KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY

(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

UNCONVENTIONAL MACHINING PROCESSES

Unit – I : INTRODUCTION

Part – A (2 Marks)

1. What is necessity for unconventional machining processes? (May 2010, AU)

2. How non-traditional machining processes are classified? (Dec, AU2008)

3. Enlist the requirement that demands the use of advanced machining process. (May, AU 2009)

4. Why unconventional mechanical machining process is not so effective on soft metals like
aluminum?

5. Name the important factors that should be considered during the selection of an
unconventional machining process for a given job. (May2011, AU)

6. Classify modern machining processes on the basis of the type of energy employed. (May
2011, AU)

7. List down the various mechanical energy based unconventional machining process.
(May2010, AU)

8. What are the advantages of unconventional Mach n g proc ss s? (May/June 2013)

9. List the unconventional Machining processes based on thermal ne gy? (May/June 2013)

10. State the needs of UCMP. (May/June 2014)

11. Write the importance of surface finishing in machining operations (May/June 2014)

12. What is the need of unconventional machining? (Dec2014)

13. List out the limitations of traditional machining processes (Dec2014)

14. Compare conventional and unconventional machining processes (May/June 2015)

15. State the need of unconventional machining (May/June 2015)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

Part-B (10 Marks)

1. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (Dec 2008, AU)

(ii) Compare and contrast the various unconventional machining process on the basis of type
of energy employed, material removal rate, transfer media and economical aspects.
(May2009, AU)

2. How will you analyses the applicability of different processes to different types of materials,
namely metals, alloys, and non metals? .(May2009, AU)
3. Explain the need for the development of Unconventional Machining Process by considering
any four simple cases of your own interest. (May 2011, 2010 AU)

4. (i) Classify Unconventional machining processes based on basic mechanism involved in the
process and medium for transfer of energies and type of energy required to shape materials.
(May 2011, 2010 AU)

(ii) Is Unconvention l machining process an alternate or complement to conventional

machining process? Justify. (May 2011, AU) (May/June 2014)

5. With a neat sketch, explain the need of U convent o al machining process (May/June 2013,
AU)

6. Classify Unconventional machining process.(May/June 2013, AU)

7. Compare the process capabilities and limitations of mechanical energy based, thermal
energy based and electrical energy based Unconventional machining process (May/June
2013, AU)

8. What are the basic factors upon which the unconventional manufacturing processes are
classified? Explain (May/June 2014)

9. Differentiate between conventional and unconventional machining process. Discuss the

reason for the development of unconventional machining methods (Dec2014)

10. Give the complete classification of unconventional machining processes with the distinctive
features of each of them. (Dec2014)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

11. Narrate the various aspects involved in the selection of an unconventional machining
process for a specific application (May/June 2015)

12. Enumerate the classification of unconventional machining processes (May/June 2015)

Unit – II: MECHANICAL ENERGY BASED PROCESSES

Part-A (2 Marks)

1. Define AJM?

2. What are the advantages of AJM process?

3. What are the applications of AJM? (Dec 2008, AU)

4. Write the Disadvantages of AJM process?

5. Give a summary of the bra ive of their application for different operation?

6. What are the Process parameters affecting the MRR in AJM? (May 2009, AU)

7. What are the different types abrasives used in AJM? (May 2010, AU)

8. Reuse of abrasives is not recommended in AJM. Why?

9. What are the properties of water jet machining about effect cutting act o ?

10. What are the advantages of WJC over conventional cutting methods?

11. What are the applications of Catcher in WJM? (May 2008, Dec 2006, AU)

12. What are the commonly used additives in WJM?

13. What is optical tracing system?

14. What is ultrasonic machining?

15. What are the advantages of USM?

16. What are the Disadvantages of USM?

17. What are the applications of USM? (Dec 2007, Dec 2004,AU)
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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

18. What is ultrasonic transducer?

19. What are the major elements of Ultrasonic machining equipment? (May 2009, Dec 2008,AU)

20. What are the magnetostrictive materials employed in USM?

21. What is the purpose of concentrator used in USM?

22. List the process parameters of Water Jet Machining? (May 2010, AU)

23. Why Abrasive Jet machining process is not recommended to machine ductile materials?
(May 2011)
24. Explain why there exists an optimum standoff distance (SOD) for maximum stock removal
rate in the case of Water Jet Machining (WJM) process (May2011, AU)

25. Write the operations principle of Water jet Machining Process? (May/June 2013)

26. What are the parameters influencing the MRR in Ultrasonic machining Process? (May/June
2013)

27. Write the material removal rate for ductile a d brittle material in AJM (May/June 2014)

28. What are the functions of dielectric fluid used in EDM (May/June 2014)

29. Why is abrasive jet machining not recommended for ductile mat rials? (Dec2014)

30. What are the characteristics of a good suspension media of the USM Process? (Dec2014)

31. What is the principle of USM? (May/June 2015)

32. List the application of WJM (May/June 2015)

Part – B (10 Marks)

1. (i) Explain the principle of AJM. Mention some of the specific applications. (6)

(ii) Discuss in detail about the AJM process variables that influence the rate of material
removal and accuracy in the machining. (10) (Dec2008, AU) (May/June 2014)

2. (i) Explain the method of AJM with help of schematic diagram. (10)

(ii) Mention the advantages and limitations of AJM. (6) (May 2010, AU)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

3. Explain the process parameters in WJM process. (16)

4. With neat sketch explain the process of AJM .List its application and limitations. (16)

5. (i) Explain the process parameters that influence WJM. (10)

(ii) Briefly discuss the application and limitation of WJM. (6)

6. Explain the USM machine setup an discuss various feed mechanisms (16) (May 2010, AU)

7. (i) Discuss the influence process parameters and applications of USM (10) (Dec2008, AU)

(ii) Give a note o the various types of transducers. (6) (May/June 2014)
8. Write the names of various elements of Abrasive Water Jet Machining (AWJC) and explain
them, in brief. (May 2011, AU)

9. Make a comparison between ultrasonic machining and conventional grinding (8) (May 2009)

10. Explain the general rrangement of an ultrasonic machining process. List down its
advantages, disadvant ges and applications (May 2011, AU)

11.With a neat sketch explain the abrasive jet machining process. (May 2013, AU)

12.Discuss about various process parameters involved AJM Process. (May 2013, AU)

13. Explain with a neat sketch, the working principle of ultrasonic Machining process. (May
2013, AU)

14. Discuss about various applications of USM process. (May 2013, AU)

15. Write the functions of slurry and oscillator in USM (May/June 2014)

16. Write the different types of abrasives used USM (May/June 2014)

17. Discuss in detail the principle and influence of process variables upon the material removal
in ultrasonic machining (Dec2014)

18. i) Discuss the effects of various process parameters of abrasive jet machining on accuracy
and MRR (8) (Dec2014)

ii) Write brief note on the special feature of the equipment used in water jet machining (8)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

19. i) Derive the equation for volumetric material removal rate involved in grain throwing
model of USM (12) (May/June 2015)

ii) Compare the types of nozzle designs employed in AWJM with neat sketches. (4)

20. Describe the process of abrasive jet machining along with the effect of all the process
parameters. (May/June 2015)

Unit-III: ELECTRICAL ENERGY BASED PROCESSES

Part - A (2 Marks)

1. Define electrical discharge machining?

2. Basic requirement of dielectric fluid used in EDM? (Dec2005, AU)

3. What the dielectric fluids commonly used in EDM?

4. What is the process par meter efficiency the MRR?

5. Explain electrode wear?

6. What are types of power supply circuits used in EDM? (D c2007, AU)

7. What are the design factors to be considered while selecting the mach ne tool?

8. What is the function of servo mechanism in EDM process? (May 2011, Dec2006, AU)

9. What are the feasible dielectric flushing techniques applicable in EDM Process? (May2011,
June 2007, AU)

10. Name any four electrode materials used in Electrical discharge Machining process?
(May/June 2013)

11. List out the applications of wire cut EDM process. (May/June 2013)

12. What are functions of dielectric fluid used in EDM? (Dec2007, AU) (May/June 2014)

13. Name some of the tool material used in EDM? (Dec2007, AU) (May/June 2014)

14. What is the function of servo mechanism in EDM process? (Dec2014)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

15. List out the importance of EDM process (Dec2014)

16. Sketch the relaxation circuit of EDM (May/June 2015)

17. State the principle of EDM (May/June 2015)

Part – B (10 Marks)

1. Explain the process of electrical discharge machining, its process parameters and
applications.(Dec2005,Dec2006, AU)

2. Describe the wire cut EDM equipment, its working, applications and advantages (Dec2005,
AU) (16)

3. (i) With the help of neat sketch, describe the EDM process. (12) (May2006, AU)

(ii) Explain briefly advantages of wire EDM process. (6). (May2006, AU)

4. (i) Explain the classific tion and characteristics of various spark erosion generators.(8)
(May2008, AU)

(ii) With help of neat sketch describe the mechanism of material removal in EDM. (8)

5. (i) Explain the working principle, eleme ts and characteristics of wire EDM. (10)

(ii) Explain how the stratified wire works. Also discuss about the recent developments in
wire EDM.

6. (i) Explain the different types of control circuits used in EDM process.(10) (May2011,AU)

(ii) What are the basic requirements of tool materials in EDM process? Name any four tool
materials. (6) (May 2011. AU)

7. Describe the working principle of wire cut EDM and list down its merits and demerits, Also
explain how the stratified wire works.(16) (May 2011, May2007,AU)

8. Explain the various operating principles involved in electrical Discharge Machining Process.
(May 2013, AU)

9. Discuss any four power circuits used for EDM process. (May 2013, AU)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

10. What is flushing in EDM process? Explain about various flushing techniques. (May 2013,
AU)
11. Explain with a neat sketch, the wire cut EDM process. (May 2013, AU)

12. Explain the following in EDM with neat sketch

i) Electrode feed control system,

ii) Factors to be considered for EDM machine tool selection (May/June 2014)

13. Explain the following on wire EDM Technology

i) Dielectric system

ii) De-ionized water

iii) Positioning system

iv) Wire drive system (May/June 2014)

14. i) Explain the working principle, elements and characteristics if wire EDM (8)

ii) Explain how the stratified wire works. Also discuss about the recent developments
in wire EDM (8) (Dec2014)

15. i) Explain the different types of control circuits used in EDM Process (10)

ii) What are the basic requirements of tool materials in EDM Process? Name any four
materials. (6) (Dec2014)

16. Explain the process of wire cut EDM with a neat sketch (16) (May/June 2015)

17. Write short notes on the following in the context of EDM (4+4+4+4 = 16)

i. Types of flushing

ii. Types of spark generators

iii. Types of electrode holders

iv. Properties of Dielectric. (May/June 2015)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

Unit-IV: CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES

Part-A (2 Marks)
1. Define ECM? What is principle of ECM? (Dec2004, AU)

2. What are the factors that influence oxidation in ECM?

3. What are the Applications of ECM? (Dec2006, AU)

4. What are the main functions of electrolytes in the ECM? (Dec2006, AU)

5. What are the properties are expected from the electrolysis used in the ECM? (Dec2007, AU)

6. What are the parameters that affect the MRR?

7. What are the advantages of ECM? (Dec2008, AU)

8. What are the limitations of ECM? (Dec2007,(May2007, AU)

9. What is self Adjusting Feature in ECM? (May2008, AU)

10. Which material is used to make the grindi g wheel?

11. What are the advantages of ECG?

12. What are the disadvantages of ECG?

13. What are the limitations of ECG?

14. What is the application of ECG?

15. Distinguish between electrochemical machining and electroplating?(May2009, AU)
16. Write the difference between Chemical Machining and Electro Chemical Machining. (May
2011, AU)

17. Why the life of Electro Chemical Grinding (ECG) wheel is much higher than conventional
grinding wheel?(May 2011, AU)

18. What are mask ants in chemical Machining process? (May/June 2013)

19. Write the formula for finding the MRR in ECM process? (May/June 2013)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

20. What are the functions of electrolysis in ECM? (May/June 2014)

21. What are parameters that affect the material removal rate in ECG? (May/June 2014)

22. Elaborate the functions of electrolyte in ECM (Dec2014, AU)

23. Give the application of electro chemical grinding (Dec2014, AU)

24. What is meant by Maskant? (May/June 2015)

25. Mention the applications of ECH(May/June 2015)

Part – B (10 Marks)

1. (i) Describe the chemistry involved in ECM process. (8) (Dec2005, AU)

(ii) Briefly discuss about the effect of high temperature and pressure of electrolyte on
the ECM process. (4)

(iii) Discuss about the economics of CM. (4)

2. (i) Describe the working principle and elements of chemical machining. What are the
factors on which the selection of a resist for use in chemical machining?(May 2007, AU)

(ii) What are the specific advantages of using chemical machining over electro chemical
machining? Give some of the practical applications of chemical mach n g process (6)

3. (i) Explain the principle of ECG with sketch. (8)

(ii) List out the advantage of EGC over conventional grinding. (4) (Dec2007, AU)

(iii) Mention the product applcation of ECG. (4)

4. Explain in detail the ECM process with neat sketch and also mention the advantages
and application. (16)(May2010, AU)

5. (i) Describe the process of electrochemical machining. (8)

(ii) Discuss about the electrochecmical honing and electrochecmical grinding (May 2010)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

6. With the help of a simple schematic diagram, explain the working of Electro chemical
machining process. Also show the block diagram of a typical power supply for an ECM
machine. (May 2011, AU)

7. (i) Why maskants are required in Chemical machining process? Explain. (6) (May 2011)

(ii) Describe the Electrochemical Horning process with a neat sketch. (10) (May 2011, AU)

8. Discuss the various process param,eters affecting the surface finish and MRR in chemical
machining process. (May 2013, AU)

9. List the advantages of chemical machining process. (May 2013, AU)

10. Explain with a neat sketch, ECM process. List its advantages, limitations and applications.
(May 2013, AU)

11. Compare the chemical machining with Electro chemical machining with respect to the
Process parameters (M y/June 2014)

12. Explain the following on ECM with suitable sketches

i) Correction of tool

ii) Cathode tool (May/June 2014)

13. i)Discuss the effect of high temperature and pressure of el ctrolyte on ECM Process (4)

ii) Briefly discuss Electro chemical deburring process (12) (D c2014)

14. i) Why maskants are required in chemical machining process? Explain (6)

ii) Describe the electro chemical horning process with a neat sketch (10) (Dec2014)

15. Explain the processes of chemical blanking and chemical milling with neat sketches (16)
(May/June 2015)

16. i) Describe the process of ECM with a neat sketch (8)

ii) Describe the process of ECG with a neat sketch (8) (May/June 2015)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

Unit V: THERMAL ENERGY BASED PROCESSES

Part –A (2Marks)
1. What are the advantages of laser beam machining? (May2010, AU)

2. What are the characteristics of Laser beam? (Dec 2006, AU)

3. What are the gases commonly used in LASER?

4. What is the function of water muffler in PAM? (May 2008, AU)

5. Define plasma.

6. What are the advantages of plasma arc welding?

7. What are the metals that can't be machined by plasma arc machining?

8. How the basic plasma does is generated?

9. Write the principle of P.A.M. State the two stages of PAM. (June 2009,Dec 2008, AU)

10. What are the parameters that govern the performance of PAM? (Dec2006, AU,2006)

11. What is the characteristic of the electron beam?

12. What are the main elements of the EBM equipment?

13. Write the advantages of EBM? Limitations of EBM. (Dec2004, AU)

14. Write the disadvantages of EBM?

15. Write any four application of EBM?

16. Why vacuum is needed in Electron Beam Machining (EBM) processes? (May 2011,)

17. What is the principle of Plasma Arc Machining process? (May/June 2013)

18. What are the techniques used for controlling beam in EBM process? (May/June 2013)

19. Compare EBM with LBM (May/June 2014)

20. Write the advantages of PAM (May/June 2014)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

21. Can you machine electrically non-conductive materials by PAM? Justify your answer.

(Dec2014, May 2011, May 2008, AU)

22. Contrast LBM and EBM (Dec2014)

23. Name the beam control techniques of EBM(May/June 2015)

24. What is meant by laser beam drilling? (May/June 2015)

Part – B (10 Marks)

1. Explain the process of LBM and PAM with a neat sketch. (16) (Dec2005, AU)

2. (i) Discuss the process parameters of EBM and their influence on machining quality. (8)

(ii) Explain the process capabilities of EBM and PAM. (8) (Dec2005, AU)

3. (i) Explain the principle of LBM with neat sketch (10)

(ii) List out the advantage and limitation of LBM process (6) (Dec2006, AU)

4. (i) Mention the application of EBM (4)

(ii) What is EBM? Sketch its set up and indicate its main parts and explain the principle of
operation. (12) (Dec2006, AU)

5. (i) Explain the principles and elements of EBM, also how the work table is protected from
getting damaged by electron beam. (8)(Dec2006, June2007,AU)

(ii) Discuss how the process variables influence MRR, HAZ and pattern generation.

6. Explain the production of laser beam and working principle of LBM Process. (May 2011)

7. Describe the Electron Beam Machining (EBM) process with a simple sketch and write about
its process parameters, advantages and applications.(May 2011, AU)

8. Sketch the electron Beam Gun and explain the functions of each part. (May 2013, AU)

9. (i) Explain the principle of PAM with sketch (10)

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 KOMMURI PRATAP REDDY INSTITUTE OF TECHNOLOGY
(COLLEGE OF ENGINEERING)
GHANPURAM(V), GHATKESAR (M), R R DIST -500088

(ii) List out the advantage and limitation of PAM process, parameters (16) (May 2014)

10. Explain with a neat sketch, the working principle of Laser beam Machining process. List its
applications. (May 2013, AU) (May/June 2014)

11. Explain the production of laser beam and working principle of LBM Process (Dec2014)

12. Explain the principle, construction and working of electron beam machining. Also how can
a complex shape be cut using EBM process (16) (Dec2014)

13. With a neat sketch, explain the process of LBM along with the effect of all the process
parameters (16) (May/June 2015)

14. i) Explain the principle of PAM with a neat sketch (8)

ii) Describe the process of EBM with a neat sketch (8) (May/June 2015)

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