ME8073 UNCONVENTIONAL MACHINING PROCESSES

UNIT- 1 MECHANICAL ENERGY BASED PROCESSES

MULTIPLE CHOICE QUESTIONS

ONE MARK MCQ

1. In Abrasive jet machining, work piece material removed by which of the following
means
a) Vaporization
b) Electro plating
c) Mechanical abrasion
d) Corrosion

2. In AJM, which of the following materials are used as abrasive grains

a) Al2O3
b) SiC
c) Glass beads
d) All of the mentioned

3. . Which type of materials can be machined using abrasive jet machining

a) Glass
b) Ceramics
c) Hard materials
d) All of the mentioned

4. Which of the following gas, should never be used as the carrier of abrasives
a) Nitrogen
b) Carbon dioxide
c) Oxygen
d) Air
5. What is the frequency of mixing chamber, consisting of gas and abrasives
a) 10000 Hz
b) 3 Hz
c) 50 Hz
d) 700 Hz

6. What are the processes where Abrasive jet machining can be used
a) Cleaning
b) Cutting
c) Deburring
d) All of the mentioned

7. In Abrasive water jet cutting, How are the abrasives fed into the water jet stream
(a) Suspension
(b) Injection
(c) All of the mentioned
(d) None of the mentioned

8. What is the use of filtration system in the machining system of AWJM

a) To deliver colloidal solution
b) Prevent damage to the pipelines
c) To feed abrasives
d) None of the mentioned filtration

9. 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,
d) None of the mentioned
10. 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
d) All of the mentioned

11. For compressing water which is used in WJM process

(a) Compressor
(b) Intensifier
(c) Condensor
(d) Float valve

12. Which type of carrier medium is used in AJM

(a) Grease
(b) Oil
(c) Air
(d) Water

13. AJM is used for machining

(a) Cubic boron nitride
(b) Low carbon steels
(c) Tungsten carbide
(d) Silicon carbide

14. AWJM can be used to cut

(a) Metals
(b) Non-metals
(c) Both a & b
15. For longer life of nozzle in AWJM, what type of material is used
(a) Tungsten carbide
(b) Sapphire
(c) Boron carbide
(d) Stainless steel

16. Abrasive water jet machining and abrasive jet machining are two different names for
the same process:
(a) True
(b) False

17. Abrasive jet machining is best suited to machine

(a) Brittle materials
(b) Heat sensitive materials
(c) Soft materials
(d) All the above

18. The minimum velocity required for machining a glass by SiC particles (size: 25
microns) in AJM is to be
(a) 70 m/s
(b) 100 m/s
(c) 150 m/s
(d) 175 m/s

19. Abrasive particles used for grinding or finishing of metals are characterized by
(a) High ductility
(b) High hardness
(c) High electrical conductivity
(d) All the above
20. The range of speed of abrasive gas jet in case of AJM is close to (in m/s)
(a) 1-10
(b) 10-50
(c) 100-150
(d) 150-300

21. The main advantage of Abrasive jet machining over other methods is
(a) AJM is capable of high MRR
(b) AJM Setup is inexpensive and simple
(c) Width of grovee in the range of 20-50nm
(d) All the above

22. In Abrasive jet machining the size of abrasive particles ranges from
(a) 1-2 nm
(b) 2 – 3mm
(c) 10 -50 microns
(d) Non of the above

23. In USM the power capacity of piezoelectric transducer is

(a) 750 W
(b) 230 W
(c) 900 W
(d) 550 W

24. USM works very well when the workpiece hardness is greater than
(a) HRC 30
(b) HRC 40
(c) HRC 60
(d) HRC 90
25. What type of tool material is used in USM
(a) Brittle
(b) Ductile
(c) Tough

26. The dominant mechanism involved in USM of all materials is

(a) Two body abrasive
(b) Three body abrasive
(c) Direct hammering

27. The main drawback of the magnetostrictive transducer is

(a) Low efficiency
(b) Low loss
(c) Need for extra power
(d) Need for continuous heating
(e) Elastic deformation

28. The vibrating frequency used for the tool in Ultrasonic machining is of the order of
(a) 10,000 oscillations per second
(b) 20,000 oscillations per second
(c) 35,000 oscillations per second
(d) 45,000 oscillations per second

29. In Ultrasonic machining, the material is removed by

(a) anodic dissolution
(b) thermal melting
(c) abrasive action
(d) electrochemical oxidation
30. Abrasive carrying liquid for the abrasive slurry in USM is
(a) Water
(b) Heavy paraffin oil
(c) Silicone oil
(d) Glycerol

31. In USM process, which type of material can be easily machined?

(a) Glass
(b) Stainless steel
(c) Brass
(d) Mild steel

32. In Ultrasonic machining, the tool

(a) moves in transverse direction
(b) moves in longitudinal direction
(c) vibrates in transverse direction
(d) vibrates in longitudinal direction

33. Ultrasonic machines, used in material removal processes, require ultrasonic

transducers. The transducers works on different working principles. One of the working
principles of such ultrasonic transducers is based on
(a) Piezo-electric effect
(b) Magnetostrictive effect
(c) All of the above

34. In AJM Process, pressure of gas that is to be supplied, for carrying the abrasives
particles ranges from
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
35. In machining system of AJM, which of the following controls the relative motion
between work piece and nozzle?
a) Cam drives
b) Pantographs
c) Trace mechanisms
d) All of the mentioned

36. Masks, which are used to confine the jet stream location on work piece are made of,
which type of materials?
a) Copper
b) Glass
c) Rubber
d) All of the mentioned

37. The covering which is used to protect the non-machining area of workpiece is said
to be
a) Mask
b) Catcher
c) Laminate
d) Cover

38. Which of the following is a conventional process of machining?

a) Electro chemical machining
b) Electron beam machining
c) Drilling
d) Abrasive jet machining

39. 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
d) None of the mentioned
40. 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

41. The following device is used for converting electrical impulses into mechanical
vibration in USM
a) Transducer
b) oscillator
c) tank
d) pump

42. In which of the following processes, a nozzle is used?

i.Plasma arc machining
ii. Ultrasonic Machining
iii. Abrasive jet machining
a) i & ii
b) ii & iii
c) i & iii
d) i, ii & iii

43. 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

44. In AJMM, water at _____ MPa is pumped.

a) 100-150
b) 200-400
c) 200-300
d) 370-500

45. To stop the dispersion of the water jet in the atmosphere ______ is used.
a) sodium Carboxylate
b) acrylonitrile
c) long chain polymers
d) silica gel

46. Which of the following materials, is not machined using abrasive water jet machining?
a) Diamond
b) Concrete
c) Stone – Granite
d) Reinforced plastics

47. For which of the following operations, abrasive water jet machining is not used?
a) Peening
b) Pocket milling
c) Mass immunization
d) Cutting hard materials

48. The Ultrasonic machines have a power rating of

a) 0.2 - 2.5 kW
b) 0.9 – 3.5 kW
c) 0.5 – 1.5 kW
d) 1.0– 5.5 kw

49. Horn used in USM is used to

a) Connect tool and transducer
b) Connect transducer to the power supply
c) Connect the slurry unit to the tool
d) None of the above

50. The tool material selected in USM process should posses

a) Good acoustic property
b) Good brittle property
c) Poor malleability
d) Poor acoustic property

TWO MARK MCQ

1. In AJM the term ‘mass ratio’ is defined as

(a) Volume flow rate of abrasive/volume flow rate of carrier gas
(b) Mass flow rate of abrasive/Mass flow rate of abrasive
(c) Mass flow rate of abrasive/Mass flow rate of carrier gas along with abrasive
(d) Volume flow rate of Carrier gas/volume flow rate of abrasive

2. What is the function of nozzle in AWJM?

(a) Maintaining the concentration of abrasives in water
(b) Mixing abrasive and water particles
(c) forming high velocity water jet
(d) Both (b) and (c)

3. In AWJM, increase in Stand-off-distance results in

(a) Higher depth of cut
(b) Lower depth of cut
(c) Not significant effect is observed

4. In abrasive water jet machining, the abrasive particles are added to the water stream
(a) After it exits the nozzle
(b) Before it enters the pumping unit
(c) Just before it enters the nozzle
(d) While it is in the nozzle

5. In AWJM, the mixing efficiency of both water and abrasives were maximum in
(a) Single jet side feed nozzle
(b) Multiple jets central feed nozzle
(c) Both

6. With an increase in abrasive particle size in AJM

(a) MRR as well as surface finish increase
(b) MRR decreases but surface finish increases
(c) MRR increases but surface finish decreases.

7. When a thick material is to be cut by WJC, one should prefer

(a) very powerful jet and single pass cutting
(b) Multipass cutting
(c) low stand-off-distance
(d) all of these

8. Which one is/are part of gas propulsion system used in Abrasive jet machining
(a) Air compressor
(b) Control valve
(c) Drier
(d) All the above

9. The number of impacts on the workpiece by abrasive grits in each cycle is dependent
upon the
(a) Diameter of the crater
(b) Type of the abrasive grit
(c) Depth of crater
(d) Diameter of the abrasive grit

10. Increase in abrasive grain size in USM results in

(a) Lower MRR, Higher surface finish
(b) Higher MRR, Lower surface finish
(c) Higher MRR, Higher surface finish
(d) Lower MRR, Lower surface finish
11. In USM the abrasive hardness should be
(a) More than workpiece hardness
(b) Less than workpiece hardness
(c) Equal to the workpiece hardness
(d) Hardness may be of any value

12. In Ultrasonic machining, the function of transducer is to

(a) convert mechanical energy into heat
(b) convert electrical energy into heat
(c) convert electrical energy into mechanical vibrations
(d) convert mechanical energy into electrical energy

13. The relationship between amplitude of tool oscillation to material removal rate
(MRR) is,
(a) Decreases and then increases
(b) Increases and then decreases
(c) Increasing
(d) Decreasing

14. The machining system of USM contains which of the following components?
a) Magnetostrictor
b) Concentrator
c) Tools and slurry
d) All of the mentioned

15. Which is softer material in USM?

a) Tool
b) Work piece
c) Tool & Work piece
d) None of the mentioned
16. Which of the following material is not generally machined by USM
a) Copper
b) Glass
c) Silicon
d) Germanium

17. What type of tool should be used to reduce power requirement during large diameter
hole drilling in USM
(a) Trepanning tool
(b) Annular cutters
(c) Drilling tool
(d) Hypodermic need

18. Metal removal rate in abrasive jet machining increases with

a) Increase in abrasive flow rate but decreases beyond a limit
b) Decrease in abrasive flow rate
c) Decrease in grain size of abrasives
d) Increase in nozzle diameter

19. Metal removal rate in abrasive jet machining increases with

a) Increase in gas pressure
b) Decrease in abrasive flow rate
c) Decrease in gas pressure
d) None of the mentioned

20. In the machining system of AWJM, which one accelerates the abrasives to remove
material?
a) Water only
b) Water jet stream
c) Feeder
d) None of the mentioned
21. What will be the mass flow rate of water, when the water pressure is 4000 bar, being
issued from an orifice of diameter 0.3 mm, assuming all related coefficients to be 1?
a) 1 kg/min
b) 2.89 kg/min
c) 3.26 kg/min
d) 3.79 kg/min

Answer:
Explanation: Mass flow rate of water, mw = ρ*Q where, ρ = density of water and Q =
discharge of the jet.
mw = ρ*Q
= ρ*(π*d2/4)*v
= 1000*3.14*0.00032*894
= 3.79 kg/min
Where, d= diameter of the orifice.

22. The role of additives in abrasive water jet machining is to

a) Improve coherence
b) Improve viscosity
c) Improve density
d) Water treatement

23. The decrease in Stand-off distance

a) Decreases kerf width
b) Increases taper
c) Decreases accuracy
d) Increases nozzle wear

24. Increase in stand-off distance results in

a) Increases taper
b) Improves MRR
c) Decreases dimensional error
d) Decrease in kerf width

25. The tool size used in USM process is equal to

a) Hole size - 2*(Size of the abrasives)
b) Hole size - 3*(Size of the abrasives)
c) Hole size - 4*(Size of the abrasives)
d) Equal to the size of the hole
 ME8073 UNCONVENTIONAL MACHINING PROCESSES

UNIT-2 THERMAL AND ELECTRICAL ENERGY BASED PROCESSES

MULTIPLE CHOICE QUESTIONS

ONE MARK MCQ

1. During EDM, the temperature developed at the point of spark is of the order of
a) 2,000°C
b) 6,000°C
c) 10,000°C
d) 14,000°C
2. The EDM process is (select the correct answer)
a) Burr free
b) Not useful for hard metals
c) Direct contact machining
d) Capable of producing sharp corners
3. Location of spark generated during EDM is
a) Random
b) Governed by dielectric strength
c) Governed by the surface finish of the tool and work piece both
d) None of these
4. Feed to the electrode during EDM is given
a) to maintain constant velocity of dielectric flow in the IEG
b) to maintain constant IEG
c) to maintain constant current density
d) none of these
5. If the flushing system of the EDM machine is inefficient the machining cycle time will
be
a) Longer
b) Shorter
c) No effect
d) No definite trend

6. Preferable tool properties in EDM are

a) High electrical conductivity, low thermal conductivity
b) Low electrical conductivity, High thermal conductivity
c) High electrical conductivity, high thermal conductivity
d) Low electrical conductivity, low thermal conductivity
7. In EDM the metal removal is carried out by
a) Fracture of work material due to impact of grains
b) Electrolysis
c) Melting and vaporization
d) None of the above
8. The spark gap in EDM process is maintained such that
a) The gap voltage is around 99% of supply voltage
b) The gap voltage is around 70% of supply voltage
c) The gap voltage is around 50% of supply voltage
d) The gap voltage is around 10% of supply voltage
9. Deionized water is used as dielectric in
a) wire-EDM
b) Electric discharge machining
c) Electric discharge grinding
d) Electric discharge diamond grinding
10. Ineffective flushing results in
a) High MRR
b) Poor surface finish
c) Low MRR
d) High surface finish
11. Arcs are undesirable in EDM due to
a) Tool damage & work piece damage
b) Loss of energy
c) Evaporates dielectric
d) None of the above

12. Undesirable characteristic of graphite electrode is

a) Higher TWR
b) Poor surface finish
c) Brittleness
d) All of the above
13. Wear of tool during EDM process would result in
a) Deeper hole
b) Lesser diameter hole
c) Both
d) None

14. EDM is not suitable for machining of

a) Very hard metals
b) Glass
c) CFRP
d) Fragile metallic components.

15. Electrode refeed system in EDM is used to compensate wear in

a) Length
b) Diameter
c) Both
d) None

16. The workpiece in Electron beam machining is held in

(a) vacuum chamber
(b) dielectric medium
(c) electrolyte
(d) none of these
17. In Electron beam machining, as the electrons strikes the work piece
(a) Electro-chemical etching takes place
(b) They get scattered
(c) Mechanical erosion in work piece takes place
(d) Their kinetic energy is converted into heat

18. The vacuum in the Electron Beam machining chamber is of the order of
(a) 10−1 to 10−2 torr
(b) 10−4 to 10−5 torr
(c) 10−6 to 10−7 torr
(d) 10−8 to 10−9 torr

19. Electron beam can machine

(a) Conducting materials
(b) Non-conducting materials
(c) Both of them

20. The vacuum in Electron beam machining does not allow

(a) Rapid deoxidisation of incandescent filament
(b) Rapid oxidation of incandescent filament
(c) Both of them
(d) None of them

21. In Electron beam machining beam current varies from

(a) 1A- 40A
(b) 10μA-50μA
(c) 100μA-1A
(d) 100A-1000mA

22. In Electron beam machining drilling using longer pulse duration results in
(a) Small and narrow hole
(b) Wide and deeper hole
(c) inclined hole
(d) small and deeper hole

23. Performance of Electron beam machining process is significantly influenced by

(a) Physical property of workpiece material
(b) Mechanical property of workpiece material
(c) Metallurgical property of workpiece material
(d) None of them

24. Zirconium is used as an electrode material in Plasma arc cutting due to

(a) High thermal conductivity
(b) Low thermal conductivity
(c) Large heat capacity
(d) High resistance to oxidation
25. Mild steel plate cutting using plasma is commonly carried out using
(a) Air plasma torch
(b) Oxygen injected torch
(c) Water injected torch
(d) None of them
26. Thickness of heat affected zone in Plasma arc machining is in the range of
(a) 0.1-0.6 mm
(b) 6.0-9.0 mm
(c) 0.75-5.0 mm
(d) None of them

27. In Plasma arc cutting, transferred arc mode can machine

(a) Only electrically conductive workpiece
(b) Only electrically non-conductive workpiece
(c) Both type of workpiece
28. The lower part of water injected torch in Plasma arc cutting is made of ceramic to
avoid
(a) Heat affected zone
(b) Smoke
(c) Formation of oxide
(d) Double arcing

29. The efficiency of Plasma arc cutting when non-transferred arc is used in
(a) 65%-75%
(b) 85%-90%
(c) 10%-30%
(d) 40%-60%

30. The efficiency of LBM system is about

(a) 3 to 5%
(b) 13 to 15%
(c) 0.3 to 0.5%
(d) 30 to 50%.

31. While drilling deep hole by LBM process, it is (with reference to top surface)
(a) Straight sided
(b) converging
(c) diverging
(d) none of these.

32. The phenomenon of the movement of an atom to the higher energy level is called
(a) Absorption
(b) Emission
(c) Spontaneous emission
(d) Stimulated emission

33. Properties of laser beam is

(a) High divergence
(b) High degree of coherence
(c) Low monochromacity
(d) Low degree of coherence
34. Solid state lasers can’t be used for heavy duty work due to
(a) Low intensity
(b) Low degree of coherence
(c) Poor thermal properties
(d) workpiece hardness

35. Laser beam with low divergence should be recommended for

(a) Shallow hole drilling
(b) Larger sized holes drilling
(c) Deep hole drilling

36. Mechanism of material removal in Electron Beam Machining is due to

a) Mechanical erosion due to impact of high of energy electrons
b) Chemical etching by the high energy electron
c) Sputtering due to high energy electrons
d) Melting and vaporisation due to thermal effect of impingement of high energy
electron

37. Mechanism of material removal in Laser Beam Machining is due to

a) Mechanical erosion due to impact of high of energy photons
b) Electro-chemical etching
c) Melting and vaporisation due to thermal effect of impingement of high energy
laser beam
d) Fatigue failure

38. Laser Beam is produced due to

a) Spontaneous emission
b) Stimulated emission followed by spontaneous emission
c) Spontaneous emission followed by Spontaneous absorption
d) Spontaneous absorption leading to “population inversion” and followed by
stimulated emission

39. What happens when the heat is diffused into bulk material?
a) Phase change occurs
b) Melting occurs
c) Vaporization may take place
d) All of the mentioned

40. If a material machined using LBM is having high reflectivity then MRR will
a) Will decrease
b) Will increase
c) Will enhance
d) Remains same
41. LBM offers a good solution for which material properties below?
a) Thermal conductivity
b) Specific heat
c) Boiling temperature
d) All of the mentioned

42. Which of the following are different types of lasers used in Laser beam machining?
a) Solid-state ion
b) Neutral gas
c) Semiconductor
d) All of the mentioned

43. Which types of lasers are used in Laser beam machining?

a) Continuous wave
b) Pulsed mode
c) Continuous wave & Pulsed mode
d) None of the mentioned

44. 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

45. 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

46. Physics of laser is very complex due to which of the reasons below?
a) Scattering loss
b) Reflection loss
c) Scattering & Reflection loss
d) None of the mentioned
47. What happens when the heat is diffused into bulk material?
a) Phase change occurs
b) Melting occurs
c) Vaporization may take place
d) All of the mentioned

48. What happens to the process efficiency if plasma plumes are formed in LBM?
a) Increases
b) Enhances
c) Decreases
d) Improves

49. 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

50. How are minimum energies required for plastics when compared to that required for
metals?
a) Lower than
b) Higher than
c) Same as
d) None of the mentioned
 TWO MARK MCQ
1. Which one of the following statements is true for Electrical Discharge Machining
(EDM)?
(i).The material removal takes place due to the melting and evaporation of the workpiece
material.
(ii).Any electrical conductor can be machined by this method.
(iii).Some light oil like transformer oil or kerosene oil is used as dielectric.

a) Only (i)
b) (i) and (ii)
c) (i), (ii) and (iii)
d) (ii) and (iii)

2. Which one of the following statements is not true in case of EDM?

a) Erosion takes place both on work piece and tool
b) Gap between tool and work piece is controlled by servo mechanism
c) The electrode (tool) is made of graphite or copper
d) The size of impression on the work piece surface is exactly same as that of
electrode (tool)

3. During calculation of MRR in EDM, supply voltage was used as 60V in place of the actual
supply voltage of 40V. What is the ratio of actual and calculated MRR? Assume that the
condition for maximum power delivery to the discharging circuit is satisfied.
a) 1.5
b) 0.44
c) 2.25
d) None

4. Stratified wires are used so that they can

a) Withstand more mechanical forces
b) Carry more heat energy
c) Both of these
d) None of these

5. In Electron beam machining, the order in which electrons passed after emitted by
filament cathode
(a) diaphragm – anode –focusing lens – Deflector coil
(b) anode – diaphragm – focusing lens – Deflector coil
(c) focusing lens – anode – diaphragm –Deflector coil
(d) Deflector – coil anode – diaphragm – focusing lens
6. Gas in plasma state becomes
i. Electrically conductive
ii. Electrically non-conductive
 iii. Responsive to magnetism
iv. Chemically reaction

a) i and iii
b) i, ii and iii
c) ii and iii
d) iii and iv

7. Which of the following is used as dielectric medium in EDM

(a) tap water
(b) kerosene
(c) NaCL solution
(d) KOH solution

8. In a RC type generator, the maximum charging voltage is 80 V and the charging

capacitor is 100 μF. Determine spark energy.
a) 0.32 J
b) 0.55 J
c) 1.50 J
d) 0.89 J

Answer:

9. If in a RC type generator, to get an idle time of 500 μs for open circuit voltage of 100 V
and maximum charging voltage of 70 V, determine charging resistance. Assume C = 100
μF.

a) 9 ohms
b) 6 ohms
c) 8 ohms
d) 4 ohms

Answer:

10. For a RC type generator to get maximum power dissipation during charging Vc = V 0
x 0.716. Determine the idle time for Rc = 10 Ω and C = 200 μF
 a) 2.5 ms
b) 1.58 ms
c) 3 ms
d) 0.9 ms

Answer:

11. Determine on time or discharge time if V0= 100 V and Vd* = 15 V. Spark energy = 0.5
J. Generator is expected for maximum power during charging. Machine resistance = 0.5
Ω.

a) 62 μF
b) 75 μF
c) 80 μF
d) 50 μF

Answer:

12. For achieving smooth surface in EDM machining operation dielectric selected should
have

a) High density
b) High viscosity
c) Low viscosity
d) High specific gravity

13. The selected dielectric used in the EDM process should have the following functions
i. High break down voltage
ii. High break down time
 iii. Deionize quickly
iv. Non-corrosive

a) i and iii
b) i, ii and iii
c) ii and iii
d) iii and iv

14. The main requirement of servo system are

i. Sensitivity for small movements
ii. Enough power to overcome the weight of the ram
iii. To support the workpiece
iv. Maintains firm contact of tool and workpiece

a) i and ii
b) i, ii and iii
c) ii and iii
d) iii and iv

15. Arrange the layers formed in EDM machined components in correct order
a) HAZ -Conversion zone-Recast layer
b) Conversion zone-Recast layer-HAZ
c) Recast layer- HAZ -Conversion zone
d) Recast layer-Conversion zone-HAZ

16. Select the input parameters of EDM which affects the MRR of the process
i. Effect of mean current
ii. Pulse duration
iii. Wire tension
iv. Gap voltage

a) i and ii
b) i, ii and iii
c) i, ii and iv
d) ii, iii and iv

17. Thermal efficiency of transferred arc type plasma system is

a) 75-80%
b) 80-85%
c) 85-90%
d) 90-95%

18. In plasma arc machining, the plasma which is produced is combination of

Plasma is a mixture of
 i. free electrons
ii. positively charged ions
iii. neutral atoms
iv. photons

a) i & ii
b) ii & iv
c) i & iii
d) i, ii & iii

19. Which of the following is used as gas laser in Laser beam machining?
i. Helium-neon
ii. Agron
iii. CO2
iv. N2

a) i & iv
b) i & ii
c) ii & iii
d) All of these

20. The function of water muffler used in plasma arc machining

i. The high noise level of the plasma arc was sharply reduced
ii. Smoke and toxic gases were confined
iii. Protects the workpiece and improves cutting
iv. Arc glare was reduced to a level that was less dangerous to the eyes

a) i & iv
b) i, ii & iv
c) ii & iii
d) All of these

21. Laser Beam is produced due to _____

a) spontaneous emission

b) stimulated emission followed by spontaneous emission

c) spontaneous emission followed by Spontaneous absorption

d) spontaneous absorption leading to “population inversion” and followed by

stimulated emission

22. In population inversion, no of electrons in _____ are more as compared to numbers of

electrons in _____
a) quasi-stable state, ground state

b) meta-stable state, ground state

c) meta-stable state, quasi-stable state

d) mono-stable state, ground state

23. Emission current depends up on which of the following factors?

a) Cathode material

b) Temperature

c) All of the mentioned

d) None of the mentioned

24. Mechanism of material removal in Electron Beam Machining is due to _____

a) mechanical erosion due to impact of high of energy electrons

b) chemical etching by the high energy electron

c) sputtering due to high energy electrons

d) melting and vaporisation due to the thermal effect of impingement of high

energy electron

25. What is the purpose of a series of slotted rotating discs provided between the electron
beam gun and the workpiece?

a) It increases the accuracy of the beam

b) It can increase the intensity of the beam (if needed)

c) It prevents power losses

d) It prevents vapour generated during machining to reach the gun

 ME8073 UNCONVENTIONAL MACHINING PROCESSES

UNIT-3 CHEMICAL AND ELECTROCHEMICAL ENERGY BASED PROCESS

MULTIPLE CHOICE QUESTIONS

ONE MARK MCQ

1. The etchant strength during ChM process can be maintained by
(a) Proper filtration
(b) Addition of new chemicals
(c) None of them
(d) Both of them

2. The extent of undercut in ChM depends on depth of cut, type and strength of etchant,
and the workpiece material
(a) True
(b) False

3. The surface finish produced during ChM is about

(a) 0.01-0.5 μm
(b) 0.5-0.7 μm
(c) 0.75-3.75 μm
(d) 4.15-5.75 μm

4. In ChM, cut and peel method the thickness of the maskant coating is in the range of
(a) 0.3-0.5 mm
(b) 0.025-0.13 mm
(c) 0.5-0.7 mm
(d) 0.7-0.9 mm

5. ChM provides
(a) Good surface finish
(b) High material removal rate
(c) Uniform material removal
(d) None of them
6. Chemical blanking is used for production of
(a) Blind cavities
(b) Through cavities
(c) None of them

7. Material removal occurs during ChM process

(a) Downward
(b) Laterally
(c) None of them
(d) Both of them

8. Electrolyte is not consumed in ECM. Type of electrolyte used during ECM, therefore,
has no effect on MRR.
a) True
b) False

9. IEG during ECM is usually in the range of 1-3 mm.

a) True
b) False

10. Theoretically tool wear rate during ECM is zero.

a) True
b) False

11. In shaped tube electrolytic machining temperature of electrolyte is maintained

between
a) 41-45°C
b) 37-40°C
c) 25-30°C

12. In shaped tube electrolytic machining tube material is made of

a) Copper
b) Brass
c) Titanium
d) Ceramic

13. Electrostream dwell drilling is used for

a) Deep hole drilling
b) Shallow hole drilling
c) curved hole drilling

14. In electrochemical grinding process performance increases under the effect of

magnetic field in case of
a) Diamond wheel
b) Al2O3 wheel
c) SiO2 Wheel

15. In Shaped tool Electrostream drilling (STEM) the voltage rating is

a) both tool and workpiece are stationary
b) both tool and workpiece move
c) 5-15 V
d) tool moves and workpiece is stationary

16. Tools and carbide tips are sharpened by

a) Electrical discharge Machining
b) Electrochemical grinding
c) Ultrasonic Machining

17. The material removal rate of workpiece in ECM is largely governed by

a) Chemical properties of workpiece material
b) Physical properties of workpiece material
c) Mechanical properties of workpiece material
18. The surface finish produced by ECM shows
a) Low corrosion resistance
b) Low wear resistance
c) Low friction resistance
d) Low fatigue strength

19. The voltage rating during Electrostream drilling is in the range of

a) 50 – 100 V
b) 100 – 150 V
c) 150 – 850 V
d) 900 – 1200 V

20. Silicon controlled rectifiers are used in ECM to minimize damage due to spark
a) True
b) False

21. 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

22. Which of the following solutions cannot be used as chemical reactive solution in
CHM?
a) Acidic solution
b) Alkaline solution
c) Neutral solution
d) None of the mentioned
23. By using Chemical machining, which of the following can be produced?
a) Pockets
b) Contours
c) Slots
d) All of the mentioned

24. 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 the absence of contaminants
d) All of the mentioned

25. 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
d) None of the mentioned

26. Type of mask depends on which of the factor/s, given below?

a) Size of work piece
b) Number of parts
c) Desired resolution
d) All of the mentioned
27. During Chemical milling, depth of etch is controlled by which factor of immersion?
a) Time
b) Mask method
c) Mask area
d) None of the mentioned

28. 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

29. 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

30. CHM cannot eliminate which of the following defects?

a) Irregularities and dents
b) Surface scratches
c) Waviness
d) All of the mentioned

31. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
d) All of the mentioned

32. 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

33. 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

34. 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
d) All of the mentioned

35. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
c) Medium
d) High

36. 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
37. Which of the following defects cannot be altered or eliminated using CHM?
a) Waviness
b) Surface imperfections
c) Scratches
d) Dents

38. The depth of cut tolerances increases when machining ____________ depths at high
machining rates.
a) Very smaller
b) Smaller
c) Medium
d) Larger

39. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
b) Decarburized layer
c) Recast structure
d) All of the mentioned

40. Weight reduction is possible, on which type of contours?

a) Very simple
b) Simple
c) Complex
d) None of the mentioned

41. Good surface quality and absence of burr eliminates which of the following?
a) Cutting operations
b) Finishing operations
c) Drilling operations
d) None of the mentioned
42. The absence of residual stresses on the chemically machined surfaces can produce
__________ strength.
a) Favorable fatigue
b) Unfavorable fatigue
c) Constructive fatigue
d) None of the mentioned

43. Which of the following is the most popular application for weight reduction of
aerospace components?
a) Shallow cuts
b) Deep cuts
c) Very deep cuts
d) None of the mentioned

44. Removal of sharp burrs come under which application of Chemical milling process?
a) Deep cuts
b) Multiple part machining
c) Improving surface characteristics
d) None of the mentioned

45. ECG is suitable for which of the following materials?

a) Tungsten carbide
b) Polymers
c) Iron
d) Nickel

46. Nozzles are used to _____________

a) spray coolant on the wheel
b) ensure proper wetting of the wheel
c) spray chemical directly on the work piece
d) nozzles are not used in ECG
47. The grinding wheel is _________ and the work piece is ________ in ECG process.
a) Cathode, anode
b) Anode, cathode
c) Cathode, cathode
d) Anode, anode

48. Action of abrasive grains depend on which of the following factors?

a) Electric filed
b) Transport of electrolyte
c) Hydrodynamic effects
d) All of the mentioned
49. The ECH machining system employs which type of abrasive stone for removal of
material?
a) Pulsating
b) Vibrating
c) Reciprocating
d) All of the mentioned

50. For ECM of steel which is used as the electrolyte?

a) Kerosene
b) NaCl
c) Deionised water
d) HNO3

PART B
1. In ChM for high volume production the type of maskant used is
(a) Cut and peel
(b) Screen printing
(c) Photoresist
(d) None of them

2. Etchant dissolves metal

(a) By changing it into a metallic salt
(b) By rupturing the atoms
(c) By changing the metal into gaseous state

3. Etchant is heated and agitated to

(a) To increase MRR
(b) To improve surface roughness
(c) To decrease MRR
4. In ECM, value of void fraction along the path of flow of electrolyte is increasing but
temperature of the electrolyte remains approximately constant. Slope of the machined
surface will be
i. zero
ii. varying linearly
iii. varying nonlinearly
iv. unpredictable

a) i & ii
b) i ii & iii
c) ii & iii
d) i, ii & iv

5. Electrochemically machined surfaces have

a) High residual stresses and improved fatigue strength
b) High residual stresses and reduced fatigue strength,
c) Insignificant residual stresses and reduced fatigue strength,
d) Insignificant residual stresses and improved fatigue strength.

6. During electrochemical grinding material is removed by

a) Mechanical abrasive action
b) Electrochemical dissolution
c) Both of them
d) None of them

7. In which one of the following processes, an oxide layer forms on the work surface?
i. Electrochemical grinding
ii. Electrical discharge Machining
iii. Electrochemical Machining
iv. Ultrasonic Machining
a) i & ii
b) i ii & iii
c) i & iii
d) i, ii & iv
8. The main requirement of the property of the tool material in ECM is
i. High Thermal conductivity
ii. Low thermal conductivity
iii. High electrical conductivity
iv. Low electrical conductivity
a) i & ii
b) i ii & iii
c) i & iii
d) i, ii & iv

9. Equilibrium inter-electrode gap can be achieved in ECM only if

a) Constant feed rate & increasing applied current
b) Constant feed rate & constant applied current
c) Decreasing feed rate & constant applied current

10. Electrolyte’s electrical conductivity value increases due to

i. Temperature
ii. Size of hydrogen gas bubbles
iii. Distribution of hydrogen gas bubbles
iv. All of the above
a) i & ii
b) i ii & iii
c) i & iii
d) i, ii & iv

11. In Chemical milling, excessive flow of chemical reagent results in which of the
following defects?
a) Channellings
b) Grooves
c) Ridges
d) All of the mentioned

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

13. 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

14. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
c) Frequency uniformity
d) Temperature uniformity

15. 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

16. 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
17. In ECG, grinding action removes ____________
a) workpiece material from the surface
b) corroded surface layer making workpiece ready for electro-chemical process
c) oxide film formed on the surface
d) particles removed from surface after chemical action

18. Electrolyte in ECG should provide _____________

a) lower chemical activity
b) allowance to stray currents
c) high stock removal efficiency
d) higher corrosion tendency
19. Which of the following is true for ECG?
a) Higher the grinding wheel rpm, higher is the MRR
b) Higher the current density, faster the removal rate
c) Stronger the electrolyte, poor surface finish
d) Higher the hardness of the workpiece, lower the current density required

20. MRR is ECM depends on _____________

a) hardness of work material
b) atomic weight of work material
c) thermal conductivity of work material
d) ductility of work material

21. In ECM of pure iron a material removal rate of 600 mm3/min is required. What will
be the current requirement?
a) 157A
b) 183.6A
c) 247.8A
d) 268.8A

Answer:
Explanation: MRR= IA/(Fρv)
MRR = 600 mm3/min = 600/60 mm3/s = 10 mm3/s = 10×10-3cc/s
A= 56,
v= 2,
F= 96500 coulomb, and
ρ = 7.8 gm/cc
Therefore, I= (96500*10*10-3*7.8*2)/56
I= 268.8A.

22. In ECM operation of pure iron an equilibrium gap (h) of 2 mm is to be kept. What
will be the supply voltage (v), if the total overvoltage is 2.5 Volts. The resistivity(r) of
the electrolyte is 50 Ω-mm and the set feed rate (f) is 0.25 mm/min.
a) 5v
b) 7.8v
c) 11.3v
d) 13.2v

Answer:
Explanation: h= c/f
Where, c= (v- overvoltage)*A/(F*ρ*r*v)
Therefore, c= (v-2.5)*56/(96500*7.8*10-3*50*2)
c= (v-2.5)/1344.1
Now, h= c/f
2= [(v-2.5)/1344.1]/[0.25/60] Therefore, v= 13.2 volts.

23. Which of the following does not hold true about ECM?
a) ECM cell must avoid flutter and arcing
b) Part and the cathode must have adequate current-carrying capacity
c) Tool must have shape exactly same as that of the mirror image of the part
d) It gives burr free surface

24. Which of the following does not hold true about ECM?
a) Lower current density leads to poor surface finish
b) Small gap between tool and the workpiece can cause short circuit
c) Gap between the tool and the workpiece doesn’t affect the process parameters
d) MRR is dependent on feed rate and electrolyte composition

25. Conductivity of the solution can be increased by_____

a) increasing the gap between the tool and the workpiece
b) increasing the temperature of the solution
c) increasing the concentration of the solution
d) using conductive workpiece
 ME8073 UNCONVENTIONAL MACHINING PROCESSES

UNIT 4- ADVANCED NANO FINISHING PROCESS

MULTIPLE CHOICE QUESTIONS

ONE MARK MCQ

1. For abrasives to be good their hardness should be …… and toughness should be ……
a) High and High
b) High and Low
c) Low and High
d) Low and Low
e) None of the Above

2. Which of the grit size is finest of all the options below

a) 450
b) 300
c) 200
d) 100

3. Among the below mentioned operations which is not a loose abrasive operation .
a) Lapping
b) Ultra sonic machining
c) Honing
d) Sand blasting
e) None of above

4. All grinding operations use bonded abrasives, except for ……….. which use coated
abrasives.
a) Creep feed grinding
b) Micro grinding
c) Centerless grinding
d) Belt grinding
e) None of above

5. Which of the following is/are a function of cutting fluid

a) Lubrication
b) Cooling
c) Flushing of chips
d) Reducing friction
e) All of the above
6. Most of the abrasive particles are ___________ in nature
a) Ductile
b) Brittle
c) Elastic
d) Pseudoplastic
7. among the following abrasives which one is the white crystalline powder
a) SiC
b) Aluminium oxide
c) Boron carbide
d) CBN

8. Engine cylinder blocks are generally finished by __________ Process

a) Honing
b) Lapping
c) Plunge Grinding
d) Super finishing

9. Which of the following materials can be machined using Magnetic Abrasive finishing
a) Alloy steels
b) Ceramic materials
c) Iron materials
d) All of the mentioned

10. Which of the following material/s is/are used to hold the abrasives, in MAF
a) Nonmagnetic materials
b) Ferromagnetic materials
c) Ceramic materials
d) None of these

11. Which of the following are commonly used magnetic materials in finishing process
a) Iron and iron oxides
b) Nickel and Cobalt
c) Cobalt and iron
d) Steel and Stainless Steel

12. Which of the following are commonly used abrasive materials in finishing process of
MAF
 a) Silicon Carbide
b) Aluminium Oxide
c) Diamond
d) All of the mentioned

13. 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 workpiece
d) Below the workpiece

14. 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

15. 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

16. Abrasive flow machining (AFM) is used for

a) Deburring
b) Etching
c) Drilling
d) Cutting
17. A good AFF medium should be
a) Mechanically stable
b) Chemically non-reactive
c) Good abrading ability
d) All of the above

18. The AFF process is capable of achieving surface finishes up to

a) 1μm
b) 10μm
c) 50nm
 d) 1nm

19. The AFF process can deburr the holes as small as

a) 0.2 mm in diameter
b) 2 mm in diameter
c) 20 mm in diameter
d) 10 mm in diameter

20. The AFF can give hole tolerances up to

a) ±5μm
b) ±10μm
c) ±15μm
d) ±15μm

21. Abrasive Flow Finishing should not be used for

a) Bulk Material Removal
b) Smoothing over sharp corners
c) Finishing of hard components
d) Removal of EDM recast layer

22. Increase in media viscosity in AFF leads to

a) Decrease in MRR
b) Increase in MRR
c) Has no effect on MRR
d) None of the above

23. Radiusing operation using AFF is

a) Rounding sharp cornes of the workpiece
b) Increasing outer radius of the workpiece
c) Increasing inner radius of the workpiece
d) All the above

24. Which of the following metal particles can be used in magnetorheological fluid
a) Carbonyl Iron Particle (CIP)
b) Copper powder
c) Cobalt alloy powder
d) Ceramic dust
25. Application of magnetic field in MRAFF leads to
a) Abrasive particles entrapment in CIP chains
b) Formation of CIP chains
c) Improve in surface finish
d) All of the above

26. Which of the following can be used as base fluid in magnetorheological fluid
a) Water
b) Hydrocarbon oils
c) Glycol
d) All of the above

27. Yield strength of MR fluid is in the range of

a) 100-200 kPa
b) 0-100 kPa
c) 200-300 kPa
d) 300-500 kPa

28. MR fluid is ____________

a) Newtonian Fluid
b) Bingham Plastic Fluid
c) Dilatant Fluid
d) Pseudoplastic Fluid

29. Plug flow region in MR finishing occurs at

a) At the center of the cylindrical flow
b) At the wall
c) It is a function of temperature
d) It is a function of pressure

30. Bingham plastic fluid flows when ____________

a) Temperature of the fluid exceeds a specified value
b) The shear stress exceeds a specified value
c) The fluid is activated by a surfactant
d) None of the above

31. Process parameters of MRAFF process are

a) Extrusion pressure
 b) Abrasive mesh size
c) Finishing cycle
d) All of the above

32. Surfactants is added in MR fluid to

a) Reduce sedimentation
b) Increase magnetic field in the finishing zone
c) Decrease magnetic field in the non-finishing zone
d) None of these

33. Advantages of MRAFF process are

a) Complex structure can easily be finished
b) Localized finishing is possible
c) Negligible thermal distortion
d) All of the above

34. Possible application areas of MRAFF process are

(a) Aerospace
(b) Medical
(c) Automotive
(d) All of the above

35. Which property of MR fluid can be controlled using externally applied magnetic field
(a) Temperature
(b) Viscosity
(c) Pressure
(d) Specific weight

36. In R-MRAFF process, the path followed by active abrasive grain at the internal surface
of the cylindrical workpiece surface is
(a) Hexagonal path
(b) Helical path
(c) Spiral path
(d) Vertical path

37. In which one of the following process cross-hatch patterns on the workpiece surface
like in RMRAFF is generated
(a) Honing process
(b) Lapping process
(c) Buffing process
(d) grinding process

38. What are the advantages of R-MRAFF process

(a) Uniform finishing
(b) Controllable finishing force
(c) Nano-scale finishing
(d) All of the above

39. In R-MRAFF process surface finish of the workpiece reaches as low as

(a) 5 nm
(b) 2 nm
(c) 16 nm
(d) 10 nm

40. Magnetorheological fluids are

a) Viscous dominant fluids
b) Elastic dominant fluids
c) Viscoelastic fluids
d) None of these

41. the full of CMP process is

a) Chemomechanical polishing
b) Chemomechanical planarization
c) Chemomechanical presipiration
d) Both a and b

42. CIP stands for

a) Carbon iron particle
b) Carbonyl iron particle
c) Carbo iron particle
d) Carbon assist iron particle
43. Major disadvantage or limitations of AFF process is
a) Lack of control of medium viscosity
b) Costlier media
c) Lack of determinism
d) All the above

44. Magnetic Float Polishing is a technique based on_____

a) magneto-dynamic behaviour
b) magneto-hydrodynamic behaviour
c) Kinematic behaviour
d) Viscosity

45. Which one of the following is not an important element of AFF process?
a) Medium
b) Tooling
c) Volume of hydraulic oil
d) Machining setup

46. A strong flexible magnetic brush is seen in finishing of

a) Ferro magnetic materials
b) Non-Ferro magnetic materials
c) Not depend on type of material
d) Para magnetic materials

47. Which one of the following is not a machine related parameter in AFF process?
a) Number of cycles
b) Media flow rate
c) Media viscosity
d) Extrusion pressure

48. In chemo-mechanical polishing (CMP) process, material is removed due to

a) Abrasion
b) Etching
c) Vapourization
d) Impact
49. CMP process is mainly used in field of
a) Silicon wafer finishing
b) Finishing optical surfaces
c) Blind holes deburring
d) Conductive material surface finishing

50. Drawback associated with CMP process is

a) Selective etching is difficult to control
b) Low MRR
c) Low finishing compared to conventional
d) Not suitable for semiconductor materials

PART – B
1. Which is the correct ascending order of hardness values of the following abrasives?
a) Polishing abrasives, finishing abrasives, cleaning abrasives
b) Cleaning abrasives, polishing abrasives, finishing abrasives
c) Finishing abrasives, polishing abrasives, cleaning abrasives
d) Finishing abrasives, cleaning abrasives, polishing abrasives
e) None of above

2. The ratio of Fr/Fa increases with increase in ___________.

(Fr is the radial force and Fa is the axial force on abrasive particle)
a) Abrasive Concentration
b) Extrusion Pressure
c) Both (a) and (b)
d) None of the above
3. Spiral polishing in AFF includes
a) Rotation of spiral tool for media movement
b) Reciprocating pistons
c) Rotating magnetic field
d) Reciprocating workpiece

4. During finishing of stainless steel in R-MRAFF process the most significant process
parameter is
(a) Rotational speed of the magnet
(b) Hydraulic extrusion pressure
(c) Number of finishing cycle
(d) Volume ratio of CIP/SiC

5. During internal polishing of cylindrical workpiece in R-MRAFF process the out of

roundness of the workpiece varies with the increase in abrasive mesh size as
(a) Increasing and then decreasing
(b) Decreasing and then increasing
(c) Increasing
(d) Decreasing
6. Indentation by the abrasive particle on the workpiece surface by R-MRAFF process
process is due to the combined effect of
(a) Magnetic force and centrifugal force
(b) Magnetic force and radial force
(c) Centrifugal force and radial force
(d) Centrifugal force and normal force

7. The percentage change in surface roughness varies with the increase in abrasive
mesh size in RMRAFF process as
(a) Increasing and then decreasing
(b) Decreasing and then increasing
(c) Increasing
(d) Decreasing

8. Surfactants is added in MR fluid to

 i. reduce agglomeration
ii. reduce sedimentation
iii. increase magnetic field in the finishing zone
iv. increase sedimentation

(a) i
(b) i & ii
(c) i, ii, & iii
(d) ii & iv

9. The percentage change in surface roughness varies with the increase in rotational
speed of the magnet in R-MRAFF as
(a) Increasing and then decreasing
(b) Decreasing and then increasing
(c) Increasing
(d) Decreasing

10. The out of roundness varies with the increase in rotational speed of the magnet in R-
MRAFF
(a) Increasing and then decreasing
(b) Decreasing and then increasing
(c) Increasing
(d) Decreasing

11. If the abrasive mesh size is 120 then how does the percentage change in surface
roughness varies with the increase in extrusion pressure in R-MRAFF
(a) Increasing
(b) Decreasing
(c) Increasing and then show decreasing pattern
(d) Decreasing and then show increasing pattern

12. There is a decrease in yield stress when the total solid contents (CIP + abrasive) of the
MRP fluid reaches
(a) More than 35%
(b) Less than 20%
(c) Less than 35%
(d) More than 10%
13. From numerical simulation of MR polishing fluid inside a cylinder at a given magnetic
field, higher extrusion pressure gives rise to
(a) Larger plug flow region
(b) Smaller plug flow region
(c) At corner
(d) At upper part of cylinder

14. The chain formation by CIPs in MR fluid is not continuous due to the presence of
(a) Stabilizer
(b) Additive
(c) Abrasive particles
(d) Surfactant

15. R-MRAFF gives higher polishing rate than MRAFF process due to
i. Centrifugal force
ii. Tangential cutting force
iii. Magnetic force
iv. All of the above

a) i
b) i & ii
c) i, ii, & iii
d) ii & iv

16. the force that is responsible for shearing of surface peaks in magnetorheological
finishing is
a) Normal force generated between workpiece and rotating wheel
b) Tangential force at the surface of abrasive particles and surface peak
interaction
c) Vector sum o f both normal force and tangential force
d) No mechanical forces are generated in magnetorheological finishing process

17. passivation layer in CMP process indicates

a) Chemically reacted layer of surface
b) Conversion layer due to heat interaction
c) Contaminated layer due to polishing slurry
 d) Mechanically destroyed layer

18. The function of CIP particles in MRF process is

a) To remove material from the surface
b) To hold the abrasive particles firmly
c) Both a and b
d) To facilitate free motion to the abrasive particle

19. let hardness of the abrasive, parent material and passivation layer are h1, h2 and h3
respectively. The necessary condtion to get a scratch free surface from CMP process is
a) h2> h1>h3
b) h1> h2>h3
c) h1> h3>h2
d) h3> h2>h1
20. which one of the following is not an advantage of magnetorheological finishing
process?
a) Used to finish lenses in optical industry
b) Blind holes can be finished
c) Polishing and deburring options can be combined
d) Finishing rates are higher than manual finishing

21. MRAFF process adopts the advantage of

a) Complex component finishing capability
b) Controlling the viscosity of the media with external means
c) Both a and b
d) None of these

22. At a particular extrusion pressure, as the plasticizer content in AFF medium

increases, shear rate_____
a) Increases
b) Decreases
c) Increases and decreases
d) Decreases and increases

23. which of the following techniques results in sub nanometric level surface
roughness?
a) Ion beam machining
b) MRF process
c) Elastic emission machining
 d) All of the above

24. which of the following variant of AFF process is used for finishing blind holes
a) Two way AFF process
b) one way AFF process
c) orbital AFF process
d) Both b and c

25. After finishing with abrasive flow finishing technique, the machined surface
comprises of
a) Recast layer
b) Compressive residual stresses
c) Tensile residual stresses
d) Refined grain structure
 ME8073 UNCONVENTIONAL MACHINING PROCESSES

UNIT-5 RECENT ADVANCEMENTS IN NON-TRADITIONAL MACHINING

PROCESS

MULTIPLE CHOICE QUESTIONS

ONE MARK MCQ

1. Self-dressing properties of the tool is there in
a) Drag finishing
b) Vibratory finishing
c) Ice bonded abrasive finishing
d) Sand blasting

2. Which of the following is false about Ice bonded abrasive machining

a) It uses loose as well as bonded abrasives
b) It reduces health related issues for workers
c) It can provide nano meter level surface finish
d) None of the above

3. Which of the following material is not suggested to polish or finish by using Ice bonded
abrasive polishing technique?
a) Copper
b) Mild steel
c) Stainless steel
d) aluminium

4. In Ice jet machining, the abrasive particles used for material removal are replaced by
which of the following?
a) Silica particles
b) Ice particles
c) Fluids
d) Colloidal solutions

5. When compared to Abrasive water jet machining, how are the material removal rates
in Ice jet machining?
a) Very low
b) Low
c) High
d) Remains same
6. Which of the following are the components of machining system of IJM?
a) High pressure pump
b) Ice particle generator
c) Ultrasonic Atomizer
d) All of the mentioned

7. Which of the following component will be present just after the cooling coil?
a) High pressure pump
b) Ice particle generator
c) Cutting nozzle
d) Ultrasonic Atomizer

8. Ice particles of size <500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned

9. Ice particles of size >500 µm are produced by which of the following process?
a) Stream freezing
b) Ice particles supply
c) Normal cooling
d) None of the mentioned

10. In Ice jet machining, stand-off distance value varies between which of the following?
a) 1.0 – 2.0 mm
b) 2.0 – 3.0 mm
c) 3.0 – 5.0 mm
d) 5.0 – 10.0 mm
11. What are the advantages of Ice jet machining over the other advanced machining
processes?
a) Environmentally safe
b) Cost reduction
c) No heat affected zone
d) All of the mentioned

12. Which of the following is a disadvantage of ice jet machining when compared to
AWJM?
a) Environmentally safe
b) Cost reduction
c) Low material removal rate
d) No heat affected zone

13. Which of the following are the processes and applications by the use of IJM?
a) Ice Deburring process
b) Ice Cutting process
c) Ice Blasting process
d) All of the mentioned

14. Aerostatic spindles are preferably used in

(a) Small to medium load capacity
(b) High load capacity
(c) High torque applications
(b) and (c) both

15. Focused ion beam machining is used to fabricate

a) Only milling tools
b) Only single point cutting tool
c) Both milling as well as single point cutting tool
d) Only drill bits
16. Which of the following micro tool fabrication process has problem of rounding of
cutting edge?
a) Wire electric discharge grinding (WEDG)
b) Electrolytic in-process dressing (ELID)
c) Focused ion beam machining (FIB)
d) High precision grinding

17. Which of the following process is based on Faraday’s law of Electrolysis?

a) Electron beam Machining
b) Laser Beam Machining
c) Electrical discharge Machining
d) Electrochemical Machining

18. Choose the correct option regarding various grinding operations

I. Honing is used to finish the internal surfaces
II. In lapping, a slurry of abrasive materials is used between tool and workpiece
a) Both are true
b) (I) is true, (II) is false
c) (I) is false, (II) is true
d) Both are false

19. Choose correct option for electron beam welding process

a) It can accommodate very large workpieces
b) Vacuum is required in this process
c) Wide heat affected zone is formed
d) Limited depth of penetration can be achieved

20. In lapping, the mechanism for metal removal is

a) Cutting and adhesion
b) Erosion and corrosion
c) Adhesion and erosion
d) Cutting and erosion

21. In Electron beam machining beam current varies from

(a) 1A- 40A
(b) 10μA-50μA
(c) 100μA-1A
(d) 100A-1000mA
22. In Electron beam machining drilling using longer pulse duration results in
(a) Small and narrow hole
(b) Wide and deeper hole
(c) inclined hole
(d) small and deeper hole

23. Performance of Electron beam machining process is significantly influenced by

(a) Physical property of workpiece material
(b) Mechanical property of workpiece material
(c) Metallurgical property of workpiece material
(d) None of them

24. Zirconium is used as an electrode material in Plasma arc cutting due to

(a) High thermal conductivity
(b) Low thermal conductivity
(c) Large heat capacity
(d) High resistance to oxidation

25. Mild steel plate cutting using plasma is commonly carried out using
(a) Air plasma torch
(b) Oxygen injected torch
(c) Water injected torch
(d) None of them

26. Thickness of heat affected zone in Plasma arc machining is in the range of
(a) 0.1-0.6 mm
(b) 6.0-9.0 mm
(c) 0.75-5.0 mm
(d) None of them

27. In Plasma arc cutting, transferred arc mode can machine

(a) Only electrically conductive workpiece
(b) Only electrically non-conductive workpiece
(c) Both type of workpiece

28. The lower part of water injected torch in Plasma arc cutting is made of ceramic to
avoid
(a) Heat affected zone
(b) Smoke
(c) Formation of oxide
(d) Double arcing

29. The efficiency of Plasma arc cutting when non-transferred arc is used in
(a) 65%-75%
(b) 85%-90%
(c) 10%-30%
(d) 40%-60%

30. The efficiency of LBM system is about

(a) 3 to 5%
(b) 13 to 15%
(c) 0.3 to 0.5%
(d) 30 to 50%.

31. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
d) All of the mentioned

32. 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

33. 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

34. 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
d) All of the mentioned
35. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
c) Medium
d) High

36. 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
37. Which of the following defects cannot be altered or eliminated using CHM?
a) Waviness
b) Surface imperfections
c) Scratches
d) Dents

38. The depth of cut tolerances increases when machining ____________ depths at high
machining rates.
a) Very smaller
b) Smaller
c) Medium
d) Larger

39. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
b) Decarburized layer
c) Recast structure
d) All of the mentioned
40. Weight reduction is possible, on which type of contours?
a) Very simple
b) Simple
c) Complex
d) None of the mentioned

41. the full of CMP process is

e) Chemomechanical polishing
f) Chemomechanical planarization
g) Chemomechanical presipiration
h) Both a and b

42. CIP stands for

e) Carbon iron particle
f) Carbonyl iron particle
g) Carbo iron particle
h) Carbon assist iron particle

43. Major disadvantage or limitations of AFF process is

e) Lack of control of medium viscosity
f) Costlier media
g) Lack of determinism
h) All the above

44. Magnetic Float Polishing is a technique based on_____

a) magneto-dynamic behaviour
b) magneto-hydrodynamic behaviour
c) Kinematic behaviour
d) Viscosity

45. Which one of the following is not an important element of AFF process?
e) Medium
f) Tooling
g) Volume of hydraulic oil
h) Machining setup

46. A strong flexible magnetic brush is seen in finishing of

 e) Ferro magnetic materials
f) Non-Ferro magnetic materials
g) Not depend on type of material
h) Para magnetic materials

47. Which one of the following is not a machine related parameter in AFF process?
e) Number of cycles
f) Media flow rate
g) Media viscosity
h) Extrusion pressure

48. In chemo-mechanical polishing (CMP) process, material is removed due to

e) Abrasion
f) Etching
g) Vapourization
h) Impact

49. CMP process is mainly used in field of

e) Silicon wafer finishing
f) Finishing optical surfaces
g) Blind holes deburring
h) Conductive material surface finishing

50. Drawback associated with CMP process is

e) Selective etching is difficult to control
f) Low MRR
g) Low finishing compared to conventional
h) Not suitable for semiconductor materials

PART B
1. In Ultrasonic machining, the function of transducer is to
(a) convert mechanical energy into heat
(b) convert electrical energy into heat
(c) convert electrical energy into mechanical vibrations
(d) convert mechanical energy into electrical energy

2. The relationship between amplitude of tool oscillation to material removal rate (MRR)
is,
(a) Decreases and then increases
(b) Increases and then decreases
(c) Increasing
(d) Decreasing

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

a) Magnetostrictor
b) Concentrator
c) Tools and slurry
d) All of the mentioned

4. Which is softer material in USM?

a) Tool
b) Work piece
c) Tool & Work piece
d) None of the mentioned

5. Which of the following material is not generally machined by USM

a) Copper
b) Glass
c) Silicon
d) Germanium
6. What type of tool should be used to reduce power requirement during large diameter
hole drilling in USM
(a) Trepanning tool
(b) Annular cutters
(c) Drilling tool
(d) Hypodermic need

7. Metal removal rate in abrasive jet machining increases with

a) Increase in abrasive flow rate but decreases beyond a limit
b) Decrease in abrasive flow rate
c) Decrease in grain size of abrasives
d) Increase in nozzle diameter

8. For achieving smooth surface in EDM machining operation dielectric selected should
have

e) High density
f) High viscosity
g) Low viscosity
h) High specific gravity

9. The selected dielectric used in the EDM process should have the following functions
v. High break down voltage
vi. High break down time
vii. Deionize quickly
viii. Non-corrosive

e) i and iii
f) i, ii and iii
g) ii and iii
h) iii and iv

10. The main requirement of servo system are

v. Sensitivity for small movements
vi. Enough power to overcome the weight of the ram
vii. To support the workpiece
viii. Maintains firm contact of tool and workpiece

e) i and ii
f) i, ii and iii
g) ii and iii
 h) iii and iv

11. Select the input parameters of EDM which affects the MRR of the process
v. Effect of mean current
vi. Pulse duration
vii. Wire tension
viii. Gap voltage

e) i and ii
f) i, ii and iii
g) i, ii and iv
h) ii, iii and iv

12. Thermal efficiency of transferred arc type plasma system is

e) 75-80%
f) 80-85%
g) 85-90%
h) 90-95%

13. In plasma arc machining, the plasma which is produced is combination of

Plasma is a mixture of
v. free electrons
vi. positively charged ions
vii. neutral atoms
viii. photons

e) i & ii
f) ii & iv
g) i & iii
h) i, ii & iii

14. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
c) Frequency uniformity
d) Temperature uniformity
15. 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

16. 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

17. In ECG, grinding action removes ____________

a) workpiece material from the surface
b) corroded surface layer making workpiece ready for electro-chemical process
c) oxide film formed on the surface
d) particles removed from surface after chemical action

18. Electrolyte in ECG should provide _____________

a) lower chemical activity
b) allowance to stray currents
c) high stock removal efficiency
d) higher corrosion tendency

19. Which of the following is true for ECG?

a) Higher the grinding wheel rpm, higher is the MRR
b) Higher the current density, faster the removal rate
c) Stronger the electrolyte, poor surface finish
d) Higher the hardness of the workpiece, lower the current density required

20. which one of the following is not an advantage of magnetorheological finishing

process?
e) Used to finish lenses in optical industry
f) Blind holes can be finished
g) Polishing and deburring options can be combined
h) Finishing rates are higher than manual finishing
21. MRAFF process adopts the advantage of
e) Complex component finishing capability
f) Controlling the viscosity of the media with external means
g) Both a and b
h) None of these

22. At a particular extrusion pressure, as the plasticizer content in AFF medium

increases, shear rate_____
e) Increases
f) Decreases
g) Increases and decreases
h) Decreases and increases

23. which of the following techniques results in sub nanometric level surface
roughness?
e) Ion beam machining
f) MRF process
g) Elastic emission machining
h) All of the above

24. which of the following variant of AFF process is used for finishing blind holes
e) Two way AFF process
f) one way AFF process
g) orbital AFF process
h) Both b and c

25. After finishing with abrasive flow finishing technique, the machined surface
comprises of
e) Recast layer
f) Compressive residual stresses
g) Tensile residual stresses
h) Refined grain structure