
c) Applied voltage
Answer: d
Explanation: The current density values in Electro chemical grinding depend on machined
material, gap width and the applied voltage
4. What is the main mechanism of material removal in Electro chemical grinding?
a) Mechanical erosion of material
b) Electro chemical dissolution
c) Melting and vaporization
d) Electron removal from material
Answer: b
Explanation: Electro chemical grinding process removes the material mainly by electro chemical
dissolution.
5. The grinding wheel is _____ and the work piece is ____ in ECG process.
a) Cathode, anode
b) Anode, cathode
c) Cathode, cathode
d) Anode, anode
Answer: a
Explanation: The grinding wheel is cathode and the work piece is anode in the Electro chemical
grinding process.
6. Mechanical abrasion counts to how much amount of the material removal in ECG?
a) 1 to 5%
b) 5 to 10%
c) 10 to 15%
d) 15 to 20%
Answer: b
Explanation: Material removal through abrasion counts to 5 to 10% of the total material removed
7. Removal rates of ECG process are how may time to that of the conventional machining
processes?
a) 2 times
b) 3 times
c) 4 times
d) 5 times
Answer: c
Explanation: The MRR of ECG process are nearly 4 times that of the conventional machining
processes
8. How much amount of burr is produce in Electro chemical grinding process?
a) Less amount
b) Moderate amount
c) High amount
d) No burrs are produced
Answer: d
Explanation: The Electro chemical grinding process is a burr free process which produce parts that
are unstressed.
9. What are the volumetric removal rates that are obtained in ECG process?
a) 400 mm3/min
b) 800 mm3/min
c) 1600 mm3/min
d) 3200 mm3/min
Answer: c
Explanation: The volumetric removal rates that are obtained in Electro chemical grinding process
will be around 1600 mm3/min.
10. ECG is a hybrid machining process of which material removal mechanisms below?
b) Electro chemical dissolution
Answer: c
Explanation: ECG is a hybrid machining process which uses MA and ECD for material removal.
11. Action of abrasive grains depend on which of the following factors?
a) Electric filed
b) Transport of electrolyte
c) Hydrodynamic effects
Answer: d
Explanation: Action pf abrasive grains in the gap depends on the electric field, transport of
electrolyte and the hydrodynamic effects.
ECG-Accuracy, Applications, Advantages and disadvantages
1. What are the tolerance value that are obtained by using ECG process?
a) ± 0.01 mm
b) ± 0.03 mm
c) ± 0.05 mm
d) ± 0.07 mm
Answer: b
Explanation: The tolerance values that are obtained by using Electro chemical grinding are about ±
0.03 mm.
2. Under special circumstances what are the tolerances obtained?
a) ± 0.02 mm
b) ± 0.04 mm
c) ± 0.06 mm
d) ± 0.08 mm
Answer: d
Explanation: The tolerance values of about ± 0.08 mm are obtained under special circumstances in
Electro chemical grinding.
3. What are the production tolerances obtained in ECG process?
a) ± 0.005 mm
b) ± 0.015 mm
c) ± 0.025 mm
d) ± 0.035 mm
Answer: c
Explanation: The production tolerances obtained by machining using Electro chemical grinding
process is about ± 0.025 mm.
4. The tolerance values in ECG depend on which of the following factors?
a) Electrolyte flow
b) Feed rate
c) Metallurgy of material
Answer: d
Explanation: The tolerance values depend on the electrolyte flow, feed rate and the metallurgy of
work piece.
5. What are the values of accuracies obtained in ECG process?
a) ± 0.025 mm
b) ± 0.125 mm
c) ± 0.225 mm
d) ± 0.325 mm
Answer: b
Explanation: The accuracy values obtained by using Electro chemical grinding process is about ±
0.125 mm.
6. Which type of voltages are recommended for closer tolerances in ECG?
a) Low
b) Moderate
c) High
d) Very high
Answer: a
Explanation: Lower voltages are recommended for closer tolerances, reduced overcut, sharp edges
and bright surface finish in the process of Electro chemical grinding.
7. What are the values of radii of corners obtained in ECG?
a) 0.15 to 0.225 mm
b) 0.25 to 0.375 mm
c) 0.45 to 0.525 mm
d) 0.55 to 0.675 mm
Answer: b
Explanation: The values of radii of corner range from 0.25 to 0.375 mm.
8. Surface finish in ECG depend on which of the following factors?
a) Metal machined
b) Abrasive size
c) Wheel speed
Answer: d
Explanation: Surface finish in ECG process depend on metal being machined, abrasive grit size,
wheel speed and feed rate.
9. What are the values of radii of corners obtained in ECG?
a) 0.1 to 0.2 µm
b) 0.2 to 0.3 µm
c) 0.3 to 0.4 µm
d) 0.4 to 0.5 µm
Answer: b
Explanation: The values of surface finish range from 0.2 to 0.3 µm
10. What are the values of voltages used for better surface quality?
a) 1 – 2 V
b) 2 – 3 V
c) 3 – 5 V
d) 5 – 8 V
Answer: c
Explanation: Voltages ranging between 3 and 5 V can be used for better surface quality in ECG.
11. What are the machining speeds recommended for high surface quality?
a) 1 – 250 mm/min
b) 250 – 500 mm/min
c) 500 – 750 mm/min
d) 750 – 100 mm/min
Answer: b
Explanation: The machining speeds recommended for high surface quality are between 250 and
500 mm/min in ECG.
12. What are the applications of Electro chemical grinding process?
a) Milling the material
b) Tool and cutter sharpening
c) Cutting off
Answer: d
Explanation: The applications of electro chemical grinding are milling, grinding, cutting off,
sawing, tool and cutter sharpening.
13. What are the advantages of machining in Electro chemical grinding?
a) Good surface quality
b) Absence of distortion
c) Longer wheel life
Answer: d
Explanation: Good surface quality, absence of distortion, longer wheel life etc.., are some
advantages of Electro chemical grinding
14. Which of the following are the disadvantages of ECG process?
a) High capital cost
b) Limited to conductive materials
c) Corrosive nature
Answer: d
Explanation: High capital cost, limited to conductive materials, corrosive nature etc.., are some
disadvantages of ECG.
15. State whether following statement is true of false regarding ECG process.
“In ECG process, filtering and disposal of electrolyte is not necessary.”
a) True
b) False
Answer: b
Explanation: Main disadvantage of ECG is to filter and dispose the electrolyte used in the process
Electro Chemical Drilling

1. What is the full form of ECDR in advanced machining processes?
a) Electrochemical Dissolution
b) Electrochemical Drilling
c) Electrochemical Degradation
d) Electrochemical Devastation
Answer: b
Explanation: In advanced machining processes, full form of ECDR is Electrochemical Drilling.
2. What are the values of diameters produced using Electrochemical drilling process?
a) 0.01 to 0.2 mm
b) 1 to 20 mm
c) 30 to 50 mm
d) 60 to 100 mm
Answer: b
Explanation: Value of diameter produced using Electrochemical drilling, ranges between 1 to 20
mm.
3. What are the feed rates used in Electrochemical drilling?
a) 0.1 to 0.6 mm/min
b) 0.6 to 1 mm/min
c) 1 to 5 mm/min
d) 6 to 15 mm/min
Answer: c
Explanation: Value of feed rates used in Electrochemical drilling, range between 1 to 5 mm/min
4. Of the following, which type of electrodes is used as tool in ECDR?
a) Tubular electrodes
b) Flat electrodes
c) Cylindrical electrodes
Answer: a
Explanation: In ECDR, tubular electrodes are used as cathodic tools for making holes in the
materials.
5. The electrolyte is pumped the ____ of tool and exits through _____ of tool.
a) Centre, side
b) Side, centre
Answer: c
Explanation: Usually, electrolyte is pumped from centre and exits from side machining gap and
vice-versa can also be done in back pressure process.
6. Material is removed using which part of the electrode in ECDR?
a) Only front
b) Only side
c) Front and side
Answer: c
Explanation: Material is removed at the frontal gaps and also dissolution takes place at the side
machining gaps of the cathodic tool and work piece.
7. Overcut produced in ECRD is difference between which of the following parameters?
a) Diameter of tool, diameter of hole
b) Diameter of hole, diameter of tool
c) Depth of tool, diameter of tool
d) Diameter of tool, depth of tool
Answer: b
Explanation: Overcut is the difference between the diameter of hole produced in work piece and
the diameter of tool.
8. For high machining accuracy and smaller diametrical oversize, which type of feed rates are
required?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: High feed rates are recommended for smaller diametrical oversize and more accuracy
9. What happens to the overcut size, if we use the electrolyte flow mode under backward pressure?
a) Decreases
b) Increases
Answer: a
Explanation: If we use backward pressure for electrolyte flow, the overcut size decreases
10. What are the values of pressure, used in backward pressure mode of electrolyte flow?
a) 0.01 to 0.12 MPa
b) 0.15 to 0.46 MPa
c) 0.6 to 2 MPa
d) 5 to 12 MPa
Answer: c
Explanation: To reduce overcut size, reverse flow of electrolyte can be used under backward
pressure mode, whose value ranges between 0.6 to 2 MPa.
11. What happens to the electrolyte conductivity if the gap increases, in ECDR?
a) Increases
b) Decreases
c) Remains same
Answer: a
Explanation: In ECDR, as the gap increases, the electrical conductivity increases and the
dissolution of material increases.
12. Electrolyte back pressure _____ the flow lines on work piece machined using ECDR?
a) Enhances
b) Eliminates
c) Maintains
d) Increases
Answer: b
Explanation: Electrolyte back pressure eliminates the flow lines on the machined surfaces which is
a major advantages of ECDR.
13. What happens to the roundness error if we use the rotation of ECDR tool?
a) Increases
b) Remains same
c) Decreases
d) Enhances
Answer: c
Explanation: Roundness error decreases, if the tool is rotated in ECDR, since it ensures the
homogenous flow of electrolyte in the machining gaps
14. If sparking occurs due to very less gap between work surfaces, which parts gets damaged?
a) Tool
b) Work piece
Answer: c
Explanation: Sparking, which occur due to very less gap between tool and work piece, which
damages both the parts in ECDR.
15. Current efficiencies <100 percent may be related to, which of the following incidents?
a) Gas evolution
b) Passive oxide film formation
c) Less dissolution
Answer: d
Explanation: Current efficiencies less than 100 percent may be related to gas evolution, passive
oxide formation, which in turn lead to less dissolution
Shaped tube Electrolytic Machining
1. What is the full form of STEM in advanced machining processes?
a) Small Tool Electrode Machining
b) Small Tube Electrode Manufacturing
c) Shaped Tube Electrolytic Machining
d) Shaped Tube Electrode Machining Answer: c
Explanation: Full form of STEM in advanced machining processes is Shaped tube electrolytic
machining.
2. Material is removed on which basis, in Shaped tube electrolytic machining?
a) Dissolution
b) Vaporization
c) Abrasion
d) Erosion
Answer: a
Explanation: In STEM, dissolution takes place when a potential difference is applied between the
anodic work piece and cathodic tool.
3. Which of the following can be used as electrolytes in STEM process?
a) Sulphuric acid
b) Nitric acid
c) Hydrochloric acids
Answer: d
Explanation: Electrolytes used in STEM are sulphuric acid, nitric acid and hydrochloric acids.
4. What is the percentage of electrolyte dissolved in water?
a) 1 – 5%
b) 10 – 25%
c) 40 – 70%
d) 75 – 90%
Answer: b
Explanation: Concentration of electrolyte, used in STEM, is 10 – 25% weight in water.
5. What may be the temperature of sulphuric acid used in STEM process?
a) 10 oC
b) 21 oC
c) 38 oC
d) 50 oC
Answer: c
Explanation: The temperature of sulphuric acids used in STEM process may be around 38 oC.
6. What may be the temperatures of acids used, other than sulphuric acid, in STEM?
a) 10 oC
b) 21 oC
c) 38 oC
d) 50 oC
Answer: b
Explanation: Temperature of acids used in STEM, other than sulphuric acid, is about 21 oC.
7. What are the values of pressures used for electrolyte in STEM?
a) 10 – 100 kPa
b) 150 – 250 kPa
c) 275 – 500 kPa
d) 600 – 750 kPa
Answer: c
Explanation: Values of pressure used in STEM process, range between 275 – 500 kPa
8. What are the voltage values used in STEM process?
a) 1 – 4 V
b) 8 – 14 V
c) 16 – 24 V
d) 28 – 34 V
Answer: b
Explanation: In STEM, voltage values used for the process to carry on, range between 8 – 14 V
9. Compared to the forward voltages, how are the reverse voltages?
a) 0.01 – 0.1 times
b) 0.1 – 1 times
c) 1 – 10 times
d) 10 – 100 times
Answer: b
Explanation: Reverse voltages used in STEM are 0.1 – 1 times the forward voltages, used in STEM
10. Between which of the following values, does the feed rate range?
a) 0.01 – 0.1 mm/min
b) 0.25 – 0.5 mm/min
c) 0.75 – 3 mm/min
d) 5 – 7.5 mm/min
Answer: c
Explanation: Feed rates used in STEM, range between 0.75 – 3 mm/min
11. What may the hole sizes, that can be machined using STEM process?
a) 0.02 – 0.3 mm
b) 0.5 – 6 mm
c) 8 – 20 mm
d) 50 – 76 mm
Answer: b
Explanation: The hole sizes that can be machined using STEM process, range between 0.5 – 6 mm.
12. What are the tolerance values for a 1.5 mm diameter hole, which is machined using STEM?
a) ± 0.025 mm
b) ± 0.050 mm
c) ± 0.075 mm
d) ± 0.100 mm
Answer: c
Explanation: Diametrical tolerance value increases with the increase in hole diameter, which varies
as – ± 0.050 mm for 0.6 mm diameter hole, ± 0.075 mm for 1.5 mm diameter hole and ± 0.100 mm
for 6 mm hole diameter
13. Which of the following parts can be machined using STEM process?
a) Turbine blade cooling nozzles
b) Fuel nozzles
c) Starting holes for wire-EDM
Answer: d
Explanation: STEM has its applications in jet engines and gas turbine parts such as cooling nozzles
for turbine blades, fuel nozzles and any holes where EDM recast is undesirable.
14. Which of the following are the advantages of STEM?
a) Depth to diameter ratio of 300
b) Non parallel holes can be drilled
c) No recast layer
Answer: d
Explanation: Main advantages of STEM are depth to diameter ratio of 300, non-parallel holes can
be drilled, no recast layer are produced, shaped and curved holes can be produced.
15. What are the limitations of STEM process?
a) Used for corrosion resistant materials
b) Hazardous waste is generated
c) Complex machining and tooling systems
Answer: d
Explanation: Some of the limitations of STEM are only used for corrosion resistant materials,
hazardous wastes are generated, special work place environment are required, complex machining
and tooling systems are required.
Electrostream (Capillary) Drilling
1. In advanced machining processes, what is the full form of ES drilling?
a) Electro stream
b) Electrical shaped
c) Electron shaped
d) Electric shock
Answer: a
Explanation: In advanced machining processes, full form of ES drilling is Electrostream drilling.
2. This Electrostream drilling is used when we cannot drill which of the following type of holes?
a) Too deep holes by EDM
b) Small holes by STEM
Answer: c
Explanation: ES drilling is used to drill finer holes which are too deep to be produced by EDM and
too small to be drilled by STEM.
3. What is the value of diameter of glass nozzle used in Electrostream drilling?
a) 0.01 – 0.02 mm
b) 0.025 – 0.5 mm
c) 0.5 – 0.75 mm
d) 0.75 – 1.25 mm
Answer: b
Explanation: Electrostream drilling uses a gas nozzle, whose diameter ranges between 0.025 – 0.5
mm.
4. Compared to the required diameter of the hole, how is the nozzle diameter?
a) Smaller
b) Larger
c) Same as required
Answer: a
Explanation: The diameter of nozzle used is smaller than the hole size required to be drilled in
work piece.
5. Which of the following acts as the cathodic tool in ES drilling?
a) Titanium base
b) Platinum wire
c) Glass nozzle
d) Work piece
Answer: b
Explanation: Unlike the case of STEM process, which uses coated Ti tube as cathode, ES drilling
used platinum wire as cathode electrode.
6. What is the concentration of electrolytes that are commonly used in ES drilling?
a) 1 to 10wt %
b) 12 to 20wt %
c) 23 to 30wt %
d) 34 to 50wt %
Answer: b
Explanation: Commonly used electrolytes have a concentration between 12 to 20wt %.
7. State whether following statement is true or false regarding ES drilling.
“In ES drilling, hydrochloric acid is used for machining aluminium and its alloys.”
a) True
b) False
Answer: a
Explanation: Hydrochloric acids are used for machining Al and its alloys and sulphuric acid is
recommended for other metals.
8. Which of the following are the metals, which can be machined using sulphuric acid?
a) Carbon steels
b) Haste alloy
c) Inconel
Answer: d
Explanation: Haste alloy, Rene alloy, Inconel, carbon and stainless steels are the materials
machined using sulphuric acid.
9. What are the values of electrolyte pressure recommended for ES drilling?
a) 50 – 100 kPa
b) 100 – 250 kPa
c) 275 – 400 kPa
d) 500 – 750 kPa
Answer: c
Explanation: Electrolyte pressure values must range between 275 – 400 kPa for ES drilling to take
place.
10. Which of the following parameters must be carefully monitored for satisfactory machining?
a) Acid temperature
b) Pressure
c) Concentration
Answer: d
Explanation: Acid temperature, pressure, concentration and feed rate are to be carefully monitored
for satisfactory machining.
11. What are the values of voltages used in ES drilling process?
a) 10 to 40 V
b) 40 to 70 V
c) 70 to 150 V
d) 150 to 300 V
Answer: c
Explanation: Voltage values used in ES drilling, range between 70 to 150 V.
12. What are the values of feed rates used in ES drilling process?
a) 0.01 to 0.5 mm/min
b) 0.75 to 2.5 mm/min
c) 3 to 4.5 mm/min
d) 5 to 7.5 mm/min
Answer: b
Explanation: Feed rate values used in ES drilling, range between 0.75 to 2.5 mm/min
13. Higher material removal rates are associated with _____ feed rates and _____ tool diameters.
a) Larger, smaller
b) Smaller, larger
c) Smaller, smaller
d) Larger, larger
Answer: d
Explanation: Rates of material removal are high, when feed rates are high and larger tool
diameters.
14. What are the normal hole depth tolerance values in ES drilling?
a) ± 0.03 mm
b) ± 0.05 mm
c) ± 0.07 mm
d) ± 0.09 mm
Answer: b
Explanation: The normal hole depth tolerances obtained in ES drilling, range between ± 0.05 mm
15. How many holes can be drilled simultaneously using ES drilling process?
a) One hole
b) Two holes
c) Three holes
d) Multiple holes
Answer: d
Explanation: Depending upon the size of diameters, multiple holes can be drilled using ES drilling
Electrochemical Jet Drilling
1. In advanced machining processes, what is the full form of ECJD?
a) Electrochemical Jet Dimensioning
b) Electrochemical Jet Drilling
c) Electrical Jet Drilling
d) Electrical Jet Dimensioning
Answer: b
Explanation: In advanced machining processes, full form of ECJD is Electrochemical Jet Drilling.
2. What is the value of diameter-to-depth ratio obtained using ECJD process?
a) 1:10
b) 2:25
c) 1:12
d) 1:100
Answer: c
Explanation: Electrochemical jet drilling is the process used for producing fine holes, having
diameter to depth ratio of 1:12.
3. Compared to the diameter to depth ratio of ES drilling, how is ECJD’s ratio?
a) Lower
b) Higher
c) Same as ES
Answer: a
Explanation: ES drilling has a diameter to depth ratio of 1:100, while ECJD has a ratio of 1:12.
4. How is the material removed in Electrochemical jet drilling process?
a) Using Platinum wire
b) Using Ti coated electrode
c) By spraying electrolyte
d) Using glass nozzle
Answer: c
Explanation: Material is removed by spraying electrolyte through the cathode, in Electrochemical
jet drilling.
5. What is the material removal mechanism used in Electrochemical jet drilling?
a) Abrasion
b) Dissolution
c) Vaporization
d) Erosion
Answer: b
Explanation: Electrochemical dissolution is the means of material removal in Electrochemical jet
drilling.
6. What are the values of voltages used in Electrochemical jet drilling process?
a) 100 to 200 V
b) 200 to 400 V
c) 400 to 800 V
d) 800 to 1600 V
Answer: c
Explanation: The optimum range of voltages used in Electrochemical jet drilling are between 400 to
800 V.
7. The lower limit of the hole size in ECJD, is determined by which of the following factors?
a) Smallest hole
b) Pressure required
c) Amount of overcut
Answer: d
Explanation: The lower limit of hole size depend on smallest hole that can be drilled in cathodic
nozzle, pressure required for pumping electrolyte and the overcut amount.
8. State whether following statement is true or false regarding ECJD.
“In ECJD, diameter of hole produced, depend up on the throwing power of electrolyte.”
a) True
b) False
Answer: a
Explanation: Diameter of the hole produced, depend up on the throwing power of electrolyte
9. Compared to the diameter of the electrolyte jet, how are the produced hole diameters?
a) 2 times
b) 3 times
c) 4 times
d) 5 times
Answer: c
Explanation: In ECJD, the holes produced are nearly 4 times that of the electrolyte jet diameter
used in the process.
10. What is the value of the ratio of hole diameter to capillary diameter in ECJD?
a) 2
b) 4
c) 6
d) 8
Answer: a
Explanation: Generally, ratio of hole diameter to capillary diameter in ECJD is 2.
11. What are the values of tapers produced in Electrochemical jet drilling process?
a) 1 to 2 included angles
b) 5 to 10 included angles
c) 10 to 15 included angles
d) 20 to 30 included angles
Answer: b
Explanation: In Electrochemical jet drilling tapers produced are about 5 to 10 included angles.
12. State whether following statement is true or false regarding ECJD?
“In ECJD, there is no need of room for exit of electrolyte.”
a) True
b) False
Answer: b
Explanation: In ECJD, enough room is required for the exit of electrolyte, preferably in the form of
spray.
13. How much part of tool needs to be in contact with work piece for removal of material?
a) Quarter
b) Half
c) Full
d) No contact
Answer: d
Explanation: As this is an electrochemical dissolution process, electrodes should not be in contact in
order to avoid sparking.
Electrochemical Deburring – 1
1. In advanced machining processes, full form of ECDB is _____
a) Electrochemical Drill buffing
b) Electrochemical Dimension Breaking
c) Electrochemical Deburring
d) Electrochemical Dimensioning
Answer: c
Explanation: In advanced machining processes, full form of ECDB is Electrochemical Deburring.
2. Which of the following processes can be used for deburring?
a) Water blasting
b) Abrasive flow machining
c) Electrochemical deburring
Answer: d
Explanation: Different methods used for deburring include vibratory and barrel finishing,
tumbling, water blasting, Abrasive flow machining, Electrochemical deburring and many more
3. Of the following electrodes, on which one the process of deburring takes place?
a) Cathode
b) Anode
Answer: c
Explanation: Anode is the electrode, on which, the process of deburring is done.
4. Burrs are removed at which amount of current densities below?
a) Very low
b) Low
c) High
d) Medium
Answer: c
Explanation: High current densities are required to remove the burrs from the work pieces.
5. After deburring is done, which of the following is formed?
a) Flat surfaces
b) Controlled radius
c) Sharp edges
Answer: b
Explanation: Dimensions of the part are changes by the removal of burrs leaving a controlled
radius.
6. To which components mentioned below, ECDM can be applied?
a) Spline shafts
b) Milled components
c) Drilled holes
Answer: d
Explanation: ECDB can be applied to gears, spline shafts, milled components, drilled holes, and
punched blanks.
7. What are the values of deburring speeds used in ECDB process?
a) 100 to 200 mm/min
b) 200 to 400 mm/min
c) 400 to 500 mm/min
d) 500 to 700 mm/min
Answer: c
Explanation: Values of speeds of deburring, range between 400 to 500 mm/min.
8. What are the normal cycle times for deburring process using ECDB?
a) 10 to 20 s
b) 30 to 45 s
c) 50 to 70 s
d) 80 to 100 s
Answer: b
Explanation: The normal cycle times are between 30 to 45 s after which, spindle is retracted and
part is removed.
9. What is the value of burr height that can be removed using ECDB process?
a) 0.1 mm
b) 0.3 mm
c) 0.5 mm
d) 0.7 mm
Answer: c
Explanation: Burr height of around 0.5 mm can be removed using ECDB process.
10. Burr is removed to a radius of _____ in ECDB process.
a) 0.01 to 0.04 mm
b) 0.05 to 0.20 mm
c) 0.25 to 0.40 mm
d) 0.50 to 0.75 mm
Answer: b
Explanation: Burr of height 0.5 mm to a radius of 0.05 to 0.2 mm can be removed using ECDB.
11. What is the value of surface roughness obtained in Electrochemical deburring process?
a) 0.1 to 1 µm
b) 1 to 2 µm
c) 2 to 4 µm
d) 5 to 8 µm
Answer: c
Explanation: Surface roughness obtained in ECDB process is about 2 to 4 µm
Electrochemical Deburring – 2
1. What is the value of pressure of electrolyte used in ECDB process?
a) 0.1 to 0.2 MPa
b) 0.3 to 0.5 MPa
c) 0.7 to 0.9 MPa
d) 1.1 to 1.5 MPa
Answer: b
Explanation: Pressure of electrolyte used in ECDB is maintained between 0.3 to 0.5 MPa.
2. What is the value of applied voltage used in ECDB process?
a) 1 to 5 V
b) 5 to 11 V
c) 12 to 24 V
d) 25 to 50 V
Answer: c
Explanation: Value of voltage used in ECDB process ranges from 12 to 24 V
3. What are the values of current densities used in ECDB process?
a) 1 – 5 A/cm2
b) 5 – 10 A/cm2
c) 10 – 15 A/cm2
d) 15 – 20 A/cm2
Answer: b
Explanation: Current densities used in ECDB process range between 5 – 10 A/cm 2.
4. Which of the following electrolyte can be used for deburring process in ECDB?
a) NaNO2
b) NaNO3
c) NaCl
Answer: d
Explanation: Sodium nitrite, sodium nitrate and sodium chloride are the electrolytes used in ECDB
process.
5. What are the values, of inter electrode gaps so that machining occurs easily?
a) 0.01 to 0.1 mm
b) 0.1 to 0.3 mm
c) 0.3 to 0.5 mm
d) 0.5 to 0.7 mm
Answer: c
Explanation: The inter electrode gap maintained in ECDB process, range between 0.30 – 0.50 mm
6. In order to produce a proper radius, by how much should the tool tip overlap the machined
area?
a) 0.5 to 1 mm
b) 1 to 1.5 mm
c) 1.5 to 2 mm
d) 2 to 2.5 mm
Answer: b
Explanation: In ECDB, the tool tip should overlap the machined area by 1.5 to 2 mm in order to
produce a proper radius.
7. Which of the following materials can be machined using ECDB process?
a) Carbon steels
b) Copper alloys
c) Aluminium alloys
Answer: d
Explanation: All the materials mentioned above, can be machined using ECDB process.
8. In ECDB process, rotating and feeding the tool electrode _____ the deburring process.
a) Enhances
b) Degrades
c) Damages
Answer: a
Explanation: Rotating and feeding the tool in ECDB process, enhances the process of deburring.
9. Electrochemical deburring ensures which of the following factors after removal of burrs?
a) Required accuracy
b) Proper radius
c) Clean edge
Answer: d
Explanation: ECDB ensures the removal of burrs art required accuracy, uniformity, proper radius
and clean edges.
10. Which of the following are the advantages of using ECDB process?
a) Increased product quality
b) Reduced labour cost
c) Increased reliability
Answer: Increased product quality and reliability, reduced labour costs, elimination of costly hand
deburring etc.., are some of the advantages of ECDB.
11. State whether following statement is true or false regarding the advantages of ECDB.
“In ECDB, automation does not contribute to productivity.”
a) True
b) False
Answer: b
Explanation: Electrochemical deburring can be automated for higher productivity.
UNIT-3
Electro Discharge Machining-Introduction
1. In advanced machining processes, what is the full form of EDM?
a) Electro discharge Machining
b) Electro discharge Manufacturing
c) Electrical dimensioning Machining
d) Electrode dimensions Manufacturing
Answer: a
Explanation: Full form of EDM in advanced machining processes is, Electrodischarge machining.
2. The evolution of wire EDM took place in which part of history?
a) 1940s
b) 1950s
c) 1960s
d) 1970s
Answer: d
Explanation: Evolution of wire EDM in 1970s was due to powerful generators, new wire electrodes,
improved machining intelligence and better flushing.
3. Machining speeds have gone up to how many times after the invention of EDM?
a) Ten
b) Twenty
c) Thirty
d) Fifty
Answer: b
Explanation: Machining speeds have gone up to 20 times after the invention of EDM.
4. By using EDM, how much percentage of machining costs can be reduced?
a) 10 %
b) 20 %
c) 30 %
d) 50 %
Answer: c
Explanation: EDM decreased the machined cost at least by 30 %.
5. After invention of EDM, surface finish have improved by how much factor?
a) 10
b) 15
c) 20
d) 25
Answer: b
Explanation: Surface finish have been improved by a factor of 15 after the invention of EDM
6. Cavities with, which of the following factors can be produced using Electro discharge machining?
a) Thin walls
b) Fine features
Answer: c
Explanation: Cavities with thin walls and fine features can be machined using EDM.
7. Which of the following geometries can be machined using EDM?
a) Simple
b) Complex
c) Difficult to cut
Answer: d
Explanation: Electrodischarge machining can be used for simple as well as complex geometries.
8. State whether following statement is true or false regarding EDM.
“In EDM, process is affected by hardness of material.”
a) True
b) False
Answer: b
Explanation: EDM process is not affected by the hardness of material.
9. How much amount of burr is produced in this process?
a) 10 %
b) 40 %
c) 70 %
d) No burr
Answer: d
Explanation: Electro discharge machining is a burr free process
10. Which of the following mechanisms is used for material removal?
a) Electro discharge erosion
b) Magnetic abrasion
c) Electro chemical dissolution
d) Mechanical erosion
Answer: a
Explanation: Material is removed by electro discharge erosion (EDE) in EDM
EDM-Mechanism of Material Removal – 1
1. What is the value of order of frequency applied between the two electrodes in EDM?
a) 1 kHz
b) 3 kHz
c) 5 kHz
d) 7 kHz
Answer: c
Explanation: The magnitude of frequency applied between the electrodes in EDM is about 5 kHz.
2. What are the magnitude of voltages used in Electro discharge machining?
a) 1 to 20 V
b) 20 to 120 V
c) 120 to 220 V
d) 220 to 320 V
Answer: b
Explanation: In EDM, the magnitude of voltages range between 20 and 120 V
3. What are the values of gaps between the electrodes in EDM?
a) 0.001 – 0.05 mm
b) 0.01 – 0.5 mm
c) 0.1 – 5 mm
d) 1 – 15 mm
Answer: b
Explanation: In EDM, very small gaps that range between 0.01 – 0.5 mm are maintained.
4. How is material removed in Electro discharge machining?
a) Melt and evaporate
b) Corrode and break
c) Mechanical erosion takes place
Answer: a
Explanation: In Electro discharge machining, material is melted and then evaporated.
5. What is the radius of channel, when electrical breakdown occur?
a) 4 µm
b) 6 µm
c) 8 µm
d) 10 µm
Answer: d
Explanation: In EDM, the electrical breakdown occurs in dielectric in a channel of radius about 10
µm.
“In EDM, negative ions (electrons) collide with positive ions to generate heat.”
a) True
b) False
Answer: b
Explanation: In Electro discharge machining, electrons collide with neutral atoms producing
positive ions and further electrons.
7. What are the values of temperature that are obtained while machining using EDM?
a) 2000 to 3000ᵒC
b) 4000 to 6000ᵒC
c) 8000 to 12000ᵒC
d) 15000 to 20000ᵒC
Answer: c
Explanation: The temperatures obtained when the ions reach their respective electrodes, range
between 8000ᵒC and 12000ᵒC.
8. What range of heat fluxes are obtained while machining using EDM?
a) 1017 W/m2
b) 1019 W/m2
c) 1024 W/m2
d) 1027 W/m2
Answer: a
Explanation: Heat flux up to the value of 1017 W/m2 are obtained in EDM
9. What is the duration of sparks that are produced in Electro discharge machining?
a) 0.001 – 1 µs
b) 0.1 – 2000 µs
c) 0.2 – 100 ms
d) 100 – 2000 ms
Answer: b
Explanation: Duration of spark in Electro discharge machining is about 0.1 to 2000 µs
10. State whether following statement is true or false about material removal in EDM.
“In EDM, high pressures allow the metal to evaporate.”
a) True
b) False
Answer: b
Explanation: High pressures in EDM try to prevent the super-heated metal from evaporation
11. What are the values of pressure of the plasma in EDM?
a) Up to 2 atm
b) Up to 20 atm
c) Up to 200 atm
d) Up to 2000 atm
Answer: c
Explanation: Pressure on the plasma channel rises to values as high as 200 atm when dielectric
evaporates.
12. At the end of pulse, super-heated metal evaporates _____.
a) Explosively
b) Normally
c) Periodically
d) Occasionally
Answer: a
Explanation: At the end of pulse, pressure drops suddenly and super-heated metal evaporates
explosively.
EDM-Mechanism of Material Removal – 2
1. After the explosion is over, how is the debris carried away?
a) Evaporation
b) Fresh dielectric
c) Old dielectric
Answer: b
Explanation: Debris is carried away by the fresh dielectric that rushes in.
2. The layer formed when unexpelled molten metal solidifies is known as _____.
a) Reabsorbed layer
b) Recast layer
c) Unevaporated layer
d) Condensed layer
Answer: b
Explanation: Unexpelled molten metal solidifies to form a layer known as recast layer.
3. Amount of material removed from anode and cathode depend on which of the following?
a) Electrons
b) Positive ions
Answer: c
Explanation: The amount of material removed from electrodes depend on the contribution of the
charged ions.
4. What happens when the electron current predominates in the discharge?
a) More anodic removal
b) More cathodic removal
c) Remains same
Answer: a
Explanation: When electron current predominates the electrical discharge, anodic material
removal is greater than cathodic material.
5. Between what values mentioned below, do the discharges and sparks usually vary?
a) 1 and 10,000
b) 500 and 500,000
c) 500,000 and 1,000,000
Answer: b
Explanation: Frequency of discharges or sparks generally vary between 500 and 500,000 sparks per
second.
6. What is the value of gap maintained between the electrodes when we use servo mechanism?
a) 10 – 100 µm
b) 100 – 200 µm
c) 200 – 500 µm
d) 500 – 1000 µm
Answer: c
Explanation: In EDM, value of gap maintained between the electrodes range between 200 and 500
µm.
7. Based on the electrode gap, which of the following electric pulses are generated?
a) Open Circuit pulses
b) Sparks
c) Arcs
Answer: d
Explanation: Based on the electrode gap, electric pulses are distinguished which are – circuit
pulses, sparks, arcs and short circuits.
“In Electro discharge machining, electric pulses generated affect the material removal.”
a) True
b) False
Answer: a
Explanation: In Electro discharge machining, electric pulses generated have an impact on the
material removal.
9. Open gap voltages contribute to how much amount of material removal?
a) 20 %
b) 50 %
c) 70 %
d) No contribution
Answer: d
Explanation: Open gap voltage that occur at too large distances do not contribute to any material
removal.
10. When the electrode gap is too small or electrodes are in contact, how much material is
removed?
a) 10%
b) 20%
c) 30%
d) No material removed
Answer: d
Explanation: When electrodes come in contact with one another, short circuits occur and material
removed is not possible.
11. Which components mentioned below are affected due to arcs?
a) Work piece
b) Tool
Answer: c
Explanation: Arcs are believed to occur at same spots on electrode surfaces which damage both tool
and work piece.
12. Which of the following pulses contribute to the desired material removal in EDM?
a) Open circuit pulses
b) Short circuits
c) Arcs
d) Sparks
Answer: d
Explanation: The sparks are the one which contribute to the desired material removal in Electro
discharge machining.
EDM-Material removal rate
1. Metal is removed on which of the components in electro discharge machining?
a) Electrode tool
b) Work piece
Answer: c
Explanation: In Electro discharge machining, material is removed from both tool and work piece
2. On which of the following components, does the MRR depend?
a) Work piece
b) Electrode Tool
Answer: c
Explanation: Material removal rate not only depends on work piece material but also the tool
material
3. Of the following, which factors influence the material removal rate?
a) Pulse condition
b) Electrode polarity
c) Machining medium
Answer: d
Explanation: The factors such as pulse conditions, electrode polarity and machining medium also
affect the material removal rate.
4. In Electro discharge machining, materials with low melting point have which type of material
removal rate?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Electro discharge machining, materials having low melting point have high
material removal rates and vice-versa.
5. In Electro discharge machining, materials with low melting point have which type of surface
roughness?
a) Rough
b) smooth
c) Fine
Answer: a
Explanation: In Electro discharge machining, materials having low melting point have high
rougher surfaces and vice-versa.
6. What are the values of material removal rates in EDM?
a) 0.001 to 0.1 mm3/min
b) 0.1 to 400 mm3/min
c) 400 to 1000 mm3/min
d) 1000 to 5000 mm3/min
Answer: b
Explanation: In EDM, material removal rates range from 0.10 to 400 mm 3/min.
7. What happens to the material removal rate if the sparks are very less in EDM?
a) Decreases
b) Increases
Answer: a
Explanation: In EDM, if sparks generated are less then material removal rate decreases.
8. What is the relation between the melting point and the material removal rate?
a) Directly Proportional
b) Inversely proportional
c) Indirectly proportional
Answer: b
Explanation: In Electro discharge machining, material removal rate is inversely proportional to the
melting point.
9. What happens to the crater size if we increase the current keeping the pulse time constant?
a) Increase
b) Decrease
c) Decrease and increase
Answer: a
Explanation: By keeping pulse time constant and increasing current, crater size also increases.
10. What happens to the crater size if we decrease the pulse time keeping the current constant?
a) Increase
b) Decrease
c) Increase and decrease
Answer: b
Explanation: By decreasing pulse time and keeping current constant, crater size also decreases
EDM-Surface Integrity
1. On which of the following factors do the craters depend?
a) Physical properties
b) Mechanical properties
c) Composition of medium
Answer: d
Explanation: In EDM, craters depend on the physical and mechanical properties of material and
composition of medium.
2. The maximum depth of damaged layer is how many times that of average surface roughness?
a) 1.5 time
b) 2 times
c) 2.5 times
d) 3 times
Answer: c
Explanation: Depth of damaged layer is two and half times the average surface roughness value.
3. What happens to the surface roughness values if the MRR increases in EDM?
a) Increases
b) Decreases
c) Decrease and increase
Answer: a
Explanation: In EDM, the surface roughness values increases linearly with increase in the material
removal rates
4. State whether following statement is true or false regarding the surface roughness in EDM.
“In EDM, graphite electrodes produce smoother surfaces than metal ones.”
a) True
b) False
Answer: b
Explanation: In EDM, graphite electrodes produce rougher surfaces than that of the metal ones.
5. In Electro discharge machining, what happens to the surface finish if the pulse energy is
decreased?
a) Reduces
b) Decreases
c) Improves
Answer: c
Explanation: In Electro discharge machining, the surface finish improves if the pulse energy is
decreased.
6. Using of a mate electrode in Electro discharge machining _____ the surface roughness of
material.
a) Increases
b) Decreases
c) Enhances
Answer: b
Explanation: By using a mate electrode in Electro discharge machining, the surface roughness
values are decreased.
7. What happens to the surface roughness if oxygen gas is introduced in the gap?
a) Increases
b) Decreases
c) Decrease and then increase
Answer: b
Explanation: In EDM, surface roughness increases with the supply of oxygen gas in gaps.
8. By how much percent surface roughness is reduced if we use proper dielectric flow?
a) 25%
b) 50%
c) 75%
d) 100%
Answer: b
Explanation: In Electro discharge machining, if we use a proper dielectric fluid flow, surface
roughness is decreased by 50 percent.
9. What are the tolerance values obtained by machining using EDM?
a) ± 10 mm
b) ± 15 mm
c) ± 25 mm
d) ± 40 mm
Answer: c
Explanation: The tolerance values of ± 25 mm are obtained when we machine components using
EDM.
10. How much extra tolerances are achieved when we choose proper variables?
a) ± 5 mm
b) ± 10 mm
c) ± 15 mm
d) ± 20 mm
Answer: a
Explanation: Extra tolerances of ± 5 mm are obtained with proper choice of process variables
EDM-Heat Affected Zone (HAZ)
1. What are the values of temperatures obtained in Electro discharge machining?
a) 1000 to 2000 oC
b) 2000 to 4000 oC
c) 4000 to 8000 oC
d) 8000 to 12000 oC
Answer: d
Explanation: The temperature attained while machining in Electro discharge machining are from
8000 to 12000 oC
2. What is the value of thickness of recast layer obtained when power of 5 µJ is given?
a) 1 µm
b) 3 µm
c) 5 µm
d) 7 µm
Answer: a
Explanation: When a power of 5 µJ is given, recast layer thickness of 1 µm is obtained.
3. What are the values of thickness of recast layers in Electro discharge machining?
a) 0.001 to 0.025 µm
b) 0.01 to 0.25 µm
c) 1 to 25 µm
d) 10 to 250 µm
Answer: c
Explanation: In Electro discharge machining, the value of thickness of recast layers ranges from 1
to 25 µm.
4. In Electro discharge machining, some annealing of the work piece can be expected _____ the
machined surface.
a) On
b) Just below
c) Above
d) At bottom
Answer: b
Explanation: Annealing of some part of the work piece in EDM can be expected just below the
machined surface
5. The depth of the annealed surface is _____ to the amount of power used in machining operation.
a) Directly proportional
b) Inversely proportional
c) Exponential
Answer: a
Explanation: The depth of annealed surface in EDM is proportional to the amount of power used.
6. What are the values of thickness of annealed surface obtained while machining using EDM?
a) 1 to 25 µm
b) 50 to 200 µm
c) 200 to 500 µm
d) 500 to 1000 µm
Answer: b
Explanation: Values of annealed surface thickness range from 50 µm to 200 µm
7. In EDM, choosing electrodes that produce which type of machining reduces the annealing effect?
a) Stable
b) Unstable
c) Uneven
Answer: a
Explanation: In Electro discharge machining, choosing the electrodes which produce more stable
machining reduces the annealing effect.
8. What happens to the fatigue strength of alloys if altered surfaces are produced in Electro
discharge machining?
a) Increases
b) Reduces
c) Enhances
d) Improves
Answer: b
Explanation: The altered surface layers that are produced in Electro discharge machining,
significantly reduces the fatigue strength of alloys.
9. The altered layers formed during the process of EDM consists of which of the following?
a) Tempered layers
b) Heat affected zones
c) Intergranular precipitates
Answer: d
Explanation: Altered layers consists of recast layers, tempered layers, HAZs and intergranular
precipitates in EDM.
10. During roughing process through Electro discharge machining, what is the thickness of layer
formed?
a) <0.075 mm
b) <0.125 mm
c) <0.500 mm
d) <0.750 mm
Answer: b
Explanation: The thickness of layer obtained after machining is <0.127 mm in EDM.
11. During finishing process through Electro discharge machining, what is the value thickness of
layer formed?
a) <0.075 mm
b) <0.125 mm
c) <0.500 mm
d) <0.750 mm
Answer: a
Explanation: The thickness of layer obtained during EDM finishing is <0.075 mm.
12. Which of the following processes can be used for restoration of fatigue properties?
a) Low-stress grinding
b) Chemical machining
c) Reheat treatment
Answer: d
Explanation: For removal of altered layers processes such as low-stress grinding, chemical
machining, reheat treatment, metallurgical type coating and application of shot peening.
13. State whether following statement is true or false regarding the HAZ in EDM.
“In EDM, post treatment to recover fatigue strength is not recommended.”
a) True
b) False
Answer: b
Explanation: After machining using EDM, post treatment to restore the fatigue strength is
recommended.
EDM-Applications – 1
1. Which of the following shapes can be produced using Electro discharge machining?
a) Complex shapes
b) Simple shapes
Answer: c
Explanation: Electro discharge machining is used to machine complex shapes to a high degree of
accuracy
2. Which of the following materials can be machined using Electro discharge machining?
a) Heat resistant alloys
b) Super alloys
c) Carbides
Answer: d
Explanation: EDM is used to machine materials such as carbides, heat resistant and super alloys
which are difficult-to-machine materials.
3. Which of the following are the applications of Electro discharge machining?
a) Holes
b) Slots
c) Texturing
Answer: d
Explanation: Micromachining of holes, slots, dies, texturing, milling, surface modification and
mechanical pulsing are some typical applications of Electro discharge machining
4. State whether following statement is true or false regarding the applications of EDM.
“In advanced machining processes, the incorporation of EDM with CIM increased the length of
time for unit operation.”
a) True
b) False
Answer: b
Explanation: The incorporation of EDM in CIM reduced the length of time per unit operation
5. Which type of electrode is used for drilling in Electro discharge machining?
a) Flat electrode
b) Cuboidal electrode
c) Tubular electrode
d) Spherical electrode
Answer: c
Explanation: Tubular electrode is mostly preferred in Electro discharge machining, for drilling
purpose
6. The dielectric fluid is flushed in thorough which part of the electrode in drilling in EDM?
a) Interior hole
b) Side gaps
Answer: a
Explanation: EDM drilling uses a tubular electrode which flushes the dielectric thorough the
interior holes for removing debris.
7. Which type of holes can be produced through drilling using Electro discharge machining?
a) Irregular
b) Curved
c) Tapered
Answer: d
Explanation: Drilling of work piece using EDM produced holes which can be irregular, curved,
tapered as well as inclined holes.
8. What are the values of general feed rates used for drilling in EDM?
a) 0.1 mm/min
b) 0.3 m/min
c) 0.5 mm/min
d) 0.7 mm/min
Answer: a
Explanation: Usually a feed rate of 0.10 mm/min is used for drilling the work piece using Electro
discharge machining.
9. What are range of diameter values obtained by drilling using EDM?
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
d) 10 to 15 mm
Answer: b
Explanation: Diameter values while drilled using Electro discharge machining, ranges from 0.10 to
0.50 mm
10. What are the values of overcuts left behind after drilling of work piece?
a) 0.01 to 0.05 mm
b) 0.1 to 0.5 mm
c) 1 to 5 mm
d) 10 to 15 mm
Answer: a
Explanation: Overcut values from 0.01 to 0.05 mm are obtained after the drilling process in EDM.
11. Electro discharge sawing is an application of EDM which employs _____ as tool material.
a) Steel band
b) Disc
Answer: c
Explanation: Electro discharge sawing is an application of EDM which employs either steel band or
disc as tool.
12. When compared to the conventional abrasive sawing, how many times faster is the MRR?
a) Twice
b) Thrice
c) Four
d) Five
Answer: a
Explanation: Electro discharge sawing cuts the work piece material at the rates which are twice
that of conventional abrasive sawing method.
13. How much amount of burr is produce while machined using Electro discharge sawing?
a) 10%
b) 20%
c) 50%
d) No Burr
Answer: d
Explanation: The cuts produced in Electro discharge sawing have smaller kerf widths which hav no
burrs in it.
14. What are the values of finish obtained by machining work piece thorough Electro discharge
sawing?
a) 0.1 to 4 µm
b) 6.3 to 10 µm
c) 12.4 to 23 µm
d) 25.6 to 40 µm
Answer: b
Explanation: The finish obtained ranges from 6.3 to 10 µm when machined using Electro discharge
sawing.
15. What are the recast layer thickness values obtained in ED sawing?
a) 0.001 to 0.022 mm
b) 0.025 to 0.130 mm
c) 0.236 to 0.352 mm
d) 0.432 to 0.568 mm
Answer: b
Explanation: The recast layer thickness values obtained from ED sawing range from 0.025 to 0.13
mm
1. Which of the following electrodes are used for machining spherical surfaces in Electro discharge
machining?
a) Tubular electrodes
b) Flat electrodes
c) Cuboidal electrodes
Answer: a
Explanation: Simple tubular electrodes are used to machine convex and concave spherical surfaces.
2. What are the values of dimensional accuracy obtained while machining spherical surfaces?
a) ± 1 µm
b) ± 3 µm
c) ± 5 µm
d) ± 7 µm
Answer: a
Explanation: Dimensional accuracy of ± 1 µm is obtained while machining spherical surfaces using
EDM.
3. What are the surface roughness values obtained while machining spherical surfaces using Electro
discharge machining?
a) <0.1 µm
b) <0.3 µm
c) <0.5 µm
d) <0.7 µm
Answer: a
Explanation: The surface roughness values obtained while machining of spherical surfaces are <0.1
µm in Electro discharge machining.
4. Which motion of tool is used for machining spherical surfaces in Electro discharge machining?
a) Oscillatory
b) Vibratory
c) Rotary
Answer: c
Explanation: The rotary motion tool is used for machining spherical surfaces of conducting ceramic
materials in EDM.
5. Which type of electrodes are used for milling application in Electro discharge machining
process?
a) Tubular type electrodes
b) Cylindrical type electrodes
c) Flat type electrodes
d) Spherical type electrodes
Answer: b
Explanation: Standard cylindrical electrodes are used for milling application in EDM process
6. Which type of cavities can be machined using milling process by Electro discharge machining?
a) Complex cavities
b) Simple cavities
Answer: c
Explanation: Simple cavities and complex cavities are machined by successive NC sweeps of
electrode over the desired path.
7. The simple electrodes are rotated at which speed for milling of work pieces in Electro discharge
machining?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: Simple electrodes are rotated at high speeds for milling in Electro discharge
machining same as that of conventional milling.
8. What happens to the dielectric flushing while milling tool is rotated at a high speed in EDM?
a) Improved
b) Worsen
c) Reduced
Answer: a
Explanation: Milling by electro discharge machining enhances the dielectric flushing due to high
speed rotation of tool.
9. State whether following statement is true or false regarding the applications of EDM.
“In EDM, milling process can machine complex shapes with sharp corners.”
a) True
b) False
Answer: b
Explanation: EDM milling has a main limitation i.e.., it cannot machine complex shapes with sharp
tools because of rotating tool.
10. Which of the following are the steps included in the die sinking process of EDM?
a) CAD of electrode
b) Electrode manufacturing
c) Programming for die sinking
Answer: d
Explanation: Designing of electrode, then manufacturing, and programming of die sinking are the
steps to be followed for die sinking process in EDM.
11. Wire EDM is a special form of Electro discharge machining which contains _____ electrode.
a) Continuously moving
b) Periodically moving
c) Discontinuously moving
Answer: a
Explanation: Wire EDM is a special type of EDM which uses a continuously moving electrode for
removal of material.
12. Which path of the components in wire EDM determines the path to be machined?
a) Horizontal worktable movement
b) Vertical worktable movement
Answer: a
Explanation: Horizontal movement of the work table determines the path to be machined in Wire
Electro discharge machining.
13. Which of the following materials are machined using Wire Electro discharge machining?
a) Polycrystalline diamond
b) Cubic Boronitride
c) Matrix composites
Answer: d
Explanation: Polycrystalline diamond (PCD), cubic boron nitride (CBN) and other matrix
composites are the material than can be machined using wire EDM
14. How much amount of burr is produce when we use Wire Electro discharge machining for
machining of work pieces?
a) 10%
b) 20%
c) No burr
d) Small amount
Answer: c
Explanation: In Wire Electro discharge machining no burr is produced without any distortion
while machining work pieces.
15. Which of the following industries use wire EDM for different applications?
a) Chemical industry
b) Aerospace industry
c) Automobile industry
Answer: d
Explanation: Industries such as chemical, aerospace, automobile, nuclear etc.., use wire EDM for
wide variety of applications in their industries.
1. While machining insulating ceramic materials using EDM, where is the sheet metal placed?
a) Over material
b) Below material
c) Under material
Answer: a
Explanation: Sheet metal is placed over the material in machining of insulating materials using
EDM.
2. Sparks occur between which of the following components?
a) Work piece and sheet metal
b) Tool electrode and sheet metal
c) Work piece and electrode
Answer: b
Explanation: Sparks occur between sheet metal and tool electrode for macining insulating
ceramics.
3. Texturing is applied to the steel sheets at which stages of cold rolling?
a) Initial stages
b) Middle stages
c) Final stages
Answer: a
Explanation: At the final stages of cold rolling, texturing is applied to the steel sheets.
4. What is the full form of EDT in EDM processes?
a) Electro discharge Tinplating
b) Electro discharge Texturing
c) Electro discharge Tapping
d) Electro discharge Turing
Answer: b
Explanation: Electro Discharge Texturing is a variant of EDM which is the full form of EDT.
5. Which of the following are the process variables for texturing process in EDM?
a) Pulse current
b) Electrode polarity
c) Dielectric type
Answer: d
Explanation: Pulse current, polarity, dielectric, electrode material and roll rotation speed are some
process variables of texturing
6. What are the values of current amplitudes used in EDT?
a) 0.2 to 1 A
b) 2 to 10 A
c) 20 to 100 A
d) 40 to 200 A
Answer: b
Explanation: The values of current amplitudes in EDT range from 2 to 10 A
7. What are duration values of current amplitude in EDT?
a) 0.1 to 1 µs
b) 1 to 10 µs
c) 10 to 100 µs
d) 100 to 1000 µs
Answer: c
Explanation: Duration of current amplitudes used for EDT range from 10 to 100 µs.
8. What are the spindle rotation speeds used in EDT?
a) 1 to 4 rpm
b) 10 to 40 rpm
c) 20 to 60 rpm
d) 30 to 90 rpm
Answer: b
Explanation: Spindle rotation speeds for EDT process range from 10 to 40 rpm.
9. What are the values of diameter which are machined using Micro-EDM?
a) 0.001 to 0.01 mm
b) 0.01 to 0.1 mm
c) 0.1 to 1 mm
d) 1 to 10 mm
Answer: c
Explanation: Values of diameter in Micro-EDM range from 0.10 to 1.0 mm.
10. What happens to the machine capital cost in EDT when there is an increase in tool quantity?
a) Decreases
b) Increases
c) Remains same
Answer: b
Explanation: With increase in tools quantity machine cost increases but texturing cost reduces
11. What is the value of depth to diameter ratio in Micro-Electro discharge machining process?
a) 10:1
b) 5:2
c) 4:3
d) 2:1
Answer: a
Explanation: Value of the depth to diameter ratio in Micro-Electro discharge machining is about
10:1.
12. What are the values of depths that can be machined using Micro-EDM?
a) 1 mm
b) 10 mm
c) 100 mm
d) 1000 mm
Answer: c
Explanation: Micro-Electro discharge machining can machine up to a depth of 100 mm in the work
piece material.
13. What are the machining rates used in Micro-EDM process?
a) 0.1 to 2 mm/min
b) 1 to 20 mm/min
c) 10 to 200 mm/min
d) 100 to 500 mm/min
Answer: b
Explanation: Machining rates used in Micro-EDM process range from 1 to 20 mm/min
14. What are the values of hole diameters obtained using Wire electro discharge grinding?
a) 1 µm
b) 3 µm
c) 5 µm
d) 7 µm
Answer: c
Explanation: Values of hole diameters up to 5 µm can be obtained using Wire electro discharge
grinding process.
15. What are the feed rates used in WEDG process?
a) 1 to 5 mm/min
b) 5 to 10 mm/min
c) 10 to 15 mm/min
d) 15 to 20 mm/min
Answer: b
Explanation: Feed rate values in WEDG process range from 5 to 10 mm/min.
EDM-Process Control, Automation, Environmental Impact
1. Which of the following is a major difficulty in the Electro discharge machining process?
a) Proper sparks
b) Abnormal discharges
c) Optimum feed rates
d) No burr
Answer: b
Explanation: Avoidance of abnormal discharges has become a major difficulty in Electro discharge
machining process.
2. What has been done to the off time when there is a no-load voltage of electric discharge?
a) Increased
b) Decreased
c) Reduced
d) Remains same
Answer: a
Explanation: The off time of pulse is increased in order to avoid the abnormal electric discharges.
3. In a simple application which of the following parameters are inputs?
a) Pulse duration and current
b) Normal and abnormal pulses
Answer: a
Explanation: Inputs used are pulse duration and current in a simple application
4. In a simple application which of the following parameters are outputs?
a) Pulse duration and current
b) Normal and abnormal pulses
Answer: a
Explanation: Outputs used are normal and abnormal pulses in a simple application.
5. Which of the following are correlated with the machining conditions at output stage?
a) Machining depth
b) Surface roughness
c) Accuracy
Answer: d
Explanation: Machining depth, surface roughness, accuracy are correlated with the machining
conditions at the output stage.
6. How are EDM’s levels of integration when compared to conventional machining?
a) Slower rate
b) Faster rate
c) Same rate
Answer: a
Explanation: EDM’s levels of computer integration is at a slower rate when compared to
conventional machining processes.
7. Manufacturing of tool electrode undergoes which of the following processes?
a) Milling
b) Turning
c) Finishing
Answer: d
Explanation: The tool electrode manufacturing used in EDM has to undergo the basic production
processes such as milling, turning and finishing.
8. High temperatures produced in the working gap results in which of the following potentials?
a) Hazardous smoke
b) Toxic vapours
c) Aerosols
Answer: d
Explanation: The temperatures in the working gap increases leading to hazardous smoke, vapours
and aerosols.
9. Hydro carbons present in the dielectric fluid have impact on which of the body parts?
a) Eyes
b) Teeth
c) Skin
d) Nails
Answer: c
Explanation: Hydrocarbons present in dielectric fluids of EDM will have a negative impact on the
skin in our body.
10. What happens to the Electro discharge machining process under unfavourable working
conditions?
a) Will remain stable
b) Explosion may occur
c) Machining rate increases
d) Nothing happens
Answer: b
Explanation: Explosion occurs if Electro discharge machining is done under unfavourable process
variables and conditions.
11. Reduction in the electrical energy consumption will have impact on which aspects mentioned
below?
a) Environmental
b) Economic
Answer: c
Explanation: The reduction of electric energy consumption has economic as well as environmental
benefits.
UNIT-4
Laser Beam Machining-Introduction
1. What is the full form of LBM in advanced machining processes?
a) Laser Beam Manufacturing
b) Laser Beam Machining
c) Light Blast Manufacturing
d) Light Beam Machining
Answer: b
Explanation: The full form of LBM is Laser Beam Machining in the advanced machining processes.
2. LBM offers a good solution for which material properties below?
a) Thermal conductivity
b) Specific heat
c) Boiling temperature
Answer: d
Explanation: LBM offers good solution for material properties such as thermal conductivity,
specific heat, melting and boiling temperatures.
3. What is the abbreviation of Laser?
a) Light allowed simple emission of radiation
b) Light amplification by stimulated emission of radiation
c) Light amplified simultaneous emission of rays
d) Light amplified stimulated emanation of rays
Answer: b
Explanation: Full form of laser is Light Amplification by Stimulated emission of radiation.
4. Which of the following are the properties of a laser?
a) Highly collimated
b) Monochromatic
c) Coherent light beam
Answer: d
Explanation: Highly collimated, high monochromaticity and the coherence of the light beam are the
properties of a laser.
5. Laser beam machining uses which type of power sources for machining?
a) Very low power
b) Low power
c) Medium power
d) High power
Answer: d
Explanation: High power densities are used for the generation of laser and for machining in Laser
beam machining.
6. Which of the following are different types of lasers used in Laser beam machining?
a) Solid-state ion
b) Neutral gas
c) Semiconductor
Answer: d
Explanation: Laser such as solid-state ion, neutral gas, molecular, semiconductor etc.., can be used
in LBM.
7. Which types of lasers are used in Laser beam machining?
a) Continuous wave
b) Pulsed mode
Answer: c
Explanation: Laser may be in continuous wave (CW) or in Pulsed mode (PM) for machining in
LBM.
8. What is the wavelength value of Ruby laser used in Laser beam machining?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm
Answer: b
Explanation: The value of wave length of Ruby laser used in Laser Beam machining is 694 nm.
9. What is the wavelength value of Nd-YAG and Nd-glass lasers used in LBM?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm
Answer: d
Explanation: The value of wave length of Nd-YAG and Nd-glass lasers used in LBM is 1064 nm.
10. What is the wavelength value of neutral gas laser used in LBM?
a) 633 nm
b) 694 nm
c) 856 nm
d) 1064 nm
Answer: a
Explanation: The value of wave length of Neutral gas laser used in Laser beam machining is 633
nm.
11. What is the wavelength value of CO2 laser used in Laser beam machining?
a) 0.16 μm
b) 1.6 μm
c) 10.6 μm
d) 106 μm
Answer: c
Explanation: The value of wave length of CO2 laser used in Laser Beam machining is 10.6 μm.
12. What are the values of wavelengths of GaAs laser used in LBM?
a) 100 – 200 nm
b) 200 – 400 nm
c) 600 – 700 nm
d) 800 – 900 nm
Answer: d
Explanation: The wavelengths of GaAs laser used in LBM range from 800 – 900 nm
13. What are the values of wavelengths of Excimer laser used in LBM?
a) 100 – 200 nm
b) 200 – 500 nm
c) 600 – 700 nm
d) 800 – 900 nm
Answer: b
Explanation: The wavelengths of Excimer laser used in LBM range from 200 – 500 nm
14. What are the values of wavelengths of Argon laser used in LBM?
a) 120 – 230 nm
b) 220 – 310 nm
c) 330 – 530 nm
d) 760 – 940 nm
Answer: c
Explanation: The wavelengths of Argon laser used in LBM range from 330 – 530 nm.
LBM-Material Removal
1. What is the material removal mechanism of Laser beam machining process?
a) Melt and evaporate
b) Electro chemical corrosion
c) Mechanical erosion of materials
d) Electro chemical dissolution
Answer: a
Explanation: The material is removed by melting and evaporation in Laser Beam Machining
process
2. Physics of laser is very complex due to which of the reasons below?
a) Scattering loss
b) Reflection loss
Answer: c
Explanation: Physics of laser is very complex because of scattering and reflection losses
3. What happens when the heat is diffused into bulk material?
a) Phase change occurs
b) Melting occurs
c) Vaporization may take place
Answer: d
Explanation: The heat diffusion into bulk material causes phase change, melting or vaporization in
the materials.
4. State whether following statement is true of false regarding LBM.
“In LBM, high intensity laser beams are recommended for more material.”
a) True
b) False
Answer: b
Explanation: High intensity laser beams are not recommended since they form a plasma plume
near surface of material.
5. What happens to the process efficiency if plasma plumes are formed in LBM?
a) Increases
b) Enhances
c) Decreases
d) Improves
Answer: c
Explanation: In Laser beam machining, the process efficiency is reduced due the absorption and
scattering loses when plasma plumes are formed.
6. Machining of LBM takes place when power density is ____ than what is lost by conduction and
radiation.
a) Greater
b) Smaller
c) Lower
d) Same as
Answer: a
Explanation: Machining of laser takes place when power density is greater than what is lost by
conduction, convection and radiatio
7. Which of the following phenomenon take place before melting and evaporating in LBM?
a) Conduction
b) Reflection
c) Absorption
Answer: d
Explanation: Material in LBM is removed through several effects such as conduction, absorption,
reflection following melting and evaporation.
8. What happens to the material removal rate when reflectivity is higher?
a) Will decrease
b) Will increase
c) Will enhance
d) Remains same
Answer: a
Explanation: In LBM, as the reflectivity of the metals is increased the material removal rates of the
process are decreased.
9. Reflectivity of the materials depends on which of the following factors?
a) Wave length
b) Properties of material
c) Surface finish
Answer: d
Explanation: Reflectivity of the materials depends on wavelength, the properties of materials,
surface finish and temperature.
10. How much amount of incident radiation is reflected at lower power densities?
a) 10 percent
b) 20 percent
c) 50 percent
d) 90 percent
Answer: d
Explanation: Most of the metals reflect nearly 90 percent of incident radiation if the power
densities are low.
11. How are minimum energies required for plastics when compared to that required for metals?
a) Lower than
b) Higher than
c) Same as
Answer: a
Explanation: The minimum energies required for plastic are lower than that required for metals.
12. Which of the following has high machining speeds in Laser Beam Machining?
a) Metals
b) Non metals
c) Metal alloys
Answer: b
Explanation: Non metallic material machine at higher speeds than metallic ones due to higher
reflectivity in metallic materials.
LBM-Applications – 1
1. Which of the following are the applications of Laser Beam Machining?
a) Drilling
b) Cutting
c) Texturing
Answer: d
Explanation: Drilling, cutting and grooving, texturing and structuring, milling and dressing etc..,
are the applications of Laser beam machining process.
2. State whether following statement is true or false regarding the drilling using LBM.
“Compared to LBM, conventional machining is more accurate and efficient.”
a) True
b) False
Answer: b
Explanation: Conventional machining is less sufficient than Laser Beam machining because of their
material toughness.
3. Other non-conventional processes lay behind Laser beam machining in drilling process because
of which factors below?
a) High cost
b) Long lead times
c) Low machining speeds
Answer: d
Explanation: Other non-conventional processes need high costs for tools, long lead times, and low
machining speeds when compared to LBM.
4. Laser drilling has proven to be more efficient in which of the following factors?
a) Cost
b) Quality
c) Reliability
Answer: d
Explanation: Laser drilling has proven to be an efficient one in terms of cost, quality, and reliability
for large-scale production applications.
5. Which of the following are different laser drilling processes in Laser beam machining?
a) Direct drilling
b) Drill and ream
c) Trepanning
Answer: d
Explanation: Laser drilling can be performed by three methods that are – direct (percussion)
drilling, trepanning, drill and ream
6. The hole size in direct drilling depend up on which of the factors below?
a) Input power
b) Focusing adjustments
Answer: c
Explanation: The hole size in the direct drilling method of Laser drilling process, depend on input
power and focusing adjustments.
7. Which method mentioned below is used for drilling of large size holes?
a) Direct drilling
b) Drill and ream
c) Trepanning
Answer: c
Explanation: Trepanning method of laser drilling process is used for drilling large holes either by
rotating or moving the part.
8. What are the values of diameters obtained by using Laser drilling process?
a) 0.0001 – 0.001 mm
b) 0.001 – 0.01 mm
c) 0.005 – 1.25 mm
d) 1.5 – 10.5 mm
Answer: c
Explanation: Values of diameters obtained by using Laser drilling process range between 0.005 –
1.27 mm.
9. What is the value the maximum optimum depth that can be machined using Laser drilling
process?
a) 0.17 mm
b) 1.7 mm
c) 17.1 mm
d) 171.7 mm
Answer: b
Explanation: The maximum depth obtained when by using laser drilling is about 1.7 mm.
10. What are the values of entrance angles that vary in Laser drilling process?
a) 0.1 – 1 oC
b) 1 – 5 oC
c) 15 – 90 oC
d) 90 – 150 oC
Answer: c
Explanation: Values of the entrance angles in Laser drilling process range between 15 – 90 oC.
11. The taper obtained in Laser drilling process is how much of the hole diameter?
a) 1 – 5%
b) 5 – 20%
c) 20 – 50%
d) 50 – 90%
Answer: b
Explanation: Taper value obtained in Laser drilling process range between 5 – 20% of the hole
diameter.
12. What is the depth-to-diameter ratio obtained in drilling process using Laser beam machining?
a) 10:1
b) 20:1
c) 50:1
d) 80:1
Answer: c
Explanation: Value of the maximum depth-to-diameter ratio obtained in drilling using Laser beam
machining is 50:1.
13. What is the maximum value of drilling depth in trepanning method of laser drilling process?
a) 1.7 mm
b) 4.3 mm
c) 6.4 mm
d) 7.9 mm
Answer: c
Explanation: The depth increases when we use a trepanning method for laser drilling process and
that is about 6.40 mm.
14. What are the tolerance values obtained when we use laser drilling process?
a) 0.1 – 5%
b) 5 – 20%
c) 25 – 50%
d) 50 – 80%
Answer: b
Explanation: The tolerance values are will range between 5 – 20% of the diameters obtained in
Laser drilling process.
15. What is the value of minimum corner radius obtained by drilling in Laser beam machining?
a) 0.10 mm
b) 0.25 mm
c) 0.50 mm
d) 0.65 mm
Answer: b
Explanation: The value of the minimum corner radius obtained while drilling using LBM is about
0.25 mm.
1. Peak power should be increased in Laser drilling process by ______ pulse energy.
a) Increasing
b) Decreasing
c) Reducing
d) Constant
Answer: a
Explanation: Required peak power in the laser drilling process can be obtained by increasing the
pulse energy while keeping the pulse duration constant.
2. Drilling of holes with larger pulse duration causes which effect to the holes produced?
a) Enlarge holes
b) Reduce hole size
c) Decrease the depth
Answer: a
Explanation: Drilling the holes with larger pulse duration causes enlargement of the hole entrance
3. What are pulse duration values used for laser drilling?
a) 0.01 to 0.25 ms
b) 0.1 to 2.5 ms
c) 1 to 25 ms
d) 10 to 250 ms
Answer: b
Explanation: Value of the duration of the pulse range from 0.1 to 2.5 ms.
4. _____ pulse energy and _____ pulse duration are suitable for drilling.
a) Low, short
b) Low, long
c) High, short
d) High, long
Answer: c
Explanation: In LBM, high energy pulses and low pulse duration are more suitable for hole drilling
in aerospace materials.
5. Which of the following are the functions of assist gases?
a) Removal of molten material
b) Shield the lenses
c) Better efficiency
Answer: d
Explanation: Assist are used to remove the molten material, it also shield the lenses from expelled
material and they are also used for obtaining better process efficiencies.
6. Selection of assist gas depends on which of the following properties of work piece?
a) Material
b) Thickness
Answer: c
Explanation: The selection of different assist gases depends on the work piece material and its
thickness
7. Which of the following properties of material affect the quality of holes obtained?
a) Reflectivity
b) Absorption coefficient
c) Thermal conductivity
Answer: d
Explanation: Quality of holes depend on reflectivity, absorption coefficient, thermal conductivity,
density, specific heat, and latent heat of material.
8. What range of powers are used for cutting through steel?
a) 1 to 20 W
b) 20 to 100 W
c) 200 to 1000 W
d) 1 to 20 kW
Answer: c
Explanation: The power ranges from 200 W to 1 kW for cutting through steel.
9. Which gas jet assisted process is suitable for most of the metals?
a) Oxygen gas
b) Nitrogen gas
c) Helium gas
Answer: a
Explanation: Oxygen-jet assistance is used for most metals, as the gas liberates additional energy by
the exothermal chemical reactions.
10. What happens to the cutting speed with an increase in the work piece?
a) Increases
b) Decreases
c) Enhances
d) Remains same
Answer: b
Explanation: The cutting speed of the process of drilling decreases with an increase in the thickness
of the work piece material.
11. What is the full form of LBT in the processes of LBM?
a) Laser Beam Tempering
b) Laser Beam Templating
c) Laser Beam Texturing
d) Laser Beam Tinning
Answer: c
Explanation: Full form of LBT is Laser beam texturing which is an application of Laser beam
machining.
12. Depth and the crater size depends on which of them below?
a) Energy of beam
b) Dwell time of beam
Answer: c
Explanation: Depth and the crater size depend on the energy and the dwell time of beam.
13. Where are the textured surfaces used that are obtained in LBT?
a) Mould makings
b) Bearings
c) Printer roll manufacturing
Answer: d
Explanation: Textured surfaces obtained in LBT are widely used in mold making, bearings and
printer roll manufacturing.
14. The roll is _____ and the laser beam is moved ____ along the roll.
a) Stationary, axially
b) Stationary, perpendicularly
c) Rotated, axially
d) Rotated, perpendicularly
Answer: c
Explanation: In texturing process of LBT, the roll is rotated and laser is moved axially along the
roll.
15. State whether following statement is true regarding the texturing in LBT.
“In LBT, hardness of the material is a limitation to the process.”
a) True
b) False
Answer: b
Explanation: In Laser beam texturing, hardness of material is not a limitation to the process.
1. Which of the following are the other applications of LBM?
a) Dressing of grinding wheels
b) Scribing
c) Micromachining
Answer: d
Explanation: Dressing of grinding wheels, scribing, micromachining, controlled fracturing are
some of the other applications of Laser beam machining.
2. How the grooves in grinding wheels are produced using laser?
a) Evaporation
b) Damage of composite
Answer: c
Explanation: Grooves on the grinding wheels are produced due to evaporation and damage of the
composite wheel material.
3. Work piece tilting depends on which of the following factors?
a) Incident power
b) Beam speed
c) Groove direction
Answer: d
Explanation: Work piece tilting depends on the incident power, beam speed, groove direction, and
optical absorption coefficient of the material.
4. What are the values of thickness used is fine cutting process?
a) 0.01 to 0.05 mm
b) 0.05 to 0.1 mm
c) 0.5 to 15 mm
d) 15 to 50 mm
Answer: c
Explanation: The thickness of material used in fine cutting process vary from 0.5 to 16 mm.
5. The advantages of excimer laser are due to _____ laser wavelength and ____ pulse duration.
a) Short, short
b) Short, long
c) Long, short
d) Long, long
Answer: a
Explanation: The practical advantages of excimer laser are mainly due to short laser wavelength
and pulse duration.
6. Lasers of which type are used for modification of electronic components?
a) High power
b) Small spot size
c) Short pulse length
Answer: d
Explanation: Lasers of high power density, small spot size and short pulse length are useful devices
for modification of electronic components.
7. Material removal rates which are about mg/pulse produces which type of holes?
a) Shallow
b) Deep
c) Very deep
Answer: a
Explanation: In LBM, material removal at the rate of milligrams per pulse produces shallow holes
in the material.
8. Which of the following materials can be easily separated by laser scribing?
a) Silicon
b) Glass
c) Ceramic
Answer: d
Explanation: Brittle materials such as silicon, glass and ceramics may be effectively shaped or
separated by laser scribing.
9. Which type of holes can be drilled using Nd-YAG laser?
a) Small holes
b) Large holes
Answer: c
Explanation: Nd-YAG laser can be used for drilling small holes as well as large holes by trepanning
process.
10. Which type of laser can be used for direct drilling or percussion?
a) Ruby laser
b) Nd-YAG laser
Answer: c
Explanation: Both Ruby and Nd-YAG laser can be used for direct (percussion) drilling purpose.
11. Which of the following lasers is used for cutting thick materials in LBM?
a) CO2 + gas assisted
b) CO2 only
c) Nd-YAG
d) Ruby
Answer: a
Explanation: CO2 + gas assisted laser is used for cutting thicker materials in Laser beam machining
process
12. Which of the following lasers is used for slitting of thin metallic materials in LBM?
b) CO2 only
c) Nd-YAG
d) Ruby
Answer: c
Explanation: Nd-YAG laser is used for slitting of thin metallic materials in Laser beam machining
process
13. Which of the following lasers is used for slitting of thin plastic materials in LBM?
b) CO2 only
c) Nd-YAG
d) Ruby
Answer: b
Explanation: CO2 laser is used for slitting of thin plastic materials in Laser beam machining
process.
14. Which of the following lasers is used for organics and non-metallic materials in LBM?
b) Pulsed CO2
c) Nd-YAG
d) Ruby
Answer: b
Explanation: Pulsed CO2 laser is used for organics and non-metallic materials in Laser beam
machining process.
15. Which of the following lasers is used for ceramic materials in LBM?
a) Pulsed CO2
b) Nd-YAG
Answer: c
Explanation: Both pulsed CO2 and Nd-YAG lasers can be used for ceramic materials in LBM.
LBM-Advantages and Limitations
1. Which of the following is not an advantage of LBM?
a) Rapid machining
b) Low operating cost
c) High equipment cost
d) No tool wear
Answer: c
Explanation: Rapid machining, low operating cost and no tool wear are some of the advantages of
Laser beam machining.
2. Which of the following systems is used for locating the hole accurately for alignment?
a) Mechanical control system
b) Optical laser system
c) Measurement system
d) Alignment system
Answer: b
Explanation: Holes can be accurately located using optical laser system for alignment in Laser
beam machining.
3. Very _____ holes with a _____ aspect ratio can be produced using Laser beam machining.
a) Small, small
b) Small, large
c) Large, small
d) Large, large
Answer: b
Explanation: In Laser beam machining, very small holes with large aspect ratios can be produced.
4. How are the machining times in Laser beam machining?
a) Very slow machining times
b) Slow machining times
c) Moderate machining times
d) Fast machining times
Answer: d
Explanation: Machining is very much rapid and the setup times are economical in Laser beam
machining.
5. How is the operating cost of the machines used in Laser beam machining?
a) Low
b) Moderate
c) High
d) Very high
Answer: a
Explanation: The operating cost of the machines in LBM is low but the equipment cost itself is of
high cost.
6. State whether following statement is true or false regarding the advantages of LBM.
“In LBM, difficult to cut machine material can also be machined.”
a) True
b) False
Answer: a
Explanation: A large variety of hard and difficult to cut materials can be machined using LBM.
7. How much amount of tapers are occurred in Laser drilled holes?
a) No taper
b) Negligible amount of taper
c) Some amount
Answer: c
Explanation: Tapers are generally occurred in the direct drilling of holes using Laser beam
machining.
8. State whether following statement regarding Laser beam machining is true or false.
“In LBM, a blind hole of precise depth is easy to achieve.”
a) True
b) False
Answer: b
Explanation: A blind hole of precise is difficult to achieve in Laser beam machining.
9. What is the maximum depth up to which holes can be drilled using LBM?
a) 10 mm
b) 30 mm
c) 50 mm
d) 70 mm
Answer: c
Explanation: The thickness of the material that can be laser drilled is restricted to 50 mm.
10. What is to be done to the adherent material which are found at exit holes?
a) Shape them
b) Leave away
c) Remove them
d) Flatten them
Answer: c
Explanation: Adherent material found at the exit of holes has to be removed in LBM.
UNIT-5
Ion Beam Machining-Introduction, Material Removal Rate
1. What is the full form of IBM in the advanced machining processes?
a) Ion Beam Machining
b) Ion Beam Manufacturing
c) Ion Blast Machining
d) Ion Blast Manufacturing
Answer: a
Explanation: The full form of IBM is Ion Beam Machining in the advanced machining processes.
2. State whether following statement is true or false regarding IBM.
“In IBM, vacuum chamber is not necessary unlike that of Electron beam machining.”
a) True
b) False
Answer: b
Explanation: Ion beam machining also requires a vacuum chamber like that required for Electron
beam machining.
3. Which of the following are the components of Ion beam machining?
a) Vacuum chamber
b) Voltage source
c) Tungsten filament cathode
Answer: d
Explanation: Main components of IBM are vacuum chamber, voltage source, tungsten cathode
filament, plasma source of argon atoms and lens.
4. How does the ions strike the work piece in machining using IBM?
a) Oblique striking
b) Normal incident striking
Answer: c
Explanation: The ions may strike obliquely or at normal incidence in Ion Beam machining
5. Number of atoms yielded in oblique cutting is _____ normal incidence.
a) Greater than
b) Lesser than
c) Same as
Answer: a
Explanation: Number of atoms yielded for an incident atom in oblique cutting is greater than
normal incidence in IBM.
6. How much amount of energy is required for effective removal of atoms?
a) 1 to 5 eV
b) 5 to 10 eV
c) 10 to 15 eV
d) 15 to 20 eV
Answer: b
Explanation: About 5 to 10eV of energy is required for effective removal of atoms
7. Machining rates in IBM depend on which of the following factors?
b) Ions type
c) Incident angle
Answer: d
Explanation: The machining rates or yield depends on material to be machined, type of ions and
incident angle
8. What is the value of voltage required for machining in Ion beam machining?
a) 1 kV
b) 2 kV
c) 3 kV
d) 4 kV
Answer: a
Explanation: The value of voltage required for machining in Ion beam machining process is about 1
kV.
9. What are the values of current densities required in IBM?
a) 0.25 mA/cm2
b) 0.35 mA/cm2
c) 0.55 mA/cm2
d) 0.85 mA/cm2
Answer: d
Explanation: The value of current density of about 0.85 mA/cm2 is required for machining the work
piece materials in Ion beam machining.
10. What is the value of beam diameter that is obtained in IBM?
a) 1 cm
b) 3 cm
c) 5 cm
d) 7 cm
Answer: c
Explanation: The value of the beam diameter for machining the work piece material in Ion beam
machining is about 5 cm.
IBM-Surface effects and Applications
1. What are the dimensions that can machined on IBM?
a) 0.1 to 1 nm
b) 1 to 10 nm
c) 10 to 100 nm
d) 100 to 1000 nm
Answer: c
Explanation: Small dimensions as 10 to 100 nm can also be machined on Ion beam machining.
2. The slope of the side walls depends on which of the following factors?
a) Voltage supply
b) Angle of incidence
c) Flux
d) Current density
Answer: b
Explanation: The slope of the sidewalls of the surface and its surface finish depend on the angle of
incidence.
3. What are the accuracy levels that are obtained by using IBM?
a) ± 1.0%
b) ± 2.0%
c) ± 3.0%
d) ± 4.0%
Answer: a
Explanation: The accuracy levels that are obtained when machined the work piece using IBM is
about ± 1.0 %
4. What are the values of repeatability obtained in Ion beam machining?
a) ± 1.0%
b) ± 2.0%
c) ± 3.0%
d) ± 4.0%
Answer: a
Explanation: A repeatability of about ± 1 % are obtained while machining the work piece using Ion
beam machining process.
5. Surface texturing produces a cone-and-ridge like configuration on the order of which size?
a) 0.5 µm
b) 1 µm
c) 1.5 µm
d) 2 µm
Answer: b
Explanation: Surface texturing produces a cone-and-ridge-like configuration on the order of 1 µm
in size in Ion beam machining.
6. What is the value of surface finish obtained by using Ion beam machining?
a) <1 µm
b) <3 µm
c) <5 µm
d) <7 µm
Answer: a
Explanation: The smoothness of the surface finish obtained in Ion beam machining is less than 1
µm
7. Which of the following are the applications of IBM?
a) Smoothing laser mirrors
b) Polishing surfaces
c) Shaping surface
Answer: d
Explanation: Smoothing of laser mirrors, polishing and shaping of optical surfaces are some of the
applications of Ion beam machining
8. State whether following statement is true or false regarding the applications of IBM.
“In IBM, thickness can be reduced which affects the surface finish.”
a) True
b) False
Answer: b
Explanation: Reduction of thickness of thin films can be done without affecting the surface finish.
9. What are the thickness values of silicon samples that can be thinned?
a) 1 to 5 µm
b) 5 to 10 µm
c) 10 to 15 µm
d) 15 to 20 µm
Answer: c
Explanation: Thickness ranging from 10 to 15 µm can be thinned using IBM
10. Which of the following materials can be textured using the IBM process?
a) Copper
b) Nickel
c) Stainless steel
Answer: d
Explanation: Materials such as Copper, stainless steel, nickel, silver and gold can be used for
producing textured cones using IBM.
11. How much amount of energies are required for removal of oxide layers?
a) Small
b) Larger
c) Moderate
Answer: b
Explanation: Higher energies are needed for the removal of layer of oxides on the surfaces using
Ion Beam machining.
Plasma Beam Machining-Introduction And Machining system
1. What is the full form of PBM in the advanced machining processes?
a) Plasma Beam Manufacturing
b) Plasma Beam Machining
c) Plasma Blast Manufacturing
d) Plasma Blast Machining
Answer: b
Explanation: The full form of PBM in the advanced machining processes is Plasma Beam
Machining.
2. When the Plasma Beam machining process came into the industrial world?
a) 1920s
b) 1930s
c) 1950s
d) 1970s
Answer: c
Explanation: The Plasma Beam machining process came into the industrial world in the early
1950s as an alternative for the oxy-gas flame cutting process
3. PBM is the only process which works faster in ____ steel than _____ steel.
a) Stainless, mild
b) Mild, stainless
c) Remains same all
Answer: a
Explanation: PBM is the only fabrication process which works faster in stainless steels compared to
mild steels.
4. What is the temperature reached by cathode in order to produce plasma beam?
a) 12000 ºC
b) 18000 ºC
c) 28000 ºC
d) 40000 ºC
Answer: c
Explanation: The temperature reached by cathode to produce plasma arc is about 28000 ºC in
Plasma Beam Machining
5. What is the value of velocity of plasma jet in Plasma beam machining?
a) 100 m/sec
b) 300 m/sec
c) 400 m/sec
d) 500 m/sec
Answer: d
Explanation: The value of the velocity of the plasma jet in Plasma beam machining is about 500
m/sec.
6. What is the value of material removal rate in Plasma Beam Machining process?
a) 50 cm3/min
b) 100 cm3/min
c) 150 cm3/min
d) 200 cm3/min
Answer: c
Explanation: The values of the material removal rates in Plasma beam machining will be nearly
150 cm3/min.
7. What is the value of specific energy used in Plasma beam machining process?
a) 100 W/(cm3-min)
b) 200 W/(cm3-min)
c) 300 W/(cm3-min)
d) 400 W/(cm3-min)
Answer: a
Explanation: The value of the specific energy used in Plasma beam machining process is about 100
W/(cm3-min).
8. What is the value of the power used in PBM process?
a) 0.1 – 10 kW
b) 2 – 200 kW
c) 200 – 400 kW
d) 400 – 700 kW
Answer: b
Explanation: The value of the power used in Plasma beam machining range from 2 to 200 kW.
9. What is the value of the voltage used in PBM process?
a) 0.1 – 20 V
b) 30 – 250 V
c) 300 – 400 V
d) 500 – 600 V
Answer: b
Explanation: The value of voltage in the Plasma beam machining processes is about 30 – 250V
10. What is the value of the current used in PBM process?
a) Up to 200 A
b) Up to 400 A
c) Up to 600 A
d) Up to 800 A
Answer: c
Explanation: The value of the current used in PBM will be up to 600 A.
11. What is the value of machining speed used in PBM process?
a) 0.1 – 7.5 m/min
b) 8.5 – 10.5 m/min
c) 15.5 – 19.5 m/min
d) 20.5 – 25.5 m/min
Answer: a
Explanation: The value of machining speed is about 0.1 – 7.5 m/min in Plasma beam machining
process.
12. What is the maximum value of the thickness used in PBM process?
a) 100 mm
b) 200 mm
c) 300 mm
d) 400 mm
Answer: b
Explanation: The maximum value of the thickness used in the Plasma beam machining process is
about 200 mm.
13. Which of the following are the different shielded plasmas used in PBM?
a) Gas-shielded plasma
b) Water-shielded plasma
Answer: c
Explanation: Both gas-shielded plasma and water shielded plasma are used in Plasma beam
machining process.
PBM – MRR, Surface Quality, Applications, Advantages and Disadvantages
1. Material removal rates depend on which of the following factors?
b) Type of cutting
c) Shielding gases
Answer: d
Explanation: Material removal rates in PBM depend on work piece material, type of cutting and
the shielding gas.
2. A low power factors indicates _____ energy required and _____ removal rates.
a) Low, low
b) Low, high
c) High, low
d) High, high
Answer: b
Explanation: A low power factor in Plasma beam machining indicates low energy required and
high material removal rates.
3. What happens to the machining speed if the thickness of material is increased in PBM?
a) Decreases
b) Increases
c) Enhanced
d) Remains same
Answer: a
Explanation: Machining speed in Plasma beam machining reduces with an increase in the thickness
of the work piece material.
4. What is the machining speed required for machining of 12mm thick plate with 220 kW energy?
a) 1000 mm/min
b) 1500 mm/min
c) 2000 mm/min
d) 2500mm/min
Answer: d
Explanation: Machining speed required for cutting 12-mm thick plate with 220 kW power is about
2500 mm/min.
5. How much distortion is produced while machining using PBM?
a) 10%
b) 20%
c) 30%
d) No distortion is produced
Answer: d
Explanation: Heat does not penetrate more than few microns from the edges of the cuts produced
by machining using PBM that produce no distortion.
6. The cut edge of the material tends to be _____ than the base metal in PBM.
a) Smoother
b) Harder
c) Same as
Answer: b
Explanation: The cut edge of material in PBM tends to be harder than the base metal
7. What is the thickness of the HAZ in PBM?
a) 0.001 to 0.23 mm
b) 0.25 to 1.12 mm
c) 1.3 to 2.56 mm
d) 2.73 to 5.26 mm
Answer: b
Explanation: The thickness of the HAZ obtained in PBM range from 0.25 to 1.12 mm.
8. How much thickness of cracks may arise beyond HAZ due to rapid cooling?
a) 1.6 mm
b) 2.6 mm
c) 3.6 mm
d) 4.6 mm
Answer: a
Explanation: The cracks due to rapid cooling in PBM may extend beyond HAZ to a thickness of 1.6
mm.
9. What are the values of tolerances obtained by using PBM?
a) ± 0.6 mm
b) ± 1.6 mm
c) ± 2.6 mm
d) ± 3.6 mm
Answer: b
Explanation: The values of the tolerances obtained by using Plasma beam machining will be about
± 1.6 mm.
10. What is the maximum thickness of the walls of tube machined using plasma arc?
a) 10 mm
b) 30 mm
c) 50 mm
d) 70 mm
Answer: c
Explanation: The maximum thickness of the wall tubes that can be produced using PBM is about
50 mm
11. Which of the following are the advantages of PBM?
a) No chemical
b) Less harmful
c) Operates cleanly
Answer: d
Explanation: Main advantages of Plasma bema machining are no complicated chemical analysis,
less harmful and no harmful exposure and it operates cleanly
12. Which of the following chemicals are used in PBM?
a) Harmful chlorinated fluorocarbons
b) Acid cleaning chemicals
c) Dissolvable solvent chemicals
Answer: d
Explanation: Plasma beam machining uses no harmful chlorinated fluorocarbons, acid cleaning
chemicals or any dissolvable solvents.
13. How much amount of energy is required for machining using PBM?
a) Low
b) Moderate
c) High
d) Very high
Answer: a
Explanation: The cost for operating the jobs in Plasma beam machining is less and also less energy
is required for operating the machine in PBM
14. What are the disadvantages of PBM?
a) Large power supplies
b) Heat produced
c) Toxic fumes produced
Answer: d
Explanation: Large power for more thick materials, production of heat and toxic fumes are some of
the main disadvantages of PBM.
Magnetic Abrasive Finishing – Introduction
1. In this type of machining, machining forces are controlled by which of the following fields?
a) Magnetic field
b) Electric field
c) Radiative field
Answer: a
Explanation: In this machining, magnetic field controls all the major forces of machining
2. Which of the following type of tools, are required for magnetic field assisted polishing?
a) Rigid tools
b) Expensive tools
c) Magnetic tools
d) Ultra precession tools
Answer: c
Explanation: Magnetic field assisted polishing requires only magnetic machining elements, for the
purpose of machining.
3. Which of the following is not a magnetic field assisted machining process?
a) Electro-plating process
b) Magnetic abrasive finishing
c) Magnetic float polishing
Answer: a
Explanation: There are only two types of magnetic field assisted polishing: Magnetic abrasive
machining and Magnetic float polishing.
4. In the advanced machining processes, what is the full form of MAF?
a) Magnet Automated Finishing
b) Magnetic Abrasive Finishing
c) Magnet Assisted Floating
d) Magnetic Association for Floating
Answer: b
Explanation: In advanced machining processes, full form of MAF is Magnetic Abrasive Finishing.
5. In Magnetic abrasive finishing, which of the following particles do not contribute to the material
removal?
a) Abrasive particles
b) Magnetic particles
c) Non-magnetic particles
Answer: c
Explanation: Material is removed by colloidal dispersion of the magnetic particles in abrasive
particles.
6. Which of the following motions are opted, in order to carry on with the Magnetic abrasive
finishing?
a) Rotary motion
b) Oscillatory motion
c) Vibratory motion
Answer: d
Explanation: All the motions mentioned above, are needed for machining parts in MAF.
7. Magnetic Abrasive finishing is used for which of the following application/s?
a) Surface finishing
b) Cutting
c) Drilling
d) Boring
Answer: a
Explanation: Magnetic abrasive finishing is a process, which is opted for finishing of parts that are
already machined on the other machines.
8. Which is the place, where Magnetic field assisted polishing was invented?
a) The United States of America
b) The United Arab Emirates
c) Union of Soviet Socialist Republics
d) Japan
Answer: a
Explanation: Magnetic field assisted polishing was invented in the United States of America
9. Which of the following processes cannot be machined using Magnetic abrasive finishing?
a) Surface finishing
b) Surface polishing
c) Hole Drilling
Answer: c
Explanation: Holes drilling is one of the processes that cannot be done using Magnetic Abrasive
Finishing.
MAF – Machining System
1. Which of the following components, come under machining system of Magnetic Abrasive
finishing?
a) Rotatory spindle
b) Oscillating Magnets
c) Holding chuck
Answer: d
Explanation: The components, which are mentioned above come under machining system of
Magnetic Abrasive Finishing.
2. Which of the following materials can be machined using Magnetic Abrasive finishing?
a) Alloy steels
b) Ceramic materials
c) Iron materials
Answer: d
Explanation: Magnetic abrasive finishing is a process which is used for different materials,
magnetic and nonmagnetic
3. State whether following statement is true or false about Magnetic abrasive finishing.
“Vibratory motion that is axial, is introduced in the magnetic field by the oscillation of magnetic
poles.”
a) True
b) False
Answer: a
Explanation: Axially vibrating motion is required for machining in MAF.
4. Which of the following material/s is/are used to hold the abrasives, in MAF?
a) Nonmagnetic materials
b) Ferro magnetic materials
c) Ceramic materials
Answer: b
Explanation: Ferro magnetic materials hold the abrasives in order to remove material through
finishing.
5. What is the other name of ferromagnetic material used for holding the abrasives in MAF?
a) Magnetic abrasive conglomerate
b) Magnetic abrasive holder
c) Magnetic abrasive container
d) Magnetic abrasive ampule
Answer: a
Explanation: Ferro magnetic material is also called as Magnetic abrasive conglomerate.
6. What are the sizes magnetic abrasive conglomerates required in the machining system of MAF?
a) 1 – 10 microns
b) 20 – 50 microns
c) 50 – 100 microns
d) 100 – 200 microns
Answer: c
Explanation: The sizes of magnetic abrasive conglomerates range between 50 – 100 microns
7. What are the size ranges of the abrasives used in Magnetic abrasive finishing?
a) 0.1 to 1 microns
b) 1 to 10 microns
c) 10 to 100 microns
d) 100 to 1000 microns
Answer: b
Explanation: The size of abrasives used for finishing range between 1 to 10 microns.
8. Which of the following are commonly used magnetic materials in finishing process?
a) Iron and iron oxides
b) Nickel and cobalt
c) Steel and stainless steel
Answer: d
Explanation: All the materials mentioned above, are commonly used magnetic materials.
9. Which of the following are commonly used abrasive materials in finishing process of MAF?
a) Silicon Carbide
b) Aluminium Oxide
c) Cubic Boron Nitride
Answer: d
Explanation: All the materials mentioned above, are used as abrasives in Magnetic abrasive
finishing process.
10. Which of the following materials combine to form the magnetic abrasive brush in MAF?
a) Work piece
b) Magnetic and abrasive particles
c) Magnets
Answer: d
Explanation: All the materials mentioned above, combine to form the magnetic abrasive brush
11. In order to achieve uniform circulation of abrasives, the magnetic abrasives are undergone
through which of the following?
a) Stirring
b) Oscillation
c) Vibration
Answer: a
Explanation: To achieve uniform circulation of abrasives, the abrasives are undergone thorough
stirring.
12. Magnetic lines of force flows on which part of the work piece material?
a) Through the work piece
b) Over the surface
c) Above the work piece
d) Below the work piece
Answer: a
Explanation: Magnetic lines of force flow through the work piece.
MAF – Process parameters and MRR

1. What is the limit of the roller speed used in MAF?
a) Up to 0.5 m/s
b) Up to 1.3 m/s
c) Up to 2.6 m /s
d) Up to 3.3 m/s
Answer: b
Explanation: Roller speed used can be up to 1.3 m/s.
2. What is the value of magnetic field intensity used in MAF?
a) 0 – 0.53 Tesla
b) 0.6 – 0.70 Tesla
c) 0.70 – 0.90 Tesla
d) 0.90 – 1.1 Tesla
Answer: a
Explanation: Value of the magnetic field intensity used in MAF range between 0 – 0.53 Tesla.
3. What is the value of magnetic pressure used in Magnetic abrasive machining?
a) 0 – 30 kPa
b) 50 – 100 kPa
c) 100 – 200 kPa
d) 200 – 500 kPa
Answer: a
Explanation: In Magnetic abrasive finishing, value of magnetic pressure ranges between 0 – 30 kPa
4. What is the value of frequency used in Magnetic abrasive finishing process?
a) 1 – 10 Hz
b) 12 – 25 Hz
c) 30 – 50 Hz
d) 60 – 100 Hz
Answer: b
Explanation: In MAF process, value of the frequencies used range between 12 – 25 Hz.
5. In which direction, oscillatory motion of magnets are carried out?
a) Axial to work piece
b) Perpendicular to work piece
c) Inclined to work piece
Answer: a
Explanation: Axial oscillation motion of magnets takes with respect to work piece.
6. Which of the following surface defects are removed using Magnetic abrasive finishing?
a) Scratches
b) Hard spots
c) Lay lines and tool marks
Answer: d
Explanation: All the surface defects mentioned above, can be removed using Magnetic abrasive
finishing
7. What is the value of the limited depth to which form errors, tapers, looping can be corrected?
a) 10 microns
b) 20 microns
c) 30 microns
d) 40 microns
Answer: b
Explanation: Form errors, tapers, looping etc.., can be corrected up to a limited depth of 20
microns
8. State whether following statement is true or false about magnetic abrasive finishing.
“Increasing the magnetic flux density raises the rate of material removal in finishing.”
a) True
b) False
Answer: a
Explanation: In MAF, as the magnetic flux density increases, material removal rate increases.
9. On which of the following factors, does material removal rate depend on?
a) Magnetic flux density
b) Working clearance
Answer: d
Explanation: All the factors mentioned above, are responsible for change in material removal rate.
10. Which of the following factors does not affect the magnetic abrasive conglomerates in MAF?
a) Abrasive type
b) Abrasive size
d) Volume fraction
Answer: c
Explanation: In Magnetic abrasive finishing, work piece material has no effect on magnetic
abrasive conglomerates.
“Higher rates of material removal are obtained, with an increase in amplitude and frequency.”
a) True
b) False
Answer: a
Explanation: As the amplitude and frequency increases, rate of material removal increases.
MAF – Applications
1. Which of the following applications where MAF is used?
a) Finishing of inner surfaces
b) Polishing of balls and rollers
c) Chamfering and deburring of gears
Answer: d
Explanation: All the applications mentioned above can be fulfilled using MAF.
2. Diamond abrasives used for finishing operation results in which type of surface defects?
a) Deep pits
b) Surface scratches
c) Micro cracks
Answer: d
Explanation: All the defects mentioned above occur, when we use diamond abrasives for material
removal.
3. Which of the following conditions is/are not suitable for finishing of ceramic balls?
a) Controlled force
b) Large abrasive sizes
c) Small abrasive sizes
d) Less harder abrasives
Answer: b
Explanation: For a better finish, controlled force, fine and less hard abrasives are required
4. In MAF, ceramic balls and the bearing rollers are placed in between which components?
a) Abrasives and float
b) Drive shaft and float
c) Float and magnets
d) Magnets and abrasives
Answer: b
Explanation: Ceramic balls are placed in between drive shaft and float.
5. Polishing in Magnetic abrasive finishing is done, by which action of material removal?
b) Mechanical erosion
c) Chemical corrosion
d) Material vaporization
Answer: a
Explanation: Abrasives are used for the polishing and finishing operations of the parts, in Magnetic
abrasive finishing.
6. State whether following statement is true or false regarding MAF.
“As the forces exerted on the rollers are very small, polishing actions takes place very finely.”
a) True
b) False
Answer: a
Explanation: Since the forces exerted are very small, polishing is very fine.
7. For obtaining a better finish using Magnetic abrasive finishing, tubes are rotated at which
speeds?
a) Very low
b) Low
c) Medium
d) Very High
Answer: d
Explanation: To obtain a better finish in Magnetic abrasive finishing, tubes are rotated at very high
speeds
8. Which of the following is an advantage of MAF over Electrolytic finishing?
a) Disposing of electrolyte
b) Cost effective
c) More flexible
d) More accuracy
Answer: a
Explanation: In MAF, the problem of disposing electrolyte as in case of Electrolytic finishing is not
present.
“Mirror finishing, removed burrs with lowering the accuracy of the shape are achieved by MAF.”
a) True
b) False
Answer: b
Explanation: Removed burrs without lowering the accuracy are obtained using MAF.
10. What are the other applications where Magnetic abrasive finishing can be used?
a) Removal of oxide layers
b) Removal of protective coatings
c) Chamfering
Answer: d
Explanation: All the processes mentioned above can be done using Magnetic abrasive finishing.
Chemical Milling – Introduction
1. In advanced machining processes, what is the full form of CHM?
a) Chemical machining
b) Chemical manufacturing
c) Chemical milling
Answer: c
Explanation: In advanced machining processes, full form of CHM is Chemical milling
2. Of the following, which mechanism is used for the removal of material using Chemical milling
process?
a) Material Vaporization
b) Chemical dissolution
c) Mechanical erosion
d) Mechanical abrasion
Answer: b
Explanation: Chemical dissolution takes place in Chemical milling for the removing the material.
3. Which of the following solutions cannot be used as chemical reactive solution in CHM?
a) Acidic solution
b) Alkaline solution
c) Neutral solution
Answer: c
Explanation: Both acidic or alkane solutions are used for chemical dissolution in Chemical milling
4. By using Chemical machining, which of the following can be produced?
a) Pockets
b) Contours
c) Slots
Answer: d
Explanation: By the use of CHM, pockets, contours, slots and materials having high strength to
weight ratio can be machined
5. Pre cleaning is done on the work piece surface in order to achieve, which of the following factors?
a) To provide good adhesion
b) To provide clean surface
c) To assure absence of contaminants
Answer: d
Explanation: All the factors mentioned above, are achieved thorough pre-cleaning process
6. Special coatings applied on work piece materials in order to protect them from chemical reaction
are known as?
a) Maskants
b) Protective coverings
c) Protective varnishing
Answer: a
Explanation: The protective coatings on work pieces are known as Maskants.
7. Type of mask depends on which of the factor/s, given below?
a) Size of work piece
b) Number of parts
c) Desired resolution
Answer: d
Explanation: All the factors mentioned above, are required to select the type of mask.
8. During Chemical milling, depth of etch is controlled by which factor of immersion?
a) Time
b) Mask method
c) Mask area
Answer: a
Explanation: As the immersion time increases, depth of the etching increases.
9. What is the range of reagent temperatures used for chemical dissolution in CHM?
a) 12ᵒC to 35ᵒC
b) 37ᵒC to 85ᵒC
c) 90ᵒC to 101ᵒC
d) 121ᵒC to 142ᵒC
Answer: b
Explanation: The optimum temperature of reagent used should range between 37ᵒC to 85ᵒC
10. In Chemical milling, excessive flow of chemical reagent results in which of the following defects?
a) Channellings
b) Grooves
c) Ridges
Answer: d
Explanation: In Chemical milling, if the reagent flows excessively, then the defects mentioned above
may occur
11. State whether the following statement about Chemical milling is true or false.
“At higher temperatures, faster etching rates occur in Chemical milling.”
a) True
b) False
Answer: a
Explanation: As the temperature increases, reaction rate increases which in turn increases etching
rate in CHM.
12. Of the following, which ratio defines the etch factor?
a) Etching depth to undercut
b) Undercut to etching depth
c) Undercut to mask area
d) Mask area to undercut
Answer: b
Explanation: Etch factor is defined as the ratio of undercut to etching depth
13. CHM cannot eliminate which of the following defects?
a) Irregularities and dents
b) Surface scratches
c) Waviness
Answer: d
Explanation: CHM is not a finishing process as that of MAF, there are some sort of defects in
Chemical milling.
CHM – Tooling for CHM
1. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
Answer: d
Explanation: All the components mentioned above, are required to carry out Chemical milling
process.
2. State which of the following statement is true or false regarding Chemical milling.
“Maskants are generally used in CHM, to protect the work piece from the etching chemical agent.”
a) True
b) False
Answer: a
Explanation: In CHM, maskants are used to protect the work piece from chemical agents
3. Which of the following are the materials used for making maskants?
a) Synthetic materials
b) Rubber materials
c) Polymeric materials
Answer: d
Explanation: All the materials mentioned above, can be used for making maskants
4. What are the properties that a maskant used in Chemical milling should possess?
a) Be tough and adhere well
b) Scribe easily
c) Be inert to chemical reagent
Answer: d
Explanation: All the properties mentioned above, should be possessed by the maskants
5. Which of the following can be used to apply the maskants on work piece in Chemical milling?
a) Dipping or spraying
b) Rolling or electro coating
c) Adhesive tapes
Answer: d
Explanation: Maskants can be applied to work piece, by the above mentioned means.
6. State whether following statement is true or false regarding maskants.
“After etching, maskants should be removed easily and inexpensively.”
a) True
b) False
Answer: a
Explanation: After etching is done, maskants should be removed easily by inexpensive means.
7. In maskant application, photo-resist masks ensure which of the following advantages?
a) High accuracy
b) Ease of repetition
c) Ease of modification
Answer: d
Explanation: We will have the advantages which are mentioned above, if we use photo resist
masking.
8. Which of the tolerance values are obtained, when we use cut and peel mask method for maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: d
Explanation: Tolerance value of ± 0.179 mm, will be obtained, when we use cut and peel mask
method.
9. Which of the tolerance values are obtained, when we use silk-screen resist method for maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: c
Explanation: Tolerance value of ± 0.077 mm, will be obtained, when we use silk screen resist
method.
10. Which of the tolerance values are obtained, when we use photo resist method for maskant
application?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: a
Explanation: Tolerance value of ± 0.013 mm, will be obtained, when we use photo resist method.
11. Which of the following, are the main uses of etchants applied in Chemical milling?
a) Good surface finish
b) Uniform material removal
c) Control intergranular attack
Answer: d
Explanation: In CHM, etchants are used for the above mentioned factors.
12. State whether the following statement is true or false about etchants.
“Etchants are used for controlling H2 absorption in case of Ti alloys.”
a) True
b) False
Answer: a
Explanation: Etchants control the H2 absorption in Ti alloys
13. Scribing plates are used to define, which of the following parameters in Chemical milling?
a) Areas to be exposed
b) Volumes to be exposed
c) Areas not to be exposed
d) Volumes not to be exposed
Answer: a
Explanation: Scribing plates defines the areas that are to be exposed for removal of material.
14. Which of the following are can be used as guides for scribing process in Chemical milling?
a) Layout lines
b) Simple templates
c) Fibre glass
Answer: d
Explanation: All the guides mentioned above, can be used for scribing process.
15. Which of the following are the accessories, included in the tooling of Chemical milling?
a) Tanks and hooks
b) Brackets and racks
c) Fixtures
Answer: d
Explanation: The accessories mentioned above are included in the tooling of Chemical milling
CHM – Process Parameters and Material removal
1. Which of the following come under process parameters of Chemical milling?
a) Reagent type
b) Concentration
c) Operating temperature
Answer: d
Explanation: All the parameters mentioned above, are different process parameters required for
Chemical milling
2. State whether the following statement is true or false about Chemical milling.
“Maskants, applied on work pieces, are not responsible for CHM process.”
a) True
b) False
Answer: b
Explanation: Maskants are also responsible for process to take place in Chemical milling
3. To machine high quality parts using CHM, which of the following need not be necessary?
a) Heat treatment of work piece
b) Grain size of work piece
c) Frequency of vibrations
d) Range of work pieces
Answer: c
Explanation: To machine high qualities products vibrational frequency is not necessary in CHM
4. The process parameters will have direct impact on which of the following factors?
a) Etch factor
b) Machining rate
c) Production tolerance
Answer: d
Explanation: All the factors mentioned above, will have direct impact due to above process
parameters.
5. Thickness of the maskant coating ranges between which of the following values?
a) 0.0025 – 0.013 mm
b) 0.025 – 0.13 mm
c) 0.25 – 1.3 mm
d) 2.5 – 13 mm
Answer: b
Explanation: Maskant material coatings should have a thickness, which range between 0.025 – 0.13
mm
6. Which of the following, are the general materials used for maskant application?
a) Neoprene
b) Poly vinyl chloride
c) Polyethylene
Answer: d
Explanation: All the materials mentioned above, can be used as maskant materials
7. State whether following statement is true or false regarding MRR.
“The rate of material removal, does not depend on uniformity of the solution temperature.”
a) True
b) False
Answer: b
Explanation: Material removal rate also depends on uniformity of the solution temperature.
8. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
c) Frequency uniformity
d) Temperature uniformity
Answer: c
Explanation: Chemical milling is independent of frequency distribution
9. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In castings, as grain size increases, surface roughness increases.
10. Which of the following materials have the highest machining rate and best surface quality?
a) Rolled metal sheets
b) Thick metal plates
c) Polymeric plates
d) Plastic sheets
Answer: a
Explanation: Rolled metal sheets will have highest machining rate and surface quality in CHM
11. For softer materials, which type of etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
Answer: b
Explanation: In Chemical milling, softer materials need low etching rates
12. For harder materials, which of the following etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Chemical milling, harder materials need higher etching rates
13. State whether following statement is true or false about etching rates.
“As the etching rate increases, low surface roughness values occur.”
a) True
b) False
Answer: a
Explanation: High etching rates are results in low surface roughness values
CHM – Accuracy and Finish
1. Which of the following are necessary for best surface quality in Chemical milling?
a) Fine grain size and homogenous metallurgy
b) Coarse grain size and heterogeneous metallurgy
c) Fine grain size and heterogeneous metallurgy
d) Coarse grain size and homogenous metallurgy
Answer: a
Explanation: In CHM, for best surface quality, fine grain size and homogenous metallurgical work
piece must be required.
2. Which of the following are the factors, on which, surface finish depends?
a) Grain size
b) Heat treatment
c) Induced stresses
Answer: d
Explanation: All the factors mentioned above, are responsible for different qualities of surface
finish.
3. State whether following statement is true or false regarding surface finish in CHM.
“The surfaces, which are machined using Chemical milling, will have regular lay pattern.”
a) True
b) False
Answer: b
Explanation: In CHM, surfaces do not have regular lay pattern.
4. Which of the following defects cannot be altered or eliminated using CHM?
a) Waviness
b) Surface imperfections
c) Scratches
d) Dents
Answer: b
Explanation: Using CHM, surface imperfections cannot be eliminated
5. Which type of etching rate, mentioned below, produces low surface roughness?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Chemical milling, high etching rate produces low surface roughness values and
tolerances
6. The depth of cut tolerances increases when machining ____ depths at high machining rates?
a) Very smaller
b) Smaller
c) Medium
d) Larger
Answer: d
Explanation: In Chemical milling, tolerance increases when machining depth increases.
7. What is the value of etching rate, which can be achieved using Chemical milling?
a) 0.001 mm/min
b) 0.025 mm/min
c) 0.050 mm/min
d) 0.075 mm/min
Answer: c
Explanation: While we use Chemical milling etch rates of around 0.025 mm/min are achieved.
8. What are the tolerance values achieved in Chemical milling, which depend on work piece
material and depth of cut?
a) ± 10%
b) ± 20%
c) ± 30%
d) ± 40%
Answer: a
Explanation: Tolerances of ± 10% of cut width are achieved using CHM
9. For what value of machining depths, surface roughness sharply increases with depth of cut?
a) <100 µm
b) <200 µm
c) <300 µm
d) <400 µm
Answer: b
Explanation: For material depths <200 µm, surface roughness increases with depth of cut
10. What is the value of surface roughness, which is generally obtained using Chemical milling?
a) 0.01 – 0.08 µm
b) 0.1 – 0.8 µm
c) 1 – 8 µm
d) 10 – 80 µm
Answer: b
Explanation: Surface roughness obtained when general conditions are applied, is between 0.1 – 0.8
µm.
11. What is the value of surface roughness, when special conditions are applied?
a) 0.001 – 0.025 µm
b) 0.025 – 0.05 µm
c) 0.05 – 0.075 µm
d) 0.075 – 0.1 µm
Answer: b
Explanation: Surface roughness obtained when special conditions are applied, is between 0.025 –
0.05 µm.
12. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
b) Decarburized layer
c) Recast structure
Answer: d
Explanation: All the layers mentioned above, can be removed using Chemical milling
13. State whether following statement is true or false about Chemical milling.
“CHM can also affect mechanical properties, if they differ from surface layer to base metal.”
a) True
b) False
Answer: a
Explanation: Chemical milling can affect the mechanical properties of the machined parts, if they
are different at surface layers and base metal.
CHM – Advantages
1. What are the advantages when we use Chemical milling process?
a) Weight reduction
b) No burrs
c) No stresses
Answer: d
Explanation: All the advantages mentioned above, can be obtained using Chemical milling process
2. Weight reduction is possible, on which type of contours?
a) Very simple
b) Simple
c) Complex
Answer: c
Explanation: Weight reduction can be possible using Chemical milling, on complex contours,
compared to conventional machining.
3. Simultaneous material removal using Chemical milling, results in which of the following?
a) Improves productivity
b) Reduces wrapping
c) Minimizing part distortion
Answer: d
Explanation: All the factor mentioned above occur, when we use Chemical milling for material
removal
4. State whether following statement is true or false regarding the advantages of CHM.
“As there are no stresses induced, machining of delicate parts is possible.”
a) True
b) False
Answer: a
Explanation: In CHM, no stresses are induced, which makes machining of delicate parts easier.
5. Which type of taper can be achieved, using Chemical milling, on contours?
a) Discontinuous
b) Continuous
c) Periodic
Answer: b
Explanation: Using Chemical milling, a continuous taper, on contours can be achieved.
6. State whether following statement is true or false regarding the advantages?
“Capital cost of equipment, for machining large components, is relatively high.”
a) True
b) False
Answer: b
Explanation: Capital cost of equipment, is relatively low for machining large components.
7. Which of the following, are the other advantages of CHM?
a) Design changes
b) Less skilled operator
c) Minor tooling costs
Answer: d
Explanation: All of the advantages mentioned above, are obtained using CHM
8. Good surface quality and absence of burr eliminates which of the following?
a) Cutting operations
b) Finishing operations
c) Drilling operations
Answer: d
Explanation: Absence of burrs and good surface quality eliminates finishing operations in CHM.
9. State whether following statement is true or false about advantages.
“Extensive web areas and decorative finishes are not possible using CHM.”
a) True
b) False
Answer: b
Explanation: Decorative finishes are obtained when we use CHM.
10. What are the values of scrap rates obtained in Chemical milling?
a) 1%
b) 3%
c) 5%
d) 7%
Answer: b
Explanation: Low scrapes rates around 3% are obtained when we use Chemical milling process
CHM-Limitations
1. Which of the following are the limitations of Chemical milling process?
a) Disposal of chemicals
b) Limited scribing accuracy
c) Surface imperfections
Answer: d
Explanation: All the factors mentioned above, are the limitations of Chemical milling process.
2. What is the value of shallow cuts obtained on sheets and plates, when we use CHM?
a) 3.83 mm
b) 6.39 mm
c) 12.27 mm
d) 20.32 mm
Answer: c
Explanation: Very shallow depths of value 12.27 mm, are obtained when we use CHM.
3. Hand masking, scribing and stripping can be difficult, due to which of the following factors?
a) Time consuming
b) Repetitive
c) Tedious
Answer: d
Explanation: All the factors mentioned above, are main disadvantages for different processes in
CHM.
4. Which type of metallurgical surfaces are needed in Chemical milling process?
a) Homogenous
b) Heterogeneous
c) Mixture
Answer: a
Explanation: Metallurgic homogenous surfaces are needed for chemical milling to take place
5. Porous castings yield, which type of surfaces in Chemical milling process?
a) Uniform surfaces
b) Even surfaces
c) Uneven surfaces
Answer: c
Explanation: As there are porous castings, there would be pores on the surface which lead to
uneven surfaces.
6. State whether following statement regarding the limitations of CHM.
“Welded areas etch, at a rate that is same as base metal.”
a) True
b) False
Answer: b
Explanation: Welded areas etch at a different rate, when compared to that of base material
7. The absence of residual stresses on the chemically machined surfaces can produce _____
strength.
a) Favorable fatigue
b) Unfavorable fatigue
c) Constructive fatigue
Answer: b
Explanation: Absence of residual stresses produce unfavorable fatigue strength, unlike to the
processes that induce compressive residual stresses
8. Which of the following, indicate the accuracy of scribing by Chemical milling process?
a) Unlimited
b) Boundless
c) Infinite
Answer: d
Explanation: Scribing accuracy is limited in CHM process due to uneven surface finish
9. Which of the following are the other limitations of Chemical milling process?
a) Hydrogen pickup
b) Intergranular attack
c) Complex designs becoming expensive
Answer: d
Explanation: Hydrogen pick up, intergranular attack are some other limitations in Chemical
milling process
10. Which of the following is not a limitation of Chemical milling process?
a) Steep tapers not practical
b) Low scrap rates
c) Less scribing accuracy
d) Deep narrow cuts
Answer: b
Explanation: Low scrap rates are possible in Chemical milling, which is an advantage to the
process.
CHM-Applications
1. Which of the following metals can be machined using Chemical milling process?
a) Copper
b) Zinc
c) Steel
Answer: d
Explanation: Zinc, copper, lead and nickel are some of the metals that can be chemically machined.
2. What is the range, between which, the depth of cut in Chemical milling varies?
a) 0.13 – 0. 84 mm
b) 0.93 – 1.56 mm
c) 2.54 – 12.27 mm
d) 13.3 – 104.56 mm
Answer: c
Explanation: Practically, depth of cut in Chemical milling range between 2.54 – 12.27 mm.
3. Which of the following non-metallic materials can be machined using Chemical milling process?
a) Plastics
b) Glass
c) Ceramics
Answer: d
Explanation: Non-metallic materials such as glass, ceramics and plastics can also be machined
using Chemical milling process.
4. Which of the following is most popular application for weight reduction of aerospace
components?
a) Shallow cuts
b) Deep cuts
c) Very deep cuts
Answer: a
Explanation: Shallow cuts in large thin sheets helps in reducing the weight, especially in aerospace
industries.
5. How many designs can be machined from the same sheet in Chemical milling?
a) Only one
b) Two
c) Three
d) Multiple
Answer: d
Explanation: In Chemical milling, multiple designs can b machined on a large thin sheet depending
upon the size of the designs
6. CHM is used to thin out walls, web and ribs of parts that have been produces by which of the
following processes?
a) Forging
b) Casting
c) Sheet metal forming
Answer: d
Explanation: CHM is used for applications mentioned above of the parts, which are formed by
casting, forging and sheet metal forming processes.
7. Removal of sharp burrs come under which application of Chemical milling process?
a) Deep cuts
b) Multiple part machining
c) Improving surface characteristics
Answer: c
Explanation: Removal of sharp burrs improve the surface characteristics of parts machined using
Chemical milling.
8. Which of the following can be eliminated from the surfaces using Chemical milling?
a) Alpha case from Ti-forgings
b) Decarburized layer from low cast alloys
c) Recast layer from machined parts
Answer: d
Explanation: The defects on surfaces mentioned above, can be eliminated using Chemical milling
process.
9. CHM is used to remove the thin surfaces from forgings and castings, at which time of process?
a) After penetration inspection
b) Prior to penetration inspection
c) At the starting of process
d) At the end of process
Answer: b
Explanation: Removal of thin surfaces from forgings and casting takes place, prior to penetration
depth inspection.
10. State whether following statement is true or false regarding the applications of CHM.
“Removal of thin surfaces, prior to inspection, is done for detection of hidden defects.”
a) True
b) False
Answer: a
Explanation: Removal of thin surfaces is done to detect the hidden defects in surfaces using CHM.

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Objective Type Questions

1. The machining system of USM contains which of the following components?

Explanation: Slurry is pumped through nozzle at the rate of 25 L/min, L- litres.

Abrasive Jet Machining – Introduction and Machining system

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