MCQ Ucmp Unit Iii Chemical and Electro Chemical Energy Based Processes

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R2017
ME8073 - UNCONVENTIONAL MACHINING PROCESSES
Multi Choice Questions (MCQ)
UNIT III - CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
[Syllabus]
[Chemical machining and Electro-Chemical machining (CHM and ECM)- Etchants – Maskant
- techniques of applying maskants - Process Parameters – Surface finish and MRR-
Applications. Principles of ECM- equipments-Surface Roughness and MRR Electrical circuit-
Process Parameters- ECG and ECH - Applications]
Chemical machining(CHM) / Chemical Milling – Introduction

1. In advanced machining processes, what is the full form of CHM?
a) Chemical machining
b) Chemical manufacturing
c) Chemical milling
d) None of the mentioned
Answer: c
Explanation: In advanced machining processes, full form of CHM is Chemical milling.
2. Of the following, which mechanism is used for the removal of material using Chemical
milling process?
a) Material Vaporization
b) Chemical dissolution
c) Mechanical erosion
d) Mechanical abrasion
Answer: b
Explanation: Chemical dissolution takes place in Chemical milling for the removing the
material.
3. Which of the following solutions cannot be used as chemical reactive solution in CHM?
a) Acidic solution
b) Alkaline solution
c) Neutral solution
Answer: c
Explanation: Both acidic or alkane solutions are used for chemical dissolution in Chemical
milling.
4. By using Chemical machining, which of the following can be produced?

a) Pockets
b) Contours
c) Slots
d) All of the mentioned
Answer: d
Explanation: By the use of CHM, pockets, contours, slots and materials having high strength
to weight ratio can be machined.
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5. Pre cleaning is done on the work piece surface in order to achieve, which of the
following factors?
a) To provide good adhesion
b) To provide clean surface
c) To assure the absence of contaminants
Answer: d
Explanation: All the factors mentioned above, are achieved thorough pre-cleaning process.
6. Special coatings applied on work piece materials in order to protect them from chemical
reaction are known as _________
a) Maskants
b) Protective coverings
c) Protective varnishing
Answer: a
Explanation: The protective coatings on work pieces are known as Maskants.
7. Type of mask depends on which of the factor/s, given below?

a) Size of work piece
b) Number of parts
c) Desired resolution
Answer: d
Explanation: All the factors mentioned above, are required to select the type of mask.
8. During Chemical milling, depth of etch is controlled by which factor of immersion?

a) Time
b) Mask method
c) Mask area
Answer: a
Explanation: As the immersion time increases, depth of the etching increases.
9. What is the range of reagent temperatures used for chemical dissolution in CHM?
a) 12ᵒC to 35ᵒC
b) 37ᵒC to 85ᵒC
c) 90ᵒC to 101ᵒC
d) 121ᵒC to 142ᵒC
Answer: b
Explanation: The optimum temperature of reagent used should range between 37ᵒC to 85ᵒC.
10. In Chemical milling, excessive flow of chemical reagent results in which of the following
defects?
a) Channellings
b) Grooves
c) Ridges
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Answer: d
Explanation: In Chemical milling, if the reagent flows excessively, then the defects
mentioned above may occur.
11. State whether the following statement about Chemical milling is true or false.
“At higher temperatures, faster etching rates occur in Chemical milling.”
a) True
b) False
Answer: a
Explanation: As the temperature increases, reaction rate increases which in turn increases
etching rate in CHM.
12. Of the following, which ratio defines the etch factor?

a) Etching depth to undercut
b) Undercut to etching depth
c) Undercut to mask area
d) Mask area to undercut
Answer: b
Explanation: Etch factor is defined as the ratio of undercut to etching depth.
13. CHM cannot eliminate which of the following defects?

a) Irregularities and dents
b) Surface scratches
c) Waviness
Answer: d
Explanation: CHM is not a finishing process as that of MAF, there are some sort of defects in
Chemical milling
Tooling for CHM

14. Which of the following are the tools required for Chemical milling?
a) Maskants
b) Etchants
c) Scribing plates
Answer: d
Explanation: All the components mentioned above, are required to carry out Chemical milling
process.
15. State which of the following statement is true or false regarding Chemical milling.
“Maskants are generally used in CHM, to protect the work piece from the etching
chemical agent.”
a) True
b) False
Answer: a
Explanation: In CHM, maskants are used to protect the work piece from chemical agents.
16. Which of the following are the materials used for making maskants?
a) Synthetic materials
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b) Rubber materials
c) Polymeric materials
Answer: d
Explanation: All the materials mentioned above, can be used for making maskants.
17. What are the properties that a maskant used in Chemical milling should possess?
a) Be tough and adhere well
b) Scribe easily
c) Be inert to chemical reagent
Answer: d
Explanation: All the properties mentioned above, should be possessed by the maskants.
18. Which of the following can be used to apply the maskants on work piece in Chemical
milling?
a) Dipping or spraying
b) Rolling or electro coating
c) Adhesive tapes
Answer: d
Explanation: Maskants can be applied to work piece, by the above mentioned means.
19. State whether the following statement is true or false regarding maskants.
“After etching, maskants should be removed easily and inexpensively.”
a) True
b) False
Answer: a
Explanation: After etching is done, maskants should be removed easily by inexpensive
means.
20. In maskant application, photo-resist masks ensure which of the following advantages?
a) High accuracy
b) Ease of repetition
c) Ease of modification
Answer: d
Explanation: We will have the advantages which are mentioned above, if we use photo resist
masking.
21. Which of the tolerance values are obtained, when we use cut and peel mask method for
maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: d
Explanation: Tolerance value of ± 0.179 mm, will be obtained, when we use cut and peel
mask method.
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22. Which of the tolerance values are obtained, when we use silk-screen resist method for
maskant?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: c
Explanation: Tolerance value of ± 0.077 mm, will be obtained, when we use silk screen
resist method.
23. Which of the tolerance values are obtained, when we use photo resist method for
maskant application?
a) ± 0.013 mm
b) ± 0.045 mm
c) ± 0.077 mm
d) ± 0.179 mm
Answer: a
Explanation: Tolerance value of ± 0.013 mm, will be obtained, when we use photo resist
method.
24. Which of the following, are the main uses of etchants applied in Chemical milling?
a) Good surface finish
b) Uniform material removal
c) Control intergranular attack
Answer: d
Explanation: In CHM, etchants are used for the above mentioned factors.
25. State whether the following statement is true or false about etchants.
“Etchants are used for controlling H2 absorption in case of Ti alloys.”
a) True
b) False
Answer: a
Explanation: Etchants control the H2 absorption in Ti alloys.
26. Scribing plates are used to define, which of the following parameters in Chemical
milling?
a) Areas to be exposed
b) Volumes to be exposed
c) Areas not to be exposed
d) Volumes not to be exposed
Answer: a
Explanation: Scribing plates defines the areas that are to be exposed for removal of material.
27. 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
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Answer: d
Explanation: All the guides mentioned above, can be used for scribing process.
28. Which of the following are the accessories, included in the tooling of Chemical milling?
a) Tanks and hooks
b) Brackets and racks
c) Fixtures
Answer: d
Explanation: The accessories mentioned above are included in the tooling of Chemical
milling.
CHM – Process Parameters and Material removal

29. Which of the following come under process parameters of Chemical milling?
a) Reagent type
b) Concentration
c) Operating temperature
Answer: d
Explanation: All the parameters mentioned above, are different process parameters required
for Chemical milling.
30. State whether the following statement is true or false about Chemical milling.
“Maskants, applied on work pieces, are not responsible for CHM process.”
a) True
b) False
Answer: b
Explanation: Maskants are also responsible for process to take place in Chemical milling.
31. To machine high quality parts using CHM, which of the following need not be
necessary?
a) Heat treatment of work piece
b) Grain size of work piece
c) Frequency of vibrations
d) Range of work pieces
Answer: c
Explanation: To machine high qualities products vibrational frequency is not necessary in
CHM.
32. The process parameters will have direct impact on which of the following factors?
a) Etch factor
b) Machining rate
c) Production tolerance
Answer: d
Explanation: All the factors mentioned above, will have direct impact due to above process
parameters.
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33. Thickness of the maskant coating ranges between which of the following values?
a) 0.0025 – 0.013 mm
b) 0.025 – 0.13 mm
c) 0.25 – 1.3 mm
d) 2.5 – 13 mm
Answer: b
Explanation: Maskant material coatings should have a thickness, which range between
0.025 – 0.13 mm.
34. Which of the following, are the general materials used for maskant application?
a) Neoprene
b) Poly vinyl chloride
c) Polyethylene
Answer: d
Explanation: All the materials mentioned above, can be used as maskant materials.
35. State whether the following statement is true or false regarding MRR.
“The rate of material removal, does not depend on uniformity of the solution
temperature.”
a) True
b) False
Answer: b
Explanation: Material removal rate also depends on uniformity of the solution temperature.
36. On which of the following factors, MRR will not be depend on?
a) Chemical uniformity
b) Metallurgical uniformity
c) Frequency uniformity
d) Temperature uniformity
Answer: c
Explanation: Chemical milling is independent of frequency distribution.
37. Castings having a larger grain size, will show how much surface roughness value?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In castings, as grain size increases, surface roughness increases.
38. 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
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Answer: a
Explanation: Rolled metal sheets will have highest machining rate and surface quality in
CHM.
39. For softer materials, which type of etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
Answer: b
Explanation: In Chemical milling, softer materials need low etching rates.
40. For harder materials, which of the following etching rates are obtained?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Chemical milling, harder materials need higher etching rates.
41. State whether the following statement is true or false about etching rates.
“As the etching rate increases, low surface roughness values occur.”
a) True
b) False
Answer: a
Explanation: High etching rates result in low surface roughness values
CHM – Accuracy and Finish

42. Which of the following are necessary for best surface quality in Chemical milling?
a) Fine grain size and homogenous metallurgy
b) Coarse grain size and heterogeneous metallurgy
c) Fine grain size and heterogeneous metallurgy
d) Coarse grain size and homogenous metallurgy
Answer: a
Explanation: In CHM, for best surface quality, fine grain size and homogenous metallurgical
work piece must be required.
43. Which of the following are the factors, on which, surface finish depends?
a) Grain size
b) Heat treatment
c) Induced stresses
Answer: d
Explanation: All the factors mentioned above, are responsible for different qualities of
surface finish.
44. State whether the following statement is true or false regarding surface finish in CHM.
“The surfaces, which are machined using Chemical milling, will have regular lay
pattern.”
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a) True
b) False
Answer: b
Explanation: In CHM, surfaces do not have regular lay pattern.
45. Which of the following defects cannot be altered or eliminated using CHM?
a) Waviness
b) Surface imperfections
c) Scratches
d) Dents
Answer: b
Explanation: Using CHM, surface imperfections cannot be eliminated.
46. Which type of etching rate, mentioned below, produces low surface roughness?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: In Chemical milling, high etching rate produces low surface roughness values
and tolerances.
47. The depth of cut tolerances increases when machining ____________ depths at high
machining rates.
a) Very smaller
b) Smaller
c) Medium
d) Larger
Answer: d
Explanation: In Chemical milling, tolerance increases when machining depth increases.
48. What is the value of etching rate, which can be achieved using Chemical milling?
a) 0.001 mm/min
b) 0.025 mm/min
c) 0.050 mm/min
d) 0.075 mm/min
Answer: c
Explanation: While we use Chemical milling etch rates of around 0.025 mm/min are
achieved.
49. What are the tolerance values achieved in Chemical milling, which depend on work
piece material and depth of cut?
a) ± 10%
b) ± 20%
c) ± 30%
d) ± 40%
Answer: a
Explanation: Tolerances of ± 10% of cut width are achieved using CHM.
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50. For what value of machining depths, surface roughness sharply increases with depth
of cut?
a) <100 µm
b) <200 µm
c) <300 µm
d) <400 µm
Answer: b
Explanation: For material depths <200 µm, surface roughness increases with depth of cut.
51. What is the value of surface roughness, which is generally obtained using Chemical
milling?
a) 0.01 – 0.08 µm
b) 0.1 – 0.8 µm
c) 1 – 8 µm
d) 10 – 80 µm
Answer: b
Explanation: Surface roughness obtained when general conditions are applied, is between
0.1 – 0.8 µm.
52. What is the value of surface roughness, when special conditions are applied?
a) 0.001 – 0.025 µm
b) 0.025 – 0.05 µm
c) 0.05 – 0.075 µm
d) 0.075 – 0.1 µm
Answer: b
Explanation: Surface roughness obtained when special conditions are applied, is between
0.025 – 0.05 µm.
53. Which of the following can be easily removed using Chemical milling process?
a) TiO2 layer
b) Decarburized layer
c) Recast structure
Answer: d
Explanation: All the layers mentioned above, can be removed using Chemical milling.
54. State whether the following statement is true or false about Chemical milling.
“CHM can also affect mechanical properties, if they differ from surface layer to base
metal.”
a) True
b) False
Answer: a
Explanation: Chemical milling can affect the mechanical properties of the machined parts if
they are different at surface layers and base metal
CHM – Advantages
55. What are the advantages when we use Chemical milling process?
a) Weight reduction
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b) No burrs
c) No stresses
Answer: d
Explanation: All the advantages mentioned above, can be obtained using Chemical milling
process.
56. Weight reduction is possible, on which type of contours?

a) Very simple
b) Simple
c) Complex
Answer: c
Explanation: Weight reduction can be possible using Chemical milling, on complex contours,
compared to conventional machining.
57. Simultaneous material removal using Chemical milling, results in which of the following?
a) Improves productivity
b) Reduces wrapping
c) Minimizing part distortion
Answer: d
Explanation: All the factor mentioned above occur, when we use Chemical milling for
material removal.
58. State whether the following statement is true or false regarding the advantages of CHM.
“As there are no stresses induced, machining of delicate parts is possible.”
a) True
b) False
Answer: a
Explanation: In CHM, no stresses are induced, which makes machining of delicate parts
easier.
59. Which type of taper can be achieved, using Chemical milling, on contours?
a) Discontinuous
b) Continuous
c) Periodic
Answer: b
Explanation: Using Chemical milling, a continuous taper, on contours can be achieved.
60. State whether the following statement is true or false regarding the advantages?
“Capital cost of equipment, for machining large components, is relatively high.”
a) True
b) False
Answer: b
Explanation: Capital cost of equipment, is relatively low for machining large components.
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61. Which of the following, are the other advantages of CHM?

a) Design changes
b) Less skilled operator
c) Minor tooling costs
Answer: d
Explanation: All of the advantages mentioned above, are obtained using CHM.
62. Good surface quality and absence of burr eliminates which of the following?
a) Cutting operations
b) Finishing operations
c) Drilling operations
Answer: d
Explanation: Absence of burrs and good surface quality eliminates finishing operations in
CHM.
63. State whether the following statement is true or false about advantages.
“Extensive web areas and decorative finishes are not possible using CHM.”
a) True
b) False
Answer: b
Explanation: Decorative finishes are obtained when we use CHM.
64. What are the values of scrap rates obtained in Chemical milling?
a) 1%
b) 3%
c) 5%
d) 7%
Answer: b
Explanation: Low scrapes rates around 3% are obtained when we use the Chemical milling
process
CHM-Limitations
65. Which of the following are the limitations of Chemical milling process?
a) Disposal of chemicals
b) Limited scribing accuracy
c) Surface imperfections
Answer: d
Explanation: All the factors mentioned above, are the limitations of Chemical milling process.
66. What is the value of shallow cuts obtained on sheets and plates, when we use CHM?
a) 3.83 mm
b) 6.39 mm
c) 12.27 mm
d) 20.32 mm
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Answer: c
Explanation: Very shallow depths of value 12.27 mm, are obtained when we use CHM.
67. Hand masking, scribing and stripping can be difficult, due to which of the following
factors?
a) Time consuming
b) Repetitive
c) Tedious
Answer: d
Explanation: All the factors mentioned above, are main disadvantages for different
processes in CHM.
68. Which type of metallurgical surfaces are needed in Chemical milling process?
a) Homogenous
b) Heterogeneous
c) Mixture
Answer: a
Explanation: Metallurgic homogenous surfaces are needed for chemical milling to take
place.
69. Porous castings yield, which type of surfaces in Chemical milling process?
a) Uniform surfaces
b) Even surfaces
c) Uneven surfaces
Answer: c
Explanation: As there are porous castings, there would be pores on the surface which lead
to uneven surfaces.
70. State whether the following statement regarding the limitations of CHM.
“Welded areas etch, at a rate that is same as base metal.”
a) True
b) False
Answer: b
Explanation: Welded areas etch at a different rate, when compared to that of base material.
71. The absence of residual stresses on the chemically machined surfaces can produce
__________ strength.
a) Favorable fatigue
b) Unfavorable fatigue
c) Constructive fatigue
Answer: b
Explanation: Absence of residual stresses produce unfavorable fatigue strength, unlike to
the processes that induce compressive residual stresses.
72. Which of the following, indicate the accuracy of scribing by Chemical milling process?
a) Unlimited
b) Boundless
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c) Infinite
Answer: d
Explanation: Scribing accuracy is limited in CHM process due to uneven surface finish.
73. Which of the following are the other limitations of Chemical milling process?
a) Hydrogen pickup
b) Intergranular attack
c) Complex designs becoming expensive
Answer: d
Explanation: Hydrogen pick up, intergranular attack are some other limitations in Chemical
milling process.
74. Which of the following is not a limitation of Chemical milling process?

a) Steep tapers not practical
b) Low scrap rates
c) Less scribing accuracy
d) Deep narrow cuts
Answer: b
Explanation: Low scrap rates are possible in Chemical milling, which is an advantage to the
process
CHM-Applications
76. Which of the following metals can be machined using the Chemical milling process?
a) Copper
b) Zinc
c) Steel
Answer: d
Explanation: Zinc, copper, lead, and nickel are some of the metals that can be chemically
machined.
77. What is the range, between which, the depth of cut in Chemical milling varies?
a) 0.13 – 0. 84 mm
b) 0.93 – 1.56 mm
c) 2.54 – 12.27 mm
d) 13.3 – 104.56 mm
Answer: c
Explanation: Practically, depth of cut in Chemical milling range between 2.54 – 12.27 mm.
78. Which of the following non-metallic materials can be machined using the Chemical
milling process?
a) Plastics
b) Glass
c) Ceramics
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Answer: d
Explanation: Non-metallic materials such as glass, ceramics and plastics can also be
machined using Chemical milling process.
79. 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
Answer: a
Explanation: Shallow cuts in large thin sheets helps in reducing the weight, especially in
aerospace industries.
80. How many designs can be machined from the same sheet in Chemical milling?
a) Only one
b) Two
c) Three
d) Multiple
Answer: d
Explanation: In Chemical milling, multiple designs can b machined on a large thin sheet
depending upon the size of the designs.
81. CHM is used to thin out walls, web and ribs of parts that have been produces by which
of the following processes?
a) Forging
b) Casting
c) Sheet metal forming
Answer: d
Explanation: CHM is used for applications mentioned above of the parts, which are formed
by casting, forging and sheet metal forming processes.
82. Removal of sharp burrs come under which application of Chemical milling process?
a) Deep cuts
b) Multiple part machining
c) Improving surface characteristics
Answer: c
Explanation: Removal of sharp burrs improve the surface characteristics of parts machined
using Chemical milling.
83. Which of the following can be eliminated from the surfaces using Chemical milling?
a) Alpha case from Ti-forgings
b) Decarburized layer from low cast alloys
c) Recast layer from machined parts
Answer: d
Explanation: The defects on surfaces mentioned above, can be eliminated using Chemical
milling process.
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84. CHM is used to remove the thin surfaces from forgings and castings, at which time of
process?
a) After penetration inspection
b) Prior to penetration inspection
c) At the starting of process
d) At the end of process
Answer: b
Explanation: Removal of thin surfaces from forgings and casting takes place, prior to
penetration depth inspection.
85. State whether the following statement is true or false regarding the applications of CHM.
“Removal of thin surfaces, prior to inspection, is done for detection of hidden defects.”
a) True
b) False
Answer: a
Explanation: Removal of thin surfaces is done to detect the hidden defects in surfaces using
CHM
Electro Chemical Machining (ECM)

Introduction and Principle of electrolysis
86. In advanced machining processes, what is the full form of ECM?
a) Electrochemical manufacturing
b) Electrochemical milling
c) Electrochemical machining
d) Electrochemical masking
Answer: b
Explanation: In advanced machining processes, full form of ECM is Electrochemical
machining.
87. In the following scientists, who was the one to introduce first patent on ECM?
a) Balamuth
b) Steve O Flawer
c) Gusseff
d) McGeough
Answer: c
Explanation: Gusseff was the one, who introduced the first patent on ECM in 1929.
88. When was the first significant development of ECM occurred?

a) 1920s
b) 1930s
c) 1950s
d) 1960s
Answer: c
Explanation: After the first patent in 1929, the first development of ECM was done in 1950s.
4. Which of the following material removal mechanisms is implemented by ECM?
a) Mechanical abrasion
b) Electrochemical dissolution
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c) Chemical corrosion
d) Mechanical erosion
Answer: b
Explanation: In ECM, material is removed by electrochemical dissolution.
89. Electrolysis occur when which of the following takes place between electrodes?
a) Electric current flow
b) Electron flow
c) All of the mentioned
Answer: c
Explanation: When there is an electron flow there is current flow in the opposite direction.
For electrolysis to take place there should be flow of current between electrodes.
90. The system which consists of electrolytic solution and electrodes can be referred to as
____________
a) Electrolytic cell
b) Electrode system
c) Electrolytic system
d) Electrode cell
Answer: a
Explanation: The system of electrodes and electrolytic solution is referred as electrolytic cell.
91. The chemical reactions occurring at electrodes are called with, which of the following
names?
a) Anodic reactions
b) Cathode reactions
Answer: c
Explanation: Chemical reactions occurring at electrodes are called as anodic or cathodic
reactions.
92. Amount of mass dissolved is directly proportional to which of the following quantities?
a) Amount of electricity
b) Frequency of vibrations
c) Amplitude of oscillations
Answer: a
Explanation: Amount of mass dissolved is directly proportional to amount of electricity and
also substances’ chemical equivalent.
93. Chemical equivalent is the ratio of which of the following factors?

a) Work piece valence to the atomic weight
b) Atomic weight to work piece valence
c) Tool valence to molecular weight
d) Molecular weight to tool valence
Answer: b
Explanation: Chemical equivalent is the ratio of atomic weight to work piece valence
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Theory of ECM
94. What is the value of the current density used in Electrochemical machining?
a) 0.01 – 0.4 A/mm2
b) 0.5 – 5 A/mm2
c) 6 – 15 A/mm2
d) 20 – 50 A/mm2
Answer: b
Explanation: High current densities, which range between 0.5 – 5 A/mm2 are used in ECM.
95. What are the values of voltages used in ECM?

a) 1 to 8 V
b) 10 to 30 V
c) 40 to 80 V
d) 90 to 110 V
Answer: b
Explanation: Low voltages, ranging between 10 to 30 V are used in Electrochemical
machining.
96. How does the current pass between the two electrodes in ECM?
a) Electrolytic solution
b) Direct contact of electrodes
Answer: a
Explanation: Current passes through the solution of electrolyte, which fills the gap between
the electrodes.
97. What is the value of velocity with which, electrolyte flows in the inter electrode gap?
a) >1 m/s
b) >3 m/s
c) >5 m/s
d) >10 m/s
Answer: c
Explanation: The velocity of the electrolytic solution must be greater than 5 m/s, in order to
intensify the mass and charge transfer.
98. Of the following, electrolyte removes which of the dissolution products?

a) Metal hydroxides
b) Heat
c) Gas bubbles
View Answer
Answer: d
Explanation: Electrolyte removes the dissolution products such as metal hydroxides, heat
and gas bubbles formed in the inter electrode gap.
99. State whether the following statement is true or false regarding the theory of ECM.
“Application of P.D (potential difference) lead to occurrence of several reactions.”
a) True
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b) False
Answer: a
Explanation: When P.D (potential difference) is applied, different reactions occur at anode
and cathode.
100. Which of the following reactions takes place at the electrodes?

a) Generation of hydrogen
b) Dissolution of iron
c) Dissolution of NaCl
Answer: d
Explanation: All the reactions mentioned above, take place at different electrodes in ECM.
101. Which of the following reaction takes place at anode?

c) Generation of hydroxyl ions
Answer: b
Explanation: At anode, dissolution of Fe takes place in the process of ECM.
102. Which of the following reactions take place at cathode?

c) Dissolution of NaCl
Answer: a
Explanation: At cathode, generation of hydrogen takes place in the process of ECM.
103. Positively charged particles (cations) move towards which electrode?

a) Anode
b) Cathode
c) Anode & Cathode
Answer: b
Explanation: Positively charge particles are directed towards the cathode, which is
negatively charged.
104. Negatively charged particles (anions) move towards which electrode?

a) Anode
b) Cathode
c) Anode & Cathode
Answer: a
Explanation: Negatively charged particles are directed towards the anode, which is positively
charged.
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ECM – Equipment
105. Which of the following come under the main components of ECM?
a) Feed control system
b) Work piece holding devices
c) Electrolyte supply system
Answer: d
Explanation: The main components of Electro chemical machining include feed control
system, electrolyte supply system, power supply unit, work piece holding devices.
106. Feed control system is responsible for which action in ECM?

a) Giving feed to tool
b) Electrolyte supply
c) Power supply
Answer: a
Explanation: Feed control system is used for feeding the tool at constant rate during
equilibrium machining.
107. In ECM equipment, what is the role of electrolyte supply system?

c) Power supply
Answer: b
Explanation: As the name itself indicates, electrolyte supply system is used to supply the
electrolyte required for anodic dissolution.
108. What is the role of power supply unit in ECM equipment?

c) Power supply
Answer: c
Explanation: In ECM, power supply unit is used to supply the machine current at constant dc
voltage.
109. For large size machining, which type of facilities are used in ECM?
a) Semi-automated facilities
b) Automated facilities
c) Automated & Semi-automated facilities
Answer: c
Explanation: Automated and semi-automated facilities are used for large size machining.
6. Electrolyte supply system should concentrate on which of the following factors?
a) Pressure
b) Supply rate
c) Temperature
20
Answer: d
Explanation: Electrolyte supply system should supply electrolyte at a given rate, temperature
and pressure.
110. For high strength or rigidity, which type of coatings are recommended for metals?
a) Other metal coatings
b) Non-metallic coatings
Answer: b
Explanation: For high strength and rigidity, non-metallic coatings are recommended for
metals.
111. What is the value of voltage that the power supply unit supplies for ECM?
a) 0.01 to 1 V
b) 2 to 30 V
c) 50 to 80 V
d) 100 to 160 V
Answer: b
Explanation: Voltage supply required for ECM ranges between 2 to 30 V.
112. Between which of the following values, does the current range?
a) 0.002 to 0.01 A
b) 0.01 to 10 A
c) 50 to 10000 A
d) 105 to 106 A
Answer: c
Explanation: In Electrochemical machining, current value ranges between 50 to 10000 A.
113. What are the values of current densities used in ECM?

a) 0.1 to 2 A/cm2
b) 5 to 500 A/cm2
c) 600 to 1000 A/cm2
d) 1200 to 2800 A/cm2
Answer: b
Explanation: Current density values in ECM range between 5 to 500 A/cm 2.
114. Which type of adjustment is to be done for gap voltages?

a) Continuous adjustment
b) Discontinuous adjustment
c) Periodic adjustment
Answer: a
Explanation: In ECM, usually continuous adjustment of gap voltage is required.
115. Compared to the tool used in ECM, how should be the work piece size?
a) Greater than
b) Smaller than
21
c) Same as tool
Answer: a
Explanation: By an oversize, work piece size is expected to be greater than tool size.
116. Which of the following factors are used to determine the tool geometry?
a) Required shape
b) Electrical conductivity
c) Tool feed rate
Answer: d
Explanation: For determining a tool geometry we must specify some factors such as the
required shape of the surface, tool feed rate, gap voltage, electrochemical machinability of
the work material, electrolyte conductivity, and both electrodes’ polarization voltages.
117. Which of the following are the simplest methods for applying the insulation on tools?
a) Spraying
b) Dipping
Answer: c
Explanation: In ECM, dipping or spraying are the simplest methods for insulating the tools.
118. State whether the following statement is true or false regarding the tools of ECM.
“With computer integrated manufacturing (CIM), cathodes are produced at high costs
and less accurately.”
a) True
b) False
Answer: b
Explanation: Using CIM, cathodes are produced at low costs and more accurately
119. What are the main functions of electrolyte in Electrochemical machining?

a) Conduct machining current
b) Removal of debris
c) Maintaining constant temperature
Answer: d
Explanation: Main functions of electrolyte are conducting machine current, removing the
debris, carrying away the heat, maintaining constant temperature.
120. Electrolytic solution should ensure which type of anodic dissolution?

a) Uniform
b) Non-uniform
c) Low speed
Answer: a
Explanation: Uniform and high speed anodic dissolution must be ensured by the electrolyte.
22
121. State whether the following statement is true or false regarding the electrolytic solution.
“In ECM, formation of passive film is recommended.”
a) True
b) False
Answer: b
Explanation: Electrolytic solution should avoid formation of passive layers on anode.
122. Which type of electrical conductivity is necessary for electrolytic solution?

a) Low
b) Medium
c) High
Answer: c
Explanation: High electrical conductivity is needed for electrolytic solution in ECM.
123. What are the other features of electrolytic solution in ECM?

a) Non toxic
b) Less erosive
c) Less viscous
Answer: d
Explanation: Electrolytic solution should be nontoxic, less viscous and less erosive.
124. How much should be the electrolytic solution?

a) Highly expensive
b) Inexpensive
Answer: b
Explanation: Electrolyte must be inexpensive and available at ease.
125. Which are the most common electrolytes used in Electrochemical machining?
a) Sodium chloride
b) Sodium nitride
c) Sodium hydroxide
Answer: d
Explanation: Electrolytes such as sodium chloride, sodium nitride, sodium hydroxide are
some of the electrolytes used in ECM.
126. Selection of electrolyte does not depend on which of the following factors?
a) Work piece material
b) Dimensional tolerance
c) Heat affected zones
d) Machining productivity
Answer: c
Explanation: Selection of electrolyte depend up on work piece material, dimensional
tolerance, machining productivity and surface finish required.
23
127. What must be the value of electrolytic temperature in ECM?

a) 2 to 14oC
b) 22 to 45oC
c) 46 to 57oC
d) 62 to 76oC
Answer: b
Explanation: Temperature of electrolyte should range between 22 to 45 oC.
128. What must be the value of the pressure of electrolytic solution used in ECM?
a) 1 to 10 kPa
b) 10 to 80 kPa
c) 100 to 200 kPa
d) 300 to 400 kPa
Answer: c
Explanation: Value of pressure of electrolytic solution must range between 100 to 200 kPa.
129. What must be the value of velocity of the electrolytic solution?

a) 10 to 15 m/s
b) 25 to 50 m/s
c) 60 to 100 m/s
d) 120 to 200 m/s
Answer: b
Explanation: Typical velocity of the electrolytic solution must range between 25 to 50 m/sec.
130. Local metal removal rates are high at which gap locations mentioned below?
a) Small gap
b) Medium gap
c) Large gap
Answer: a
Explanation: Local metal removal rates are high at small gap locations in ECM.
131. When local metal removal rates are high, how will be the current density and current
efficiency?
a) High
b) Medium
c) Low
d) Very low
Answer: a
Explanation: When the local metal removal rates are high then current density and efficiency
are also high.
132. Current efficiency depends on which of the following in ECM?

a) Anodic material
b) Electrolyte
c) Anodic material & Electrolyte
Answer: c
Explanation: Current efficiency in ECM depend on electrolyte and anodic material used.
24
133. State whether the following statement is true or false regarding the electrolytes in
ECM.
“In Electrochemical machining, electrolytes should deposit on cathode electrodes.”
a) True
b) False
Answer: b
Explanation: In ECM, electrolytes should not deposit on cathode, so that shape of electrode
remains unchanged
ECM-Basic Working Principles

134. What is the approximate value of faraday’s constant?
a) 65,200 C
b) 53,800 C
c) 96,500 C
d) 85,600 C
Answer: c
Explanation: 1 faraday equals to approximately 96500 C.
135. In the following ratios of metal dissolved amounts, which one represent the current
efficiency?
a) Observed to theoretical
b) Theoretical to observed
Answer: a
Explanation: In electrochemical machining, current efficiency is the ratio of observed amount
of metal dissolved to the theoretical amount of metal dissolved.
136. Apparent current efficiency is due to which of the following factors?

a) Choice of wrong valence
b) Passivation of anodic surface
c) Gas evolution at anode
Answer: d
Explanation: Current efficiency may be apparent because of choice of wrong valence,
passivation of anodic surface or gas evolution at anodic surface.
137. State whether the following statement is true or false regarding the working principles.
“In ECM, grain boundary attacks remove the grains through electrolytic forces.”
a) True
b) False
Answer: a
Explanation: In ECM, grain boundary attacks are the cause for removal of grains by
electrolytic forces.
138. In ECM, gap increase proportional to which relation of time below?

a) Square of time
b) Square root of time
c) Cube of time
25
d) Cube root of time
Answer: b
Explanation: In Electrochemical machining, gap increases proportional to the square root of
time.
139. At constant feed rates what happens to gap thickness?

a) Increases
b) Decreases
c) Becomes constant
Answer: c
Explanation: At constant feed rate, work piece becomes stationary and thus the gap
thickness becomes constant.
140. At constant gap thickness material removal becomes equal to feed rate. What is this
gap called?
a) Equal gap
b) Equilibrium gap
c) Unique gap
d) Narrow gap
Answer: b
Explanation: When rate of material removal per unit area is same as feed rate, then
corresponding thickness is called as equilibrium thickness indicated by ‘y e’.
141. If the gap thickness is greater than equilibrium thickness what will be MRR?
a) MRR is less than feed rate
b) MRR is greater than feed rate
c) MRR is equal to feed rate
Answer: a
Explanation: When gap thickness is greater than equilibrium thickness, MRR will be less
than feed rate.
142. During ECM drilling, decrease in feed rates lead to which type of machining gaps?
a) Wider
b) Narrow
c) Small
Answer: a
Explanation: Decrease in feed rate lead to wider gap thickness in ECM drilling.
143. Too small gap causes which of the following effects?

a) Sparking
b) Short circuit
c) Sparking & Short circuit
Answer: c
Explanation: Sparking or short circuit occurs when the gap is too small
26
ECM-Process Characteristics
144. Electro chemical dissolution phase starts with the movement of ions between which
two components?
a) Cathode and anode
b) Cathode and power source
c) Power source and anode
d) Power source and electrolyte
Answer: a
Explanation: ECD phase occurs by the movement of ions between the two electrodes.
145. Better surface finish and higher accuracy depend on which of the factors below?
a) Chemical composition of the electrolyte
b) Current density
Answer: c
Explanation: Proper chemical composition of electrolyte and proper current density are
responsible for better surface finish and accuracy.
146. For alloys, which type of electrolyte is used in ECM?

a) Single component
b) Double component
c) Multi component
d) Triple component
Answer: c
Explanation: Depending up on the elements in an alloy multi component electrolytes are
used.
147. Nickel can be machined with 100% current efficiency, when current density value is
______________
a) 10 A/cm2
b) 25 A/cm2
c) 45 A/cm2
d) 80 A/cm2
Answer: b
Explanation: Nickel is a metal suggested by Khayry, which can be machined at 100% current
efficiency, if current density is 25 A/cm2.
148. When the electrolyte flow is low, what happens to the current efficiency?
a) Increases
b) Decreases
c) Remains same
d) Increase and then decrease
Answer: b
Explanation: In ECM, if the electrolyte flow is low, current efficiency is reduced due to the
accumulation of machining products within the gap.
149. When machining Ti, in Nacl electrolyte, what values of current efficiencies are
obtained?
27
a) 10 – 20 %
b) 20 – 30 %
c) 30 – 50 %
d) 50 – 80 %
Answer: a
Explanation: While machining Ti using NaCl electrolyte, current efficiencies of 10 – 20
percent are obtained.
150. State whether the following statement is true or false about electrolyte in ECM.
“Machinability in ECM is enhanced, when electrolyte is heated.”
a) True
b) False
Answer: a
Explanation: Machinability is increased, when electrolyte is heated, as heating increases the
specific conductivity of the electrolyte.
151. In practice, what must be the temperature of electrolyte used in ECM?

a) 10 – 20oC
b) 20 – 40oC
c) 60 – 80oC
d) 80 – 100oC
Answer: c
Explanation: Temperature of electrolyte used in ECM must not exceed 60 – 70oC.
152. What is the value of moderate level of pH of electrolyte used?

a) 1 – 2
b) 2 – 4
c) 4 – 10
Answer: c
Explanation: Moderate level of pH of electrolyte used in ECM range between 4 – 10.
10. What must be the working voltage in Electrochemical machining?
a) 10 V
b) 20 V
c) 30 V
d) 40 V
Answer: b
Explanation: The electrolytes in ECM employ a working voltage up to 20 V.
153. Surface roughness depend on which of the following quantities?

a) Crystallographic irregularities
b) Alloy composition
c) Distribution of current density
Answer: d
Explanation: Surface roughness of machined surface in ECM depend on crystallographic
irregularities, alloy composition, current density distribution, dislocations and grain
boundaries.
28
154. For a better surface finish, which type of current distribution is required?
a) Even
b) Uneven
c) Even & Uneven
Answer: a
Explanation: More even distribution of the current density leads to a better surface finish.
155. Between which values does the frontal gap’s surface roughness vary?
a) 0.02 to 0.13 µm
b) 0.30 to 1.90 µm
c) 1.93 to 2.64 µm
d) 2.73 to 4.26 µm
Answer: b
Explanation: Surface roughness varies between 0.30 to 1.9 µm for frontal gap area.
156. Between which values does the side gap’s surface roughness vary?
a) >1 µm
b) >3 µm
c) >5 µm
d) >7 µm
Answer: c
Explanation: Surface roughness value is 5 µm or more for side gap areas.
157. In Electrochemical machining, larger grain size causes which type of finish?
a) Smoother
b) Rougher
c) Finer
Answer: b
Explanation: In ECM, larger grains cause rougher finish than finer grains
158. Which type of gap width is necessary for a higher degree of accuracy?
a) Very small
b) Small
c) Medium
d) High
Answer: b
Explanation: A small gap width represents a high level of accuracy. Very small gap width
results in sparks and short circuits.
159. Accuracy of machining is affected by, which of the following factors?

a) Material
b) Gap voltage
c) Feed rate
29
Answer: d
Explanation: Accuracy of the process is affected by material equivalent, gap voltage, feed
rate, etc.
160. Which properties of electrolyte does not affect the accuracy of the process?
a) Temperature
b) Concentration
c) Non-reactive
d) Pressure
Answer: c
Explanation: Electrolyte must be reactive in order to carry on the reactions that occur at the
electrodes.
161. For high process accuracy, which of the following factors are needed?
a) High feed rate
b) High conductivity
c) High feed rate & High conductivity
Answer: c
Explanation: For a higher degree of accuracy, there must be high feed rates and highly
conductive electrolytes.
162. Tool insulation that __________ the side machining action is needed in the process of
ECM.
a) Limits
b) Enhances
c) Maintains
Answer: a
Explanation: Tool insulation is needed, which limits the machining of other sides of work
piece.
163. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
Answer: b
Explanation: When the current density is relatively high as required, then polishing occurs.
164. What happens when the current density is low in ECM?

a) Pitting occurs
b) Etching occurs
c) Pitting & Etching occurs
Answer: c
Explanation: When current density is lower than optimum, then etching and pitting occurs
which are undesired.
165. Fine dimensional control can be obtained if throwing power of electrolyte is

___________
30
a) Low
b) Medium
c) High
d) Very high
Answer: a
Explanation: Throwing power of electrolyte must be less in order to obtain a fine dimensional
control.
166. Passivation is done on electrolytes in order to form which of the following?

a) Passive layer on machined parts
b) Passive layer on cathode
c) Passive layer on machined parts & cathode
Answer: a
Explanation: Passivation is done on the electrolytes in order to form a passive film on
machined parts.
167. If there is an increase in the electrolyte flow, what happens to the rate of film
formation?
a) Increases
b) Decreases
c) Remains same
Answer: b
Explanation: An increase in electrolytic solution flow decreases the anodic product formation,
which reduces the rate of film formation.
168. What are the typical dimensional tolerances for frontal gaps in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
Answer: c
Explanation: The dimensional tolerances obtained for frontal gaps are ± 0.130 mm.
169. What are the tolerance values for the side gap in ECM?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
Answer: d
Explanation: The dimensional tolerances obtained for side gaps are ± 0.25 mm.
170. What are the typical dimensional tolerances obtained in ECM when there is proper
control of machining?
a) ± 0.01 mm
b) ± 0.025 mm
c) ± 0.13 mm
d) ± 0.25 mm
31
Answer: b
Explanation: The dimensional tolerances obtained by proper machining are ± 0.025 mm.
171. It is difficult to machine inner radii smaller than __________ and outer radii less than
________ in ECM.
a) 0.1 mm, 0.2 mm
b) 0.5 mm, 0.8 mm
c) 0.8 mm, 0.5 mm
d) 0.2 mm, 0.1 mm
Answer: c
Explanation: It is difficult to machine inner radii < 0.8mm and outer radii < 0.5mm.
172. What is the value of the overcut that is obtained using ECM?
a) 0.3 mm
b) 0.5 mm
c) 0.7 mm
d) 0.9 mm
Answer: b
Explanation: An overcut of 0.5 mm is obtained when machined using ECM
ECM-Process Control
173. If there is a change in the selected machining conditions, it will have impact on which
of the following?
a) Process accuracy
b) Surface finish
c) Process accuracy & Surface finish
Answer: c
Explanation: Selected machining conditions should remain unchanged, because, it will have
a direct impact on accuracy and surface finish.
174. Surface roughness depends on current density, which is affected by which of the
following?
a) Tool feed rate
b) Gap voltage
c) Work piece material
Answer: d
Explanation: Roughness depend on current density, which is affected by tool feed rate, gap
voltage, work material, pH number, temperature, conductivity and pressure.
175. Machining conditions leading to high accuracy are associated with ________ surface
roughness and ________ productivity.
a) Greater, greater
b) Smaller, greater
c) Greater, smaller
d) Smaller, smaller
32
Answer: b
Explanation: Accuracy is associated with smaller surface roughness and greater machining
productivity.
176. Non stationary behaviour of ECM is due to, which of the factors below?
a) Gas generation
b) Heating
c) Passivation
Answer: d
Explanation: Non stationary behaviour of ECM is due to the inter electrode gap conditions
such as gas generation, passivation, heating and other electrode reactions.
177. For large components, actual machining time constitutes to how much percentage of
the total machining time?
a) Very low
b) Low
c) Medium
d) High
Answer: d
Explanation: Actual machining time of large components constitutes to a high percentage of
total machining time.
178. What happens to the product cycle time, if the machining performance is improved?
a) Increases
b) Decreases
c) Remains same
Answer: b
Explanation: As the machining performance is improved, the time take for a product to
complete its production cycle, decreases.
179. The cost of additional control hardware remain a _________ fraction of total machining
cost.
a) Small
b) Large
c) Equal
Answer: a
Explanation: Cost of additional control hardware is very less, which constitutes to a small
fraction in total machining cost.
180. With an increase in unmanned machining hours, what happens to the efficiency of
ECM?
a) Increases
b) Reduces
c) Decreases
d) Increase and then decrease
Answer: a
Explanation: Increase in unmanned machining hours lead to a raise in efficiency of ECM.
33
181. State whether the following statement is true or false regarding the process control of
ECM.
“In Electrochemical machining, increase in unmanned machining hours reduces the
possibility of integration of process with CAD/CAM systems.”
a) True
b) False
Answer: b
Explanation: An increase in unmanned machining hours, enhances the process integration
with CAD/CAM systems.
182. Which type of damage is caused by deterioration which is caused by spark?

a) Reparable
b) Irreparable
Answer: b
Explanation: Deterioration by sparking may cause irreparable damage to the work pieces
ECM-Applications and Micro-ECM

183. Which of the following use ECM for different applications?
a) Gas turbines
b) Jet engines
c) Bio medical implants
Answer: d
Explanation: ECM has its applications in industries such as gas turbines, jet engines,
automobiles, medical etc.
184. Which of the following processes can be done using ECM?
a) Die sinking
b) Profiling and contouring
c) Drilling and trepanning
Answer: d
Explanation: ECM can be used for die sinking, trepanning, drilling, contouring, grinding and
profiling.
185. Which of the following material cannot be machined using ECM?

a) High strength alloys
b) Hardened steels
c) Nonconductive materials
Answer: c
Explanation: ECM can be used for machining high strength alloys and hardened steels
which led to many cost-saving applications.
186. ECM is used to _________ the sharp edges produced after rough cuts.
a) Enhance
b) Dull
c) Improve
34
Answer: b
Explanation: Using deburring process through ECM, sharp edges are dulled, which are
produced after rough cuts.
187. ECM is usually characterized as low accuracy machining, for which of the following
reason?
a) Narrow gap width
b) Wider gap width
c) High current densities
Answer: b
Explanation: ECM is usually characterized as low accuracy machining because of its wider
machining gap.
188. In micro ECM, which of the following is used as micro tool?

a) Electrolyte jet
b) Electrodes
c) Power supply
Answer: a
Explanation: Electrolyte jet in micro ECM acts as the micro tool for machining.
189. Micro ECM is used to machine which type of parts?

a) Large parts
b) Micro parts
c) Normal sized parts
Answer: b
Explanation: Micro ECM is used to machine micro parts which can be from micro scale to
mesoscale in size.
190. Which of the following produces small indents and cavities using micro ECM?
a) Moving the work piece
b) Switching the pulse current
c) Moving the work piece & Switching the pulse current
Answer: c
Explanation: Indentation and cavitation can be done using micro ECM by moving the work
piece or switching the pulse current
ECM-Advantages and Disadvantages

191. What fraction of tool will always be in contact with the work piece?
a) Half
b) Full
c) No contact
d) Quarter
35
Answer: c
Explanation: Tool does not have any contact with the work piece in Electro chemical
machining.
192. How much amount of wear is present in the tool used in Electrochemical machining?
a) No wear
b) Low
c) Medium
d) High
Answer: a
Explanation: The tool wear is absent in the tool used in ECM, since tool has no contact with
the work piece.
193. Compared to other processes, machining is done at __________ voltages for high
rates of material removal.
a) Low
b) Medium
c) High
d) very low
Answer: c
Explanation: In ECM, machining is done at low voltages, when compared to other
processes.
194. Very small dimensions, up to which value can be controlled using ECM?
a) 0.01 mm
b) 0.05 mm
c) 0.07 mm
d) 0.12 mm
Answer: b
Explanation: Due to less electrode gap very small dimensions up to 0.05 mm can be
controlled.
195. Complicated profiles can be machined in how many operations in Electrochemical

machining?
a) Single
b) Double
c) Triple
d) Multiple
Answer: a
Explanation: One of the main advantage of ECM is, complicated profiles can be machined in
a single operation itself.
196. How much amount of thermal damage occurs to the work piece?
a) Small
b) Large
c) No thermal damage
d) Negligible amount
Answer: c
Explanation: As the temperatures are very low, no thermal damage occurs to the work piece
material.
36
197. Which of the following materials can be machined using ECM?

a) Hard nonconductive materials
b) Hard conductive materials
c) All nonconductive materials
Answer: b
Explanation: Hard conductive materials can be machined and nonconductive materials
cannot be machined using ECM.
198. What are the requirements of labour for machining purpose in Electrochemical
machining?
a) Low
b) Medium
c) High
d) Very high
Answer: a
Explanation: In electrochemical machining, labour requirements are low compared to
conventional or traditional machining practices.
199. How much amount of energy is consumed in Electro chemical machining?

a) Very small
b) Small
c) Medium
d) Large
Answer: d
Explanation: Very huge amount of energy is required for ECM, which is nearly 100 times
required for turning or drilling of steel.
200. How are material removal rates of ECM, when compared to that of conventional
methods?
a) Slower
b) Faster
c) Same
Answer: a
Explanation: In ECM, rates of material removal are slow compared to conventional methods.
11. State whether the following statement is true or false regarding the limitations of ECM.
“In ECM, cleaning and oiling of work piece need not be done after machining.”
a) True
b) False
Answer: b
Explanation: Work piece needs to be cleaned and oiled just after the machining is done.
201. Which of the following are the limitations of electro chemical machining?
a) Removal of hydrogen
b) Handling the electrolyte
c) Energy consumption
37
Answer: d
Explanation: Removal of hydrogen, handling and containing the electrolyte and energy
consumption are some of the limitations of ECM.
202. State whether the following statement is true or false regarding the limitations of ECM.
“In electrochemical machining, duplicating the tool is easier.”
a) True
b) False
Answer: b
Explanation: Duplication of tool is difficult in ECM, since it has side machining effects.
203. Electro chemical machining process cannot produce which of the following mentioned
below?
a) Drilled holes
b) Deburred edges
c) Sharp edges
Answer: c
Explanation: Electro chemical machining cannot produce sharp internal or external edges.
204. Pumping of electrolyte through the narrow gaps causes, which type of forces on tool
and work piece?
a) Large
b) Small
c) Negligible
d) No force
Answer: a
Explanation: Electrolyte pumping through the narrow gaps gives rise to a large amount of
forces on tool and work pieces
38

MCQ Ucmp Unit Iii Chemical and Electro Chemical Energy Based Processes

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Chemical machining(CHM) / Chemical Milling – Introduction

4. By using Chemical machining, which of the following can be produced?

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

8. During Chemical milling, depth of etch is controlled by which factor of immersion?

12. Of the following, which ratio defines the etch factor?

13. CHM cannot eliminate which of the following defects?

Tooling for CHM

d) All of the mentioned

CHM – Process Parameters and Material removal

CHM – Accuracy and Finish

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

61. Which of the following, are the other advantages of CHM?

74. Which of the following is not a limitation of Chemical milling process?

Electro Chemical Machining (ECM)

88. When was the first significant development of ECM occurred?

93. Chemical equivalent is the ratio of which of the following factors?

95. What are the values of voltages used in ECM?

98. Of the following, electrolyte removes which of the dissolution products?

100. Which of the following reactions takes place at the electrodes?

101. Which of the following reaction takes place at anode?

102. Which of the following reactions take place at cathode?

103. Positively charged particles (cations) move towards which electrode?

104. Negatively charged particles (anions) move towards which electrode?

106. Feed control system is responsible for which action in ECM?

107. In ECM equipment, what is the role of electrolyte supply system?

108. What is the role of power supply unit in ECM equipment?

d) All of the mentioned

113. What are the values of current densities used in ECM?

114. Which type of adjustment is to be done for gap voltages?

119. What are the main functions of electrolyte in Electrochemical machining?

120. Electrolytic solution should ensure which type of anodic dissolution?

122. Which type of electrical conductivity is necessary for electrolytic solution?

123. What are the other features of electrolytic solution in ECM?

124. How much should be the electrolytic solution?

127. What must be the value of electrolytic temperature in ECM?

129. What must be the value of velocity of the electrolytic solution?

132. Current efficiency depends on which of the following in ECM?

ECM-Basic Working Principles

136. Apparent current efficiency is due to which of the following factors?

138. In ECM, gap increase proportional to which relation of time below?

d) Cube root of time

139. At constant feed rates what happens to gap thickness?

143. Too small gap causes which of the following effects?

146. For alloys, which type of electrolyte is used in ECM?

151. In practice, what must be the temperature of electrolyte used in ECM?

152. What is the value of moderate level of pH of electrolyte used?

153. Surface roughness depend on which of the following quantities?

159. Accuracy of machining is affected by, which of the following factors?

164. What happens when the current density is low in ECM?

165. Fine dimensional control can be obtained if throwing power of electrolyte is

166. Passivation is done on electrolytes in order to form which of the following?

182. Which type of damage is caused by deterioration which is caused by spark?

ECM-Applications and Micro-ECM

185. Which of the following material cannot be machined using ECM?

d) None of the mentioned

188. In micro ECM, which of the following is used as micro tool?

189. Micro ECM is used to machine which type of parts?

ECM-Advantages and Disadvantages

195. Complicated profiles can be machined in how many operations in Electrochemical

197. Which of the following materials can be machined using ECM?

199. How much amount of energy is consumed in Electro chemical machining?

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