Unconventional Machining E Book

Tailor made module for various exams like HPCL, ISRO, BARC etc.
PRODUCTION TECHNOLOGY
UNCONVENTIONAL MANUFACTURING METHODS
1. Ultrasonic machining is best suited for
(a) Non-ferrous metal (b) Amorphous solids
(c) Brittle materials (d) Dielectrics
2. Which of the following processes has the highest metal removal rate?
(a) Ultrasonic machining (b) Abrasive machining
(c) Chemical machining (d) Electron beam machining
3. The vibration frequency used for the tool in the 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
4. In abrasive jet machining metal removal takes place due to
(a) Evaporation (b) Erosion (c) Corrosion (d) Melting
5. The machining process which needs vaccum for its operation is
(a) Electron beam machining (b) Electrical discharge machining
(c) Electro chemical machining (d) Plasma machining
6. In electro chemical machining, the metal is removed by
(a) Dissolution (b) Evaporation (c) Sputtering (d) Shearing
7. The function of servo mechanism in EDM process is to:
(a) Clean the dielectric fluid
(b) Provide dielectric fluid of required flow rate
(c) Provide power to generate the spark
(d) Maintain a small gap between tool and work piece
8. Which of the following is incorrect for Ultrasonic machining?
(a) Tool is made of ductile material (b) Very low material removal rate
(c) Abrasive are not used
(d) Tool vibrates with very high frequency
9. In ECM (Electro Chemical Machining):
(a) As the cutting forces are very high, thin section of work piece cannot be machined
(b) Tool material is conductor of electricity
(c) Surface finish is bad (d) Tool wear is high
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10. The following four unconventional machining processes are available in a shop floor.
The most appropriate one to drill a hole of square cross section of 6 mm × 6 mm and
25 mm deep:
(a) Is Electro discharge Machining (b) Is Plasma Arc Machining
(c) Is Laser Beam Machining (d) None of the above
11. In abrasive jet machining, as the distance between the nozzle tip and the work surface
increases, the material removal rate:
(a) Increases continuously (b) Decreases continuously
(c) Increases, becomes stable and then increases
(d) None of the above
12. Which of the following is used as a dielectric medium in EDM?
(a) Salt solution (b) Silicon carbide solution
(c) AI2O3 solution (d) Kerosene
13. Which of the following is not the unconventional machining process?

(a) EDM (b) ECM (c) USM (d) LBM
(e) Turning
14. Tool vibrates with very high frequency in:
(a) EDM (b) ECM (c) USM (d) LBM
(e) AJM
15. Which one of the following processes is the reverse of electroplating process?
(a) EDM (b) ECM (c) PAM (d) LBM
16. The wear ratio for tungsten carbide work in EDM is
(a) 0.5 (b) 1.0 (c) 2.0 (d) 3.0
17. EDM stands for
(a) Energy Discharge Method (b) Electro-Discharge Machining
(c) Energy Direct Machining (d) Efficient Direct Method
18. In ECM process, the MRR is given by
FI I.At F.ρA.V F.IA.t
(a) (b) (c) (d)
ρA.V F.ρA.V I.At ρA.V
19. In ECG process, a continuous steam of noncorrosive salt solution is passed through
work and tool. This solution acts as
(a) An electrolyte (b) A coolant
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(c) an electrolyte and coolant (d) dielectric medium

20. High rate of oscillation of tools in ultrasonic machining is produced by
(a) D.C. motor (b) A.C. motor (c) Pneumatic generator (d) Oscillator
21. For the same capacity which of the following process has the highest capital cost?
(a) Electro chemical machining (b) Plasma arc machining
(c) Electro discharge machining (d) Laser beam machining
22. Reproduction of sharp corners in the limitation of :
(a) ECM (b) EDM (c) Laser (d) Plasma
23. The mechanism of material removal in EDM process is:
(a) Melting and evaporation (b) melting and corrosion
(c) erosion and cavitation (d) cavitation and evaporation
24. EDM process is suited for the machining of–
(a) conducting materials (b) non-conducting materials
(c) both (1) and (2) (d) non-conducting but magnetic
25. Maximum MRR of EDM process is approximately given by:
(a) 5000 mm3/min (b) 5 × 105 mm3/min
(c) 50 mm3/min (d) 0.5 mm3/min
26. Consider following about Beam Machining
1. Low initial cost
2. Not very efficient process
3. Presence of Heat affected zone
4. Micro-holes cannot be drilled in difficult to machine materials
5. Not suitable for heat sensitive materials
Of above, which are properties of LBM
(a) 1, 2, 4 and 5 (b) 3, 4 and 5 (c) 2, 3 and 5 (d) 1, 3 and 4
(e) 1, 2 and 5
27. Consider the following statement concerning mechanism of material removal in
Electron Beam Machining
1. Mechanical erosion due to impact of high of energy electrons
2. Chemical etching by the high energy electron
3. Sputtering due to high energy electrons
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4. Melting and vaporisation due to thermal effect of impingement of high energy

electron
Of the above, which are correct
(a) 1 (b) 1 and 3 (c) 2 and 3 (d) 4
(e) 3 and 4
28. The type of energy used in electrical discharge wire cutting is :
(a) Mechanical energy (b) Chemical energy
(c) Electrical energy (d) Thermal energy
29. Ablation mechanism is used in which of the following machining process?
(a) Chemical machining (b) Ultrasonic machining
(c) Laser beam machining (d) Electron beam machining
30. Which of the following laser source can give the highest power density?
(a) Plasma Arc (b) Electron beam (c) Laser continuous (d) laser pulsed
31. The material removal rate will be higher in ultrasonic machining process for materials
with
(a) Higher ductility (b) Higher fracture strain
(c) Higher toughness (d) Lower toughness
32. In Electro-Discharge machining, the work piece is connected to
(a) Cathode (b) Anode (c) Earth (d) Electrolyte
33. 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)
34. While machining copper alloys by Electro chemical Machining the electrolyte used is
(a) Common salt (b) Sodium sulphate (c) Sodium Chlorate (d) Sodium Nitrate
35. For unconventional machining process, following is the correct sequence of
decreasing
order of Material Removal Rate (MRR)
(a) ECM > EDM > USM (b) ECM > USM > EDM
(c) USM > EDM > ECM (d) USM > ECM > EDM
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36. In ultrasonic machining, Material Removal Rate with respect for grain size increase in
(a) Increases (b) Decreases
(c) Increases and decreases (d) Decreases and increases
37. The machining process in which the metal of a workpiece dissolved, is
(a) Electro discharge machining (EDM) (b) Electro chemical machining (ECM)
(c) Ultrasonic machining (USM) (d) Abrasive jet machining (AJM)
38. Keeping all other parameters unchanged, the tool wear in electrical discharge
machining would be less if the tool material has
(a) High thermal conductivity and high specific heat
(b) High thermal conductivity and low specific heat
(c) Low thermal conductivity and low specific heat
(d) Low thermal conductivity and high specific heat
39. In electro discharge machining dielectric is used to :
(a) Help in the movement of the sparks (b) Control the spark discharges
(c) Act as coolant (d) All of these
40. Which of the following machining processes involves cutting of a hard workpiece by
a soft material?
(a) Turning (b) Grinding
(c) Electro-discharge machining (d) Honing
41. Ductile materials can be machined in Ultrasonic machining process.
(a) True (b) False (c) Partly true (d) Partly false
42. Non-conductive material can be machined by :
(a) LBM (b) EDM (c) ECM (d) All of these
43. Electrolyte is used in which of the following process?
(a) EDM (b) WJM (c) WEDM (d) ECM
44. In EDM, the tool and work piece are separated by
(a) Positive ions (b) Negative ions (c) Metal conductor (d) Dielectric fluid
45. In Electro Discharge machining better surface finish is obtained at
(a) Low frequency and low discharge current
(b) Low frequency and high discharge current
(c) High frequency and low discharge current
(d) High frequency and high discharge current.
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46. Which of the following non-conventional machining methods does not cause tool
wear?
(a) Anode mechanical machining (b) Ultrasonic machining
(c) Electro-discharge machining (d) Electro-Chemical Machining
47. Ultrasonic machining is best suited for
(a) tool steel (b) brass (c) diamond (d) stainless steel
48. When the metal is removed by erosion caused by rapidly recurring spark discharges
between the tool and work, the process is known as
(a) Electrochemical machining (b) Electro discharge machining
(c) Ultrasonic machining (d) Abrasive jet machining
49. In electro-discharge machining process, in order to remove maximum metal and have
minimum wear on the tool :
(a) The tool is made cathode and work piece as anode
(b) The tool is made anode and the work piece as cathode
(c) The tool and work piece should be of different metals
(d) None of the above
50. During ultrasonic machining the metal removal is achieved by :
(a) High frequency eddy currents (b) High frequency sound waves
(c) Hammering action of abrasive particles
(d) Rubbing action between tool and work piece
51. As tool and work are not in contact in EDM process
(a) No relative motion occurs between them
(b) No wear of tool occurs
(c) No power is consumed during metal cutting
(d) No force between tool and work occurs
52. Which one of the following processes does not cause tool wear
(a) Ultrasonic machining (b) Electro discharge machining
(c) Laser beam machining (d) Anode mechanical machining
53. Which of the following process has very high material removal rate efficiency?
(a) Electro beam machining (b) Electro chemical machining
(c) Electric discharge machining (d) Plasma arc machining
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54. Consider the following work piece materials:

(i) Carbides (ii) Glass (iii) Copper and (iv) Ceramics
Which of the above materials are best suited for ultrasonic Machining.
(a) (ii) Only (b) (ii) and (iii)
(c) (i), (ii) and (iv) (d) (ii), (iii) and (iv)
55. Metal in electro-chemical machining process is removed by:-
(a) Migration of ions towards the tool (b) Ionization and shearing
(c) Chemical action and abrasion (d) Chemical etching
56. In Electro-chemical machining material removal is due to:-
(a) Corrosion (b) Erosion
(c) Fusion (d) Ion displacement
57. Which of the following is not a limitation for ECM process:-
(a) Very expensive (b) Sharp corners are difficult to produce
(c) Surface finish is not good
(d) Use of corrosive media as electrolyte makes it difficult to handle
58. The rate of work material removal in USM operation is proportional to the:-
(a) Volume of work material removed per impact
(b) Number of particles making impact per cycle
(c) Frequency of vibration
(d) All of the above
59. The most suitable manufacturing process for machining a turbine blade made of
nimonic alloy is:-
(a) Milling and lapping (b) Electric discharge machining
(c) Ultrasonic machining (d) Electro-chemical machining
60. Which one of the following is most important parameter for EDM?
(a) Thermal capacity (b) Hardness
(c) Strength (d) Geometry
61. A hole of 1 mm is to be drilled in glass. It could be best done by
(a) Laser drilling (b) Plasma drilling
(c) Ultrasonic drilling (d) Electron beam drilling
62. The following is not true for ECM :
(a) It can machine highly complicated shapes in a single pass.
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(b) Tool life is very high.

(c) Machinability of the work material is independent of its physical and mechanical
properties.
(d) Kerosene is use as electrolyte.
63. Which is the false statement about electro discharge machining ?
(a) It can machine very hard material.
(b) Very good surface finish is obtained.
(c) Section to be machined should be thick.
(d) Metal removal rate is very slow.
64. The process in which the material removal rate is governed by Faraday’s law is ?
(a) ECM (b) EDM (c) AJM (d) LBM
65. In EDM, metal removal rate is proportional to
(a) Frequency of charging (b) Energy delivered in each spark
(c) Both (a) and (b) (d) None of the above
66. In USM process the material removal rate is higher for materials with
(a) Higher toughness (b) Higher ductility
(c) Higher fracture strain (d) Lower toughness
67. The mechanism of metal removal in Electron Beam Machining is
(a) Melting and vapourization (b) Shear
(c) Ion-displacement (d) Chemical action
68. Which one of the following is most important for EDM?
(a) Thermal capacity (b) Hardness
(c) Strength (d) Geometry
69. The tool material used in USM is
(a) Mild Steel (b) High Speed Steel (c) Carbides (d) Ceramics
70. The current used during EDM is
(a) AC (b) pulsed AC (c) DC (d) pulsed DC
71. For efficient cutting of material with Laser Beam Machining, the material must be
(a) Good conductor of electricity (b) Bad conductor of heat
(c) Good conductor of heat
(d) Good conductor of heat and electricity
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72. Following electrolyte is used in electrochemical machining process:

(a) Kerosene (b) transformer oil (c) brine solution (d) water
73. The correct sequence of operations for machining a precise rectangular window in a
through hardening die steel workpiece is
(a) Heat treatment, surface grinding, drilling, wire EDM
(b) Drilling, wire EDM, heat treatment, surface grinding
(c) Drilling, heat treatment, surface grinding, wire EDM
(d) Surface grinding, heat treatment, wire EDM, drilling
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UNCONVENTIONAL MANUFACTURING METHODS

SOLUTIONS
1. Solution: (c) Ultrasonic machining- Ultrasonic machining (USM) are suitable
methods for making through holes in a glass plate. In ultrasonic machining, a
vibrating formed tool is employed which vibrates at frequencies 20 to 30 kHz with
amplitude between 0.01 and 0.06 mm and is pressed lightly on to the work surface
while an abrasive slurry (such as boron carbide mixed with water) is made to flow
under pressure through the gap between the tool face and the work surface to be
machined. The tool has the same shape as that of the cavity to machined ultrasonic
machining used for brittle and nonconducting materials glass is non-conductive and
has brittle nature. So, USM can be used.
2. Solution: (c) : Material removal rate (MRR) is highest in case of electrochemical
machining (ECM) and minimum in laser beam machining (LBM). The correct
sequence in increasing order is as follows- ECM > EDM > USM > EBM > LBM
3. Solution. (b) : The vibration frequency used for the tool in the Ultrasonic machining
is of the order of 20,000 oscillations per second.
4. Solution. (b) : In abrasive jet machining metal removal takes place due to erosion.
5. Solution. (a) : Vacuums must be used to reduce contamination and minimize electron
collisions with air molecules. Because work must be done in a vacuum, EBM is best
suitable for small parts. The interaction of the electron beam with the work piece
produces hazardous x-rays, and only highly trained personnel should use EBM
equipment.:
6. Solution. (a) : ECM– ECM is a non-traditional machining process belonging to
electrochemical category. ECM is opposite of electrochemical or galvanic coating or
deposition process. In EMC, material removal takes place due to atomic dissolution of
work material.
7. Solution. (d) : The function of servo mechanism in EDM process is to maintain a
small gap between tool and work piece.
8. Solution. (c) : Ultrasonic machining—Ultrasonic machining is a non-traditional
process, in which abrasive contained in a slurry are driven against the work by a tool
oscillating at a low amplitude (25-100 microns) and high frequency (15-30 kHz). In
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ultrasonic machining tool is made of ductile material and tool vibrates with very high
frequency to remove very low material. (low material removal rate)
9. Solution. (b) : Electro Chemical Machining (ECM)—In ECM process in which
electrochemical process is used to remove materials from the workpiece. In the
process, workpiece is taken as anode and tool is taken as cathode. The two electrodes
workpiece and tool is immersed in an electrolyte (such as NaCl). When the voltage is
applied across the two electrodes the material removal from the workpiece starts. The
workpiece and tool is placed very close to each other without touching. In ECM the
material removal takes place at atomic level so it produces a mirror finish surface.
10. Solution. (a): Since the depth of hole is mentioned i.e., hole is blind so electric
discharge machining is the best for any type of die sinking, cavity sinking, blind
complex cavities etc.
11. Solution. (c) : The figure shows the abrasive jet machining for the distance between
the workpiece surface and the nozzle tip and flow rate of abrasive.
We can see that the material removal rate is increase due to increase in distance of jet
then becomes stable and suddenly starts decreasing due to decrease in the velocity of
jet.
12. Solution. (d) : In EDM a fluid is used to act as a dielectric and to help carry away
debris. Quite often kerosene based oil is used as dielectric in EDM. The dielectric
2
fluid is circulated through the tool at a pressure of 0.35 N/m or less to free it from
eroded metal particles, it is circulated through a filter.

13. Solution. (e) : EDM, ECM, USM, LBM, AJM, WJM, EBM etc. are unconventional
machining process whereas turning, milling, facing etc are conventional machinery
processes.
14. Solution. (c) : Tool vibrates with very high frequency in ultrasonic machining.
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15. Solution. (b) : Electrochemical machining (ECM) process is the reverse of

electroplating process.
16. Solution. (a) : The wear ratio for tungsten carbide work in EDM is 0.5.
17. Solution. (b) : EDM → Electro-discharge machining
IA.t
18. Solution. (b) : In electro-chemical process, the MRR is given by MRR
F.ρA.V
19. Solution. (c) : In ECG process, a continuous steam of noncorrosive salt solution is
passed through work and tool. This solution acts as an electrolyte and coolant.
20. Solution. (d) : An electric oscillator in the control unit produces a high rate
(frequency) oscillation, usually between 18 to 40 kHz. The transducer converts the
oscillation current to a mechanical Vibration.
21. Solution. (a) : For the same capacity achieved, but the highest capital cost requires in
electro-chemical machining process, in which material removal takeplace through
chemical reaction of ion dissolution.
22. Solution. (b) : Limitation of EDM process-
• Because of low material removal rates the process is economical only for very hard
and difficult materials to machine.
• The EDM process is not suitable for nonconductors.
• Rapid electrode wear makes the process more costly.
• The surface produced by EDM generally have a matt type appearance, requiring
further polishing to attain a glossy finish.
23. Solution. (a) : Melting and evaporation is the mechanism of material removal in
EDM process.
24. Solution. (a) : Irrespective of its hardness strength any material which is an electrical
conductor, can be machined.
– Fine holes can be easily drilled.
– Quicker process even harder materials can be machines a much faster rate than
conventional machining.
25. Solution. (a) : 5000 mm3/min
26. Solution. (c) : Laser Beam Machining Limitations
(i) High initial capital cost.
(ii) High maintenance cost
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(iii) Not very efficient process

(iv) Presence of heat affected zone specially in gas assist CO2 laser cutting.
(v) Thermal process not suitable for heat sensitive materials like aluminium glass
fiber laminate.
(vi) Micro-holes can be drilled in difficult to machine materials.
27. Solution. (d) : Melting and vaporisation due to thermal effect of impingement of high
energy electron.
28. Solution. (c, d) : Electrical energy and Thermal energy
29. Solution. (a) : Ablation mechanism is used in chemical machining process in which
metal can be machined with high qualities & good surface qualities.
30. Solution. (d) : Laser pulsed can give the highest power density.
31. Solution. (d) : Ultrasonic machining process uses vibrational energy of vibrating tool
which hammers on workpiece and due to mechanical impact of abrasive, workpiece
factures. Thus material removal rate will be higher for those material which are brittle
in nature or lower in toughness.
32. Solution. (b) : In Electro-Discharge machining, the work piece is connected to Anode
whereas EDM tool is connected to cathode.
33. Solution. (b) : In ultrasonic machining process the material is removed due to the
action of abrasive grains.
34. Solution. (b) : Sodium sulphate
35. Solution. (a) : ECM > EDM > USM
36. Solution. (c) : Effect of various parameter on MRR in ultrasonic machining–
1. Effect of amplitude on MRR- Increase in amplitude of vibration increase MRR.
2. Effect of frequency on MRR- Frequency used for maching process must be
resonant frequency to obtain the greatest amplitude at the tool tip and thus achieve the
maximum utilization of the acoustic system.
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3. Effect of abrasive grain size- An increase in abrasive grain size results in higher
MRR but is achieved when abrasive grain size is comparable with amplitude of
vibration of the tool. Hardness of the abrasives and method of introducing the slurry
has also effect on MRR.
37. Solution. (b) : In electrochemical machining (ECM) process the metal of workpiece
dissolved.
38. Solution. (a): High thermal conductivity and high specific heat.
39. Solution. (d) : In electro discharge machining dielectric is used to,
_ Help in the movements of the sparks.
_ Control the spark discharges
_ Act as coolant.
40. Solution : (c) : Electro-discharge machining
41. Solution: (b) : An ultrasonic machining is primarily used for machining hard and
brittle material such as glass, carbide, ceramic and harden steel most of time these
materials are not conductive except hard steel. The material of the tool is wear slowly
during machining because of softness.
42. Solution: (a) :Non- conductive material can be machined by LBM.
43. Solution: (d): In ECM same tool be used for producing infinite number of
components because of no tool wear.
44. Solution: (d): Electric discharge machining (EDM) is an advanced machining process
which are primarily used for metals difficult to machine with the conventional
machining process. Only electrically conducting materials are machined by this
process. The EDM process is best suited for making intricates cavities and contours
which would be difficult to produce with conventional machining cutting. The
material removed takes place in EDM through a rapid series of electric discharges.
The fine pieces of material removed for the workpiece gets flushed away by the
continuous flowing dielectric fluid.
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45. Solution: (c) It Electro Discharge Machining better surface finish is obtained at high
frequency and low discharge current.
The Surface produced by this process consist of microscopic craters and the quantity
of the machined surface mainly depends on the energy per pulse. In the energy
content per pulse in high then the depth of crater will increase causing a poor surface
finish and vice-versa. The surface roughness is inversely proportional to the frequency
of cutting which is equal to-
1
(Sparking time  Charging time)
Sparking time being very small compared to charging it could be said that frequency
1
of cutting =
Sparking time
46. Solution: (d) Electro-chemical machining methods does not cause tool wear.
Electrochemical Machining (ECM):- This process is an extension of already known
process of electroplating with modification in a reverse direction. A shaped tool or
electrode is used in the process which forms cathode and workpiece forms anode. A
small gap is maintained between the tool and workpiece and an electrolyte is pumped
through it. Low voltage direct current is used which in the presence of electrolyte
enables a control removal of metal form workpiece by anodic dissolution. The tool is
provided with a constant feed motion towards workpiece. the electrolyte is pumped at
a high pressure through the small gap between tool and work piece.
47. Solution: (c) Ultrasonic machining is best suited for diamond. It is mainly used for (i)
Drilling (ii) Grinding (iii) Profiling (iv) coining (v) threading (vi) welding operations
on all materials which can be treated suitable by abrasives hard materials like stainless
steel, glass, ceramic, carbide, diamond, quartz and semi conductors are machined by
this process.
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48. Solution: (b) Electro discharge machining:- when the materials is removed by
erosion caused by rapidly recurring spark discharge between the tool and work piece,
the process is known as electro discharge machining.
49. Solution: (a) In electro - discharge machining process, in order to remove maximum
metal and have minimum wear on the tool, the tool is made cathode and work piece as
Anode. The Spark frequency is normally in the range 200- 50000 Hz, the spark gap
being of the order of 0.025- 0.05mm. An metal removal rate up to 300mm3/min can
be obtained with this process. The efficiency and the accuracy of performance have
been found to improve when a forced circulation of the dielectric fluid is provided.
The most commonly used dielectric fluid is kerosene. The tool is generally made of
brass or copper only.
50. Solution: (c) During ultrasonic machining the metal removal is achieved by
hammering action of abrasive particles.
Ultrasonic machining:-Ultrasonic waves are sound waves which propagate at
frequency of 18 to 30 lc/sec and are thus beyond the human ear to respond, no heat is
generate in case of ultrasonic machining and it provides better working performance.
This process is best suited for machining circular and non-circular holes in hard to
machine and brittle metals whether Conducting or non-Conducting Ultrasonic waves
can be generated by piezoelectric or magnetostrictive effects.
51. Solution: (d) As tool and work are not in contact in EDM because no force between
tool and work occurs.
52. Solution: (c) Laser beam machining does not tool wear.
Laser beam Welding:-
* In laser welding a concentrated coherent light beam impinges at the desired spot to
melt and weld the metal.
* The most useful laser for welding is the laser in which the lasing medium is mixture
of CO2, nitrogen, and helium in the ratio of 1:1"10 at a pressure of 20 to 50 mm of
mercury.
53. Solution: (c) Electric discharge machining process has very high material removal
rate efficiency. The spork frequency is normally in the range 200- 500000Hz. the
spark gap being of the order of 0.25- 0.05mm. An metal removal rate upto 300m3/min
can be obtained with this process.
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54. Solution : (c)

Ultrasonic Machining (USM):- Ultrasonic means those vibrational waves having a
frequency above the normal hearing range (e.g. 20K-30K Hz). In this method slurry
of the abrasive grains are hammered on to the work surface by a vibrating tool normal
to work surface removing the workpiece material in the form of extremely small
chips. Tools is feed gradually is used to increase the amplitude to the level needed for
machining.
Application:-
(i) Normally used for making dies
(ii) Machining hard carbides, glasses and precious stones
(iii) Also used for dental application.
55. Solution. (a) : Metal in electro-chemical machining process is removed by migration
of ions towards the tool.
56. Solution. (d) : In Electro-chemical machining material removal is due to Ion
displacement
57. Solution. (c) : Surface finish is not good
58. Solution. (d) : All of the above.
59. Solution. (d) : The most suitable manufacturing process for machining a turbine
blade made of nimonic alloy is electro-chemical machining.
60. Solution. (a) : Thermal capacity
61. Solution. (c) : Ultrasonic drilling
62. Solution. (d) : Kerosene is use as electrolyte.
63. Solution. (c) : Section to be machined should be thick.
64. Solution. (a) : ECM

65. Solution. (c) : Both (a) and (b)
66. Solution. (c) : Higher fracture strain
67. Solution. (a) : Melting and vapourization
68. Solution. (a) : Thermal capacity
69. Solution. (a) : Mild Steel
70. Solution. (d) : Pulsed DC
71. Solution. (b) : Bad conductor of heat
72. Solution. (c) : Brine solution
73. Solution : (c) : The correct sequence of operations for machining a through hardening
die steel work piece is Drilling, heat treatment, surface grinding.
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(c) AI2O3 solution (d) Kerosene

13. Which of the following is not the unconventional machining process?

(c) an electrolyte and coolant (d) dielectric medium

4. Melting and vaporisation due to thermal effect of impingement of high energy

54. Consider the following work piece materials:

(b) Tool life is very high.

72. Following electrolyte is used in electrochemical machining process:

UNCONVENTIONAL MANUFACTURING METHODS

eroded metal particles, it is circulated through a filter.

15. Solution. (b) : Electrochemical machining (ECM) process is the reverse of

(iii) Not very efficient process

of CO2, nitrogen, and helium in the ratio of 1:1"10 at a pressure of 20 to 50 mm of

54. Solution : (c)

64. Solution. (a) : ECM

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