Advanced Machine Processes

1. Which of the following use ECM for different applications?
a) Gas turbines
b) Jet engines
c) Bio medical implants
d) All of the mentioned
2. Which of the following processes can be done using ECM?
a) Die sinking
b) Profiling and contouring
c) Drilling and trepanning
3. Which of the following material cannot be machined using ECM?
a) High strength alloys
b) Hardened steels
c) Nonconductive materials
4. ECM is used to _________ the sharp edges produced after rough cuts.
a) Enhance
b) Dull
c) Improve
d) None of the mentioned
5. 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
6. In micro ECM, which of the following is used as micro tool?
a) Electrolyte jet
b) Electrodes
c) Power supply
7. Micro ECM is used to machine which type of parts?
a) Large parts
b) Micro parts
c) Normal sized parts
8. 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
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1. Which type of gap width is necessary for a higher degree of accuracy?
a) Very small
b) Small
c) Medium
d) High
2. Accuracy of machining is affected by, which of the following factors?
a) Material
b) Gap voltage
c) Feed rate
3. Which properties of electrolyte does not affect the accuracy of the process?
a) Temperature
b) Concentration
c) Non-reactive
d) Pressure
4. For high process accuracy, which of the following factors are needed?
a) High feed rate
b) High conductivity
c) High feed rate & High conductivity
5. Tool insulation that __________ the side machining action is needed in the process of
ECM.
a) Limits
b) Enhances
c) Maintains
6. If the current density is high as required, what type of machining occurs?
a) Pitting
b) Polishing
c) Etching
7. What happens when the current density is low in ECM?
a) Pitting occurs
b) Etching occurs
c) Pitting & Etching occurs
8. Fine dimensional control can be obtained if throwing power of electrolyte is
___________
a) Low
b) Medium
c) High
d) Very high
9. 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
10. If there is an increase in the electrolyte flow, what happens to the rate of film
formation?
a) Increases
b) Decreases
c) Remains same
11. 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
12. 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
13. 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
14. 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
15. 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
1. Non-Traditional machining is recommended when we need which of the following
features?
a) Complex shapes
b) High surface quality
c) Low-rigidity structures
2. Non-Traditional machining can also be called as ________
a) Contact Machining
b) Non-contact machining
c) Partial contact machining
d) Half contact machining
3. In which of the following industries, Non-traditional machining methods play an
important role?
a) Automobile
b) Aerospace
c) Medical
4. Different classifications of Non-traditional machining based on source of energy are
________
a) Mechanical
b) Thermal
c) Chemical and electro-chemical.
5. In mechanical machining, material is removed by ___________
a) Erosion
b) Corrosion
c) Abrasion
d) Vaporization
6. Material in thermal machining is removed by which of the following means?
a) Vaporization
b) Melting
c) Electro-plating
7. Which of the following process comes under mechanical machining?
a) USM
b) EDM
c) LBM
d) PAM
8. Surface defects that may be occurred during thermal machining are ________
a) Micro cracking
b) Heat affected zones
c) Striations
9. Sources used in thermal machining are ________
a) Ions
b) Plasma
c) Electrons
10. Vacuum is the machining medium for ________
a) LBM
b) WJM
c) EBM
11. In chemical machining is material removal takes by?
a) Chemical reaction
b) Erosion
c) Electron removal
12. Which of the following is an example of hybrid machining?
a) Ultrasonic Machining
b) Electron Beam Machining
c) Ultrasonic assisted electrochemical machining
d) Laser Beam Machining
1) The Laser Beam Machining process can be carried out, when the media for
energy transfer between tool and workpiece is
a. air
b. liquid
c. vacuum
d. any of the above medium
2) What is the reason for using unconventional or advanced machining
processes?
a. Complex surfaces
b. High accuracy and surface finish
c. High strength alloys
d. All of the above
3) Which of the following is not a media of energy transfer on which the
advanced machining processes are classified?
a. Reactive atmosphere
b. Electrons
c. Electrolyte
d. Chemical ablation
4) The spark gap in Electrical Discharge Machining (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
5) Which of the following materials is/are used for Electrical Discharge
Machining (EDM) process?
a. Brass
b. Copper
c. Graphite
d. All of the above
6) In Electrical Discharge Machining (EDM) process the metal removal is
carried out by
a. electrolysis
b. melting and vaporisation
c. fracture of work material due to impact of grains
d. none of the above
7) Which of the following statements are true for Electro-Chemical Machining
(ECM)?
1. ECM is capable of machining metals and alloys irrespective of their strength

and hardness
2. No cutting forces are involved in ECM process
3. ECM process consumes very high power
4. Very small space is required to set up ECM process
a. (1), (2) and (3)

b. (2), (3) and (4)
c. (1), (3) and (4)
d. (1), (2) and (4)
8) In which process the material is removed due to the action of abrasive
grains?
a. Electro-Chemical Grinding (ECG)

b. Ultrasonic Machining (USM)
c. Laser Beam Machining (LBM)
d. Electrical Discharge Machining (EDM)
9) Which of the following processes is generally applied for dentistry work
like to drill fine holes of particular shape in teeth?
a. Electrical Discharge Machining (EDM)

b. Electron Beam Machining (EBM)
c. Laser Beam Machining (LBM)
d. Ultrasonic Machining (USM)
10) Which of the following process has highest rate of metal removal?
a. Electric Discharge Machining (EDM)

b. Electro-Chemical Machining (ECM)
c. Ultrasonic Machining (USM)
d. Laser Beam Machining (LBM)
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1. Which of the following use ECM for different applications?

a. the gap voltage is around 99% of supply voltage

1. ECM is capable of machining metals and alloys irrespective of their strength

a. (1), (2) and (3)

a. Electro-Chemical Grinding (ECG)

a. Electrical Discharge Machining (EDM)

a. Electric Discharge Machining (EDM)

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