Unconventional machining process

Question bank with answer

1. Which of the following is un-conventional machining process?

a) Grinding b) Milling c) Drilling d) EDM

2. Which of the following is mechanical energy based nontraditional machining process?

a) Grinding b) Milling c) AWJM d) USM

3. Which of the following is nontraditional machining process?

a) Grinding b) Milling c) Drilling d) USM

4. Non-Traditional machining can also be called as?

a) Contact Machining b) Non-Contact Machining c) Half contact machining

d) Partial contact machining

5. The sound wave less than audible range is called as

a) Ultrasonic b) Infrasonic c) Sonic d) None of these

6. The sound wave above than audible range is called as

a) Ultrasonic b) Infrasonic c) Sonic d) None of these

7. When the metal is removed by erosion caused by rapidly recurring spark discharges
between the tool and work, the process is known as

a) ECM b) EDM c) USM d) None of these

8. Nozzle material in AWJM

a) Silica b) Gelatin c) Tungsten carbide d) All the above

9. Abrasive used in USM

a) Diamond b) Gelatin c) Tungsten carbide d) All the above

10. Wire cut EDM process wire made up of

a) Brass b) Silica c) Tungsten d) None of these
1. What is meant by Conventional Machining Processes?
In conventional machining processes, metal is removed by using some sort of the tools
which is harder than the work piece and is subjected to wear. In this process, tool and
work piece being in direct contact with each other.
2. What is meant by Unconventional Machining Processes?
The Unconventional machining processes do not employ a conventional or traditional
tool for metal removal; instead, they directly utilize some form of energy for metal
machining. In this process, there is no direct physical contact between the tool and the
work piece.
3. Classify the different types of unconventional machining processes based on the
mechanical energy.
1. Abrasive Jet Machining (AJM)
2. Water Jet Machining (WJM)
3. Ultrasonic Machining (USM)
4. Abrasive Water Jet Machining (AWJM)
4. Classify the different types of non-traditional processes
Mechanical Processes
 Abrasive Jet Machining (AJM)
 Water Jet Machining (WJM)
 Ultrasonic Machining (USM)
 Abrasive Water Jet Machining (AWJM)
Thermal Processes
 Electron Beam Machining (EBM)
 Laser Beam Machining (LBM)
 Plasma Arc Machining (PAM)
 Electric Discharge Machining (EDM)
 Wire cut Electric Discharge Machining (WEDM)
5. Explain about the principle of AWJM, USM, EDM
AWJM:
The abrasive water jet machining process works on the principle that when a high-
velocity jet of water with abrasive particle strikes the work piece, machining of the
work piece takes place by erosion of the work piece material.
USM:
In USM, aslurry of small abrasive particles are force against the work piece by means
of a vibrating too and it causes the removal of metal from the work piece.
EDM:
In EDM metal is removed by producing powerful electric spark discharge between the
tool( cathode) and the work material (anode).
6. Define standoff distance
The distance between the nozzle tip and the work piece, it has great influence on the
diameter of cut, shape and also metal removal rate.

7. Define transducer and its type

Transducer is a device which converts one form of energy into another form of energy.
Type : 1. Piezoelectric, 2. Magnetrostriction

8. List the process parameter of AWJM

1. Tool
2. Pressure of water
3. Abrasive material
4. Mass flow rate
5. Metal removal rate
6. Nozzle material
7. Standoff distance

9. List the process parameter of USM

1. Metal removal rate
2. Tool material
3. Tool wear rate
4. Surface finish
5. Work Material
6. Abrasive material and abrasive slurry

10. List the application of USM

1. Holes as 0.1mm can be drilled
2. Machine glass, ceramics, tungsten
3. Several machining operations like
a. Drilling
b. Grinding
c. Turning
d. Threading on of all both conducting and non-conducting material

11. List the process parameter of EDM

1. Operating parameter
2. Taper
3. Surface finish
4. Current density
12. List the common tool materials used in EDM
1. Copper
2. Graphite
3. Copper – tungsten
13. What are the application of EDM
1. Thread cutting in jobs
2. Drilling of micro holes
3. Helical profile drilling
4. Curved hole drilling
14. Name the common dielectric fluid used in EDM
Petroleum base
1. Hydrocarbon fluids
2. Paraffin
3. White spirit
4. Transformer oil
5. Kerosene
6. Mineral oil