Unconventional Machining Process (ME 054)

ULTRA SONI MA !ININ" 1. What is ultrasonic machining? USM is a mechanical material removal process in which the material is removed by repetitive impact of abrasive particles carried in liquid medium on to the work surface by a shaped tool !ibrating at ultrasonic frequency. ". What are the advantages of USM ? #dvantages 1. $igh accuracy and good surface finish ". %o heat generation during machining &. 'apability of drilling circular and non(circular holes in very hard materials. ). %o thermal effects on mechanical work piece. *. %on(conductive materials can be machined. &. What are the +isadvantages of USM? ,1- .ool wear ,"- /requent turning is required ,&- 0ow material removal rate. ,)- %ot economical for soft materials. ,*- %ot suitable for heavy stock removal. ). What are the applications of USM? ,1- #lmost all the material can be machined e1cept some soft materials. ,"- +iamond .ungsten .ungsten carbide and synthetic ruby can be successfully machined. ,&- USM can be used for drilling grinding profiling coining threading and even for welding. ,)- /or preparing wire drawing dies and tool room items. ,*- Used in 2ewellery for shaping 2ewels ,3- +rilling of screw threads and curved holes in brittle materials. *. What are the components of USM? ,1- Ultrasonic transducer ,"- 'oncentrator ,&- .ool ,)- #brasive slurry ,*- #brasive feed mechanism ,3- .ool feed mechanism 3. What is ultrasonic transducer? .he device used for converting any type of energy into ultrasonic wavers or vibration is called ultrasonic transducer.

4. Write short noted on pie5oelectric crystals? 6ie5oelectric crystals are used foe inducing ultrasonic vibrations since they posses the capability of changing their dimensions to the given electrical energy or in other sense they have the capability converting electrical energy into mechanical vibrations. 7. What is magnetostrictive effect? 8t is the one in which the material changes its dimension is in response to a magnetic field. 9. What are the magnetostrivtive materials employed in USM? %ickel 8ron : cobalt called as permendum iron : aluminum called as alter. 1;.What is the purpose of concentrator used in USM? .he main purpose of the concentrator is to increase the amplitude of the vibration obtained from the transducer. 11. What is abrasive Slurry? .he abrasive slurry is nothing but a mi1ture of abrasive grains and the carrier fluid generally water. 1". What are the different types of concentrators? ,1- 'onical .ype ,"- <1ponential type ,&- Stepped type. 1&. What are the characteristics of carrier fluid? ,1- =ood wetting characteristic ,"- $igh thermal conductivity ,&- %on(to1ic and non(corrosive. ,)- Should have low viscosity. 1). What are the elements of 'arrier /luid? ,1- #ct as a coolant. ,"- #ct as an acoustic bond between the work piece and the tool. ,&- $elps efficient transfer of energy. ,)- #ct as medium to carry the abrasive machined materials and worm abrasives 1*. What are the types of feed mechanisms used in USM? ,1- Spring type ,"- 'ounter : weight type ,&- Motor type ,)- 6neumatic and hydraulic type

A#RASI$E %ET MA !ININ" 1.+efine #>M? 8t is the material removal process where the material is removed or machined by the impact erosion of the high velocity stream of air or gas and abrasive mi1true which is focused on to the work piece. ". $ow does #>M differ from conventional sand blasting process? #>M differ from the conventional sand blasting process in the way that the abrasive is much finer and effective control over the process parameters and cutting. Used mainly to cut hard and brittle materials which are thin and sensitive to heat. &. What are the advantages of #>M process? ,1- 0ow capital cost ,"- 0ess vibration. ,&- =ood for difficult to reach area. ,)- %o heat is genera3ted in work piece. ,*- #bility to cut intricate holes of any hardness and brittleness in the material. ,3- #bility to cut fragile brittle hard and heat sensitive material without damage. ). What are the applications of #>M? ,1- /or abrading and frosting glass it is more economical than acid etching and grinding. ,"- /or doing hard suffuses safe removal of smears and ceramics o1ides on metals. ,&- ?esistive coating etc from ports to delicate to withstand normal scrapping ,)- +elicate cleaning such as removal of smudges from antique documents. ,*- Machining semiconductors such as germanium etc. *.Write the +isadvantages of #>M process? ,1- 0ow metal removal rate. ,"- +ue to stay cutting accuracy is affected. ,&- 6arivles is imbedding in work piece. ,)- #brasive powder cannot be reused. 3. =ive the formula for find the material remove rate for brittle metal? M?? @ 1.;) , M!&A" A 1A)$&A) -

4.=ive a summary of the abrasive of their application for different operation? #B?#SS8!< ,1- #luminium ,"- Silicon 'arbide. ,&- =lass $eads ,)- 'rushed glass #6608'#.8C% 'leaning 'utting and +eburrig /aster cleaning 'utting. Matt polishing cleaning 6eening and cleaning.

7.Write the formula for find the M?? for ductile materials? M?? @ ;.* , M!" A $9. What are the 6rocess parameters affecting the M?? in #>M? ,1- =as 6ressure. ,"- !elocity of 6articles. ,&- #brasive mass flow rate. ,)- Mi1ing ratio. ,*- %o55le .ip +istance. 1;. What are the disadvantages of using abrasives again and again? ,1- 'utting ability of the abrasives decreases after the large ,"- 'ontamination of wears materials clogging the no55le and the cutting unit orifices. 11. What are the different types of no55les heads used in #>M? ,1- ?ight angle head. ,"- Straight head. 1". Why o1ygen should not be used in #>M? C1ygen should not be used because of fire ha5ard problem. 1&. What are the different types abrasives used in #>M? #luminium o1ides silicon carbides 'rushed glass Sodium bicarbonate +olomite. 1). ?euse of abrasives is not recommended in #>M. why? ?euse of abrasives is not recommented since the cutting ability of abrasive decrease after the usage and also the contamination of wear materials clogging the no55le and the cutting unit orifice.

LASE #EAM MA !ININ" 1.What is 0aser? 8t is acronym of light amplification by stimulated emission of radiation. ".What is Maser? 0aser can be melt diamond when focused by lens system. .he energy density being of two order 1;; ;;; DWAcm". .his energy is due to atoms that have light energy level. When such an atom impinge with electromagnetic waves having resonant frequency. &.What are the characteristics of 0aser beam? 1.Material removal ".Material shaping &.Welding )..hermo kinetic change. ).What are the gases commonly used in 0#S<?? .he gases commonly used areE $e %e #rgon 'o" etc. *.What are the advantages of 0aser drilling? %o physical contact between work root pair hence there is no possibility if breakage or wear of root. 6recision location is ensured by focusing of the beam 0arge aspect ratio can be achieved. 3.What are the characteristics of 0aser used in 0aser machining? 1. 'an be focused to ma1imum intensity or to lower intensity as needed. ". 'an be moved rapidly on the work. &. ?emote cutting over long standoff distances. 4.What are the fundamentals of photons used in 0aser? 8n the 0aser the photons are in ground state at ; o' they are brought to the e1cited state by means of absorption of energy by temperature change collision etc. 7.What are the emission lines? .he atoms when this they are bringing down goes to the e1cited state by stimulated emission and emit photons within 1; nano secs. .hey have the same wavelength as the e1cited photons. 9.What is the Maser principle? .he energy density of laser with 1;; ;;;DwAcm ". .he atoms at this state will impinge with electrons waves having resonate frequency. .his is known as maser. 1;.What is population inversion?

8f the atoms in the e1cited state are greater than that of the ground state then it is known as population inversion. 11.$ow does 0aser melting works? 8t melts and vapori5es the unwanted material by means of narrow pulsed laser operating at " to 1;;pilsesAsec Because of this high accuracy is not possible to micro si5ed holes. 1".What is solid state 0aser? Solid state 0aser is the 0asers which consist of a hot nat which may be crystalline solidA glass doped with an active material whose atoms provide the lasing action. ELE TRON #EAM MA !ININ" 1- +efine <BM? 8t is the thermo(electrical material removal process on which the material is removed by the high velocity electron beam emitted from the tungsten filament made to impinge on the work surface where kinetic energy of the beam is transferred to the work piece material producing intense heat which makes the material to melt or vapori5e it locally. "- What is the characteristic of the electron beam? ,i$igh concentrated energy. ,ii+eep penetration into the metals. ,iii0ow distortion. ,iv#ny material either conductive or non(conductive can be processed. &- Write the application of electron beam? ( .hin film machining. ( Surface treatment. ( <ngraving metals and non(metals. ( 'utting of materials. )- What are the main elements of the <BM equipment? ,i<lectron =un. ,iiBeam focusing and deflecting units. ,iiiWork .able. ,iv!acuum chamber *- What is the function of magnetic lens used in <BM? 8t converges the beam into a narrow spot into the work piece. 3- What are the two types of <BM? ,i- .hermal type. ,ii- %on(thermal .ype.

4- <1plain the thermal type <BM? 8n this type the electron beam is used to heat the material up to the point where it is selectively vapori5ed. 7-<1plain %on(thermal type <BM? 8n this type the <BM produces a chemical reaction. 9- Write the advantage of <BM? ,i- $igh accuracy. ,ii- #ny type of material can be processed. ,iii%o mechanical or thermal distortion. ,iv- %o physical or metallurgical damage results. 1;- Write the disadvantages of <BM? ,i- $igh cost of equipment. ,ii- Skilled operator is required for operation. ,iii- 0imited to 1;mm material thickness. 11- Write any four application of <BM? ,i- Micro machining application on materials. ,ii- +rilling of apertures for electron microscope. ,iii- +rilling of holes in ruby and diamond crystal. 1"- Write the ?ichardson(+ushman <quation? >@#t" e( ,<WAD.> @ 'urrent +ensity # @constant ,1"; #mphereAcm"deg"D @Bolt5man 'onstant ,1.&11;("& >AD. @ #bsolute temperature ,DelvinW @work function ,!olts1&- Write general formula for focal length of a magnetic lens? fA,S F +- @ "*!A,%.-" ! @<lectron accelerating voltage %. @#mpere turns in the lens winding S @pole piece separation + @Bore diameter / @focal length 1)- Why vacuum is needed in <BM? 1- .o reduce corrosion "- .o get correct focusing

1*-What is the drawback of electron beam machining? Cne ma2or diameter of electron beam welding has been the requirement of high degree of vacuum essential or satisfactory operation of this process because of degassing.

ELE TRO !EMI AL MA !ININ"

1- +efine <'M? 8t is the controlled removal of metals by the anodic dissolution in an electrolytic medium where the work piece ,anode- and the tool ,cathode- are connected to the electrolytic circuit which is kept immersed in the electrolytic medium. "- Write the /aradayGs first law of electrolysis? .he amount of any material dissolved or deposited is proportional to the quantity of electrolyte passed. &- Write the /aradayGs second law of electrolysis? .he amount of different substances dissolved or deposited by the same quantity of electricity are proportional to their chemical equivalent weight. )- Write ChmGs law? 'urrent 8 @ !A? ! @ !oltage ? @ resistance *- What are the factors that influence o1idation in <'M? ,i- %ature of work piece. ,ii- .ype of electrolyte. ,iii- 'urrent density. ,iv- .emperature of the electrolyte. 3- What are the materials used to make the tool electrode? 'opper and copper alloys titanium aluminum brass bron5e carbon Monel and reinforced plastic. 4- What are the main functions of electrolysis in the <'M? i- /or completing the electric circuit between the tool and the work piece and to allow the reaction to proceed efficiently. ii- .o remove the products of machining from the cutting region. iii- .o carry away the heat generated during the chemical reaction. iv- .o avoid ion concentration at the work piece( tool gap. 7- What are the properties are e1pected from the electrolysis used in the <'M? i- $igh thermal conductivity. ii- 0ow viscosity and high specific heat. iii- Should chemically stable even at high temperature. iv- Should be non(to1ic and non(corrosive.

9- What are the electrolysis commonly used in <'M? 1* ("; H %acl in water sodium nitrate potassium nitrate sodium sulphate sodium chromate and potassium chloride. 1;- What are the results which is in improper selection of electrolyte in <'M? ,i- 0ow machining rate. ,ii- Cver cut and stray cutting. 11- What are the methods generally used to filter the electrolyte? ,i- ?unning the system until it is contaminated completely and replace it. ,ii- 'entrifugal separation. ,iii- Sedimentation. ,iv- Use of clarifiers. 1"- What are the characteristics of a good <'M tool? ,i- 8t should be a good conductor of electricity and heat. ,ii- <asily machinable. ,iii- ?esistant to chemical reaction. ,iv- 8t offers resistance to the high electrolyte pressure. 1&- What are the problems that occur while improperly selecting the electrolyte flow? 'avitations stagnation and vorte1 formation. 1)- What are the parameters that affect the M??? ,i- /eed rate. ,ii- !oltage. ,iii- 'oncentration of the electrolyte. ,iv- .emperature of the electrolyte. ,v- 'urrent density. ,vi- !elocity of the electrolyte. 1*- $ow the current density affect the M??? 'urrent density is controlled not only by the amount of current but also by the si5e of the gap between the tool and the work piece. # small gap results in high current density which in turn produce more material removal. 13- What are the advantages of <'M? ,i<'M is simple fast and versatile method. ,iiSurface finish can be e1tremely good. ,iii/airly good tolerance can be obtained. 14- What are the limitations of <'M? ,i0arge power consumption and the related problems. ,iiSharp internal corners cannot be answered. ,iiiMaintenances of higher tolerances require complicated contours.

17- What are the applications of <'M? <'M is used for sinking profiling and contouring multi hole drilling trepanning broaching honing steel mill applications surfacing sawing contour machining of hand to hand machine materials. ELE TO !EMI AL "RIN&IN" 1.+efine <'=. <'= is the material removal process in which the material is removed by the combination of <lectro( 'hemical decomposition as in <'M process and abrasive due to grinding. ". Which material is used to make the grinding wheel? Metal bonded diamond ,or- #luminum o1ide. &.What are the important functions of abrasive particles used in <'=? 8t acts as insulator to maintain a small gap between the wheel and work piece. .hey are electrolysis products from the working area. .o cut chips if the wheel should contact the work piece particularly in the event of power failure. ).What are the advantages of <'=? i- %o thermal damage to work piece. ii- Wheel wear is negligible. iii- %o distortion of the work piece. *.What are the disadvantages of <'=? $igh capital costs because of the special wheel tool. 6ower consumption is quite high. <lectrolyte is corrosive. 3.What are the limitations of <'=? 1..he work material must be conductive. ".%it suitable for machining soft material. &.?equire dressing tools for preparing the wheels. 4.What is the application of <'=? 1.6recision grinding of hand metals economically. ".=rinding 'arbide cutting tools inserts. &..o grind end mill cutters more precisely.

PLASMA AR 'EL&IN" 1. +efine plasma 6lasma is defined as the gas which has been heated to a sufficiently high temperature to become ioni5ed. ". What are the advantages of plasma arc welding? a. <1othermic o1idation takes place. b. +' power supply &. What are the metals that canIt be machined by plasma arc machining? a. Stainless steel b. Monel c. Super alloys ). What is the basic heating phenomenon that takes place in plasma arc welding? .he basic heating phenomenon that takes place at the work piece is a combination of anode heating due to direct electron bombardment recombination of molecules on the work piece. *. $ow does the basic plasma is generated. .he basic plasma is generated by sub2ecting a stream of gas to the electron bombardment of the electric arc. 3. $ow the initial ioni5ation is accomplished in plasma arc machining. # high voltage arc established between electrode and no55le accomplishes initial ioni5ation. 4. Why does gas formed in plasma do in 6.#.M? .his gas stabili5es the arc and prevents it from diverging. 7. $ow another source of heating achieved in 6.#.M 8t is desirable to achieve a third source of heating by in2ecting o1ygen into work area to take advantage of e1othermic o1idation. 9. Write the principle of 6.#.M Cnce the material has been raised to molten point the high velocity gas stream blows the material away. 1;.Write the circuitry details in 6#M. F ve terminal connected to work piece and (( ve terminal connected to electrode. 1". Which type of power supply is used in 6.#.M +' power supply is used.

1&. Which part is constricted by plasma? %o55le duct is constricted by plasma. 'ATER %ET MA !ININ" 1. What are the properties of water 2et machining about effect cutting action? $igh pressure high velocity 2et of water. ". What are the types of units and its purpose used in water 2et cutting system? a. 6ump (( to generate high pressure b. Machining unit(( to actually cut the material with the 2et no55le. c. /iltration unit (( to clear the water after use. &. Why we are using the diamond no55le. a. $igh hardness metal b. Working life is more compared to other 2ewel no55le such as ruby or sapphire. ). Why do you select proper cutting fluid in W>M? 'utting fluids mainly depends on the operation requirement quality of finish cutting speed and overall cost *. +oes there is any environmental effects while using the water 2et machining. .here is no environmental pollution such as dust suspended in the air because the water 2et drains any dust simultaneously When cutting. 3. What are the advantages of W>' over conventional cutting methods? a. Because of point cutting W>' is able to cut materials almost any pattern. b. Material loss due to machining is minimum. c. W>' will not burn surfaces or produces a heat an affected 5one. d. %o environmental pollution. 4. What are the applications of W>M? J#ero space J#utomobile J6aper pulp industries 7. What are the commonly used additives in W>M? 1.'rly cerine ".6olyethylene o1ide &.0ong chain polymers

9. What is optical tracing system? 8t employs an optical scanner that traces a line drawing and produces electronic signals that control the K(rays. ELE TRI AL &IS !AR"E MA !ININ" 1. +efine electrical discharge machining? <+M is the controlled erosion of electrically conductive materials by the initiation of rapid and repetitive spark discharge between the electrode tool to the cathode and work to anode separated by a small gap kept in the path of dielectric medium. .his process also called spark erosion. ". What are functions of dielectric fluid used in <+M? 1.8t acts as an insulating medium ".8t cools the spark region and helps in keeping the tool and work piece cool. &.8t maintains a constant resistance across the gap. ).8t carries away the eroded metal particles. &. Basic requirement of dielectric fluid used in <+M? 1.Stable +ielectric strength. ".8t should have optimum viscosity. &.8t should have high flash point. ).8t should be chemically stable at high temperature and neutral. *.8t should not emit to1ic vapours. ). What the dielectric fluids commonly used in <+M? 1.6etrolium based hydrocarbon fluids. ".6arafin white sprite transformer oil. &.Derosine mineral oil. ).<thylene glycol and water miscible compounds. *. What are the prime requirements of tool material in <+M? 1.8t should be electrically conductive. ".8t should have good mach inability. &. 8t should have low erosion rate. ). 8t should have low electrical resistance. 3. %ame some of the tool material used in <+M? 1.'opper brass alloys of Linc Mtin. ".$ardend plain carbon steel &.copper tungsten silver tungsten tungsten ).'opper graphite and graphite.

4. What is the process parameter efficiency the M??? 1.<nergy discharge ".'apacitance. &.Si5e of work piece. ).MAc tool design 7. Write the formula for finding the energy discharge in <+M? W@,1A"- K <8. W(discharge energy 8('urrent .(time <(voltage 9. What is the effect of capacitance in <+M? 8ncreasing the capacitance causes the discharge to increase and increase both the peak current and discharge time. 1;. $ow do you increase the inductance of the circuit? # piece of iron or steel be allowed to lodge between the leads it would increase the inductance of the circuit and reduce the MA' rate. 11. +efine WA. ratio? 8t is the ratio of volume of work removed to the volume of tool removed. 1". What is cycle time? 8t is the sum of discharge time and waiting time. 1&. +efine over cut? 8t is the discharge by which the machined hole in the work piece e1ceeds the electrode si5e and is determined by both the initiating voltage and the discharge energy. 1). +efine ?ehardening? While metal heated to a temperature above the critical and then rapidly cooled by the flowing dielectric fluid the metal is rehardened. 1*. What is recast metal? Metal heated to a temperature above the melting point and which is not displaced by the action of the spark discharge resoldifies as recast metal. 13. <1plain electrode wear? # crater is produced in the electrode which is likewise dependent on the electrode material and the energy of the discharge.

14. What are types of power supply circuits used in <+M? 1.?('circuit. ".?otary impulse generator. &.'ontrolled pulse ,vacuum tube-. ).Cscillator controlled pulse. *..ransister pulsed circuit. 17. What are the design factors to be considered while selecting the machine tool? 1.%umber of parts to be produced. ".#ccuracy. &.Si5e of work piece. ).Si5e of electrode. *.+epth of cavity. 19. Why the servo controlled system is needed in <+M? <+M requires that a constant arc gap be maintained between the electrode and the work piece to obtain ma1imum machining efficiency. .herefore <+M tool in corporate some form of servo control. ";. +efine wear ratio? Wear ratio@Work piece material removedA0oss of electrode material.